TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN

CSB 04-5A

Compliance Necessary To Maintain Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

TELEDYNE CONTINENTAL MOTORS IGNITION SYSTEM CRITICAL SERVICE BULLETIN CSB 665A.

PURPOSE:

To Advise Owners, Operators and FBO’s of the release of TCM Ignition System Critical Service Bulletin CSB 665A “Magneto Capacitor P/N 10400615 Inspection and Replacement”

COMPLIANCE:

On receipt of this Critical Service Bulletin. Make certain that no one is allowed to move the propeller on an engine suspected of containing an affected capacitor. This could result in an engine start.

PARTS AFFECTED:

All New (10-) and Rebuilt (BL-) S20, S200 and S1200 Series magnetos of all part numbers in the affected serial number ranges as listed in Table 1, with the exception of the serial numbers listed in Table 2 of this Bulletin. All spare part number 10-400615 capacitors in the affected date code range.

Any magneto which may have an affected capacitor installed as a spare part between 10/1/2003 and the effective date of this bulletin REASON FOR REVISION: Revision to CSB665 WARNING:

DO NOT MOVE THE PROPELLER OF ANY ENGINE CONTAINING AN AFFECTED MAGNETO CAPACITOR. THE ENGINE COULD START, REGARDLESS OF IGNITION SWITCH POSITION, CAUSING PERSONAL INJURY OR DEATH.

Teledyne Continental Motors requires compliance with the attached TCM Ignition System Critical Service Bulletin CSB 665A on receipt.

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Teledyne Continental Motors, Inc. P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

© 2004 Teledyne Continental Motors, Inc.

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A

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN

CSB04-6

Compliance Necessary to Maintain Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT: INSPECTION OF TSIO-550 AND TSIOL-550 ENGINES WITH P/N 654867 PISTONS INSTALLED PURPOSE: To inspect installed pistons for heat damage and possible cracks. COMPLIANCE: Initial inspection required within 25 hours or at the next 100 Hour or Annual Inspection, whichever occurs first. Recurring inspection required at each 100 Hour / Annual Inspection thereafter, whichever occurs first, until the pistons are replaced. MODELS AFFECTED:

All New and Rebuilt TSIO-550-Series and TSIOL-550-Series engines shipped from the factory between 04/28/1998 and 09/11/2003, and any affected engine model which may have had P/N 654867 pistons installed during repair or overhaul.

GENERAL INFORMATION Between 04/28/1998 and 09/11/2003 Teledyne Continental Motors installed P/N 654867 pistons in New and Rebuilt TSIO-550-Series and TSIOL-550-Series engines. (Reference Table 1 for affected engines by serial number.) During factory installation, some of the pistons may have been position-stamped above the piston pin bore. Reports from the field have indicated a small number of these pistons have cracked, generally in the area of the position stamp. INSPECTION PROCEDURES (1) During the borescope portion of the routine engine inspection, visually inspect the piston upper surface for the presence of a piston position stamp. (Reference the most current revision of SB03-3 Differential Compression Test and Borescope Inspection Procedures For Cylinders.) Pistons stamped at the factory may have an 1/8” numerical stamp located over the piston pin bore approximately 1” from the piston outer edge. (2) If a stamp is found located over the piston pin bore, closely inspect the area surrounding the numerical stamp for evidence of excessive heat indications or cracking. Also carefully inspect the entire area noted in Figure 1 for crack indications. (3) If no stamp is found, carefully inspect the entire area noted in Figure 1 for excessive heat indications or cracking. Damage may be present anywhere in the noted inspection area, even in the absence of a position stamp. ISSUED

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 2004 Teledyne Continental Motors, Inc.

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P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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(4) If evidence of heat damage or cracking is noted, the piston must be removed and replaced with the latest part number replacement piston, using the procedures contained in the appropriate Overhaul or Maintenance Manual. Engines with pistons being replaced due to heat damage indications must also have: (a)The fuel system adjustment verified in accordance the most current revision of Service Information Directive SID97-3 and (b) The magneto timing checked in accordance with the most current revision of Mandatory Service Bulletin MSB94-8 and the appropriate engine Maintenance or Overhaul Manual. (5) If no indications of excessive heat or cracking are noted, make a log book entry indicating compliance with the initial inspection requirements of Critical Service Bulletin CSB04-6. Indicate in the entry the next recurring inspection to be accomplished at the next 100 Hour/Annual Inspection, whichever occurs first. (6) All P/N 654867 pistons must be replaced at the next overhaul or any time a cylinder is removed. Replacement will cancel all requirements of this bulletin. (7) Any new uninstalled P/N 654867 pistons may be returned to TCM for exchange with the latest part number replacement piston.

WARNING FAILURE TO COMPLY WITH THIS BULLETIN CAN LEAD TO UNDETECTED PISTON DAMAGE, WHICH CAN RESULT IN LOSS OF ENGINE POWER AND/OR ENGINE FAILURE

INSPECTION AREA PISTON PIN BORE

FIGURE 1 P/N 654867 PISTON

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 2004 Teledyne Continental Motors, Inc.

M O T O R S

A Teledyne Technologies Company

P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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TABLE 1 Engine Models and Serial Numbers

Column 1 Engine Model Number TSIO550C1B

Column 2

Engine Serial Number 802581 820582 802586 802587 802589 802590 802591 802593 802596 802597 802598 802599 802601 802602 802603 802604 802605 802608 802611 802613 814503 814504 814505 814506 814507 814508 814509 814510 814511 814512 814513 814514 814515 814517 814518 814520 814521 814524 814525 814526 814527 814528 814529 814530 814531

ISSUED

Engine Model Number TSIO550C1B

TSIO550C3B TSIO550C5B TSIO550C6B TSIO550E1B

Column 3

Engine Serial Number 814532 814533 814535 814536 814537 814538 814539 814540 814541 814542 814543 814545 814546 814548 814550 814552 814553 814554 814555 814556 814557 814558 814559 814560 814561 814562 814563 814564 814565 802607 814547 802609 802614 803601 803065 803069 803077 803078 803079 803081 83082 803087 803088 803090 803091

Engine Model Number TSIO550E1B

TSIO550E2B

TSIO550E3B

REVISED

Engine Serial Number 803095 803097 803099 803104 803106 803107 803108 803109 803110 803112 803113 803114 803115 803119 803125 803127 803128 803131 803132 803135 803136 803137 803141 803142 803144 803146 803148 803149 803151 803153 803154 803159 803160 803168 803182 803197 803060 803121 803147 803155 803184 803186 803064 803068 803084

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 2004 Teledyne Continental Motors, Inc.

M O T O R S

A Teledyne Technologies Company

P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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Column 4 Engine Model Number TSIO550E3B

Column 5

Engine Serial Number 803085 803086 803089 803093 803094 803098 803100 803101 803102 803103 803105 803116 803120 803126 803129 803130 803133 803134 803138 803139 803140 803143 803150 803157 803158 803161 803162

ISSUED

Engine Model Number TSIO550E3B

TSIO550E4B TSIO550E5B

TSIOL550A1G

TSIOL550A9B

Column 6

Engine Serial Number 803163 803164 803165 803166 803170 803171 803173 803174 803177 803179 803180 803190 803192 803193 803194 803196 803198 803195 803071 803073 803075 829751 800651 800652 809259 809261 800648

Engine Model Number TSIOl550A9B TSIOL550C1B

REVISED

Engine Serial Number 800653 803259 803260 803261 803262 803263 803264 803265 803266 803267 803268 803269 803270 803271 803272 803273 803274 803275 803276 803297 803298 803300 803301 803302 803303 803304

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 2004 Teledyne Continental Motors, Inc.

M O T O R S

A Teledyne Technologies Company

P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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WARRANTY (1) TCM will cover up to 5 hours labor under warranty to perform the initial inspection. The completed, signed compliance form and labor invoice must be submitted to TCM for warranty consideration. (2) Contact TCM Warranty Services at 1-888-826-5465 Option 2 or 1-251-438-3411 if pistons are found to be damaged as explained in items (2), (3) and (4) above, or if you have new unused P/N 654867 pistons in stock. On completion of this Critical Service Bulletin, complete the Compliance form below. Failure to complete this form and submitt it to TCM may result in a delay in processing your warranty claim. You may mail this form to: Teledyne Continental Motors P.O. Box 90 Mobile, AL 36601 Attn: Bill Ross or Joe Barton

COMPLIANCE FORM Owner Name:

Date:

Address: City:

State/Country:

Zip Code:

City:

State/Country:

Zip Code:

Aircraft Registration #:

Make/Model:

S/N:

Engine Model:

Serial Number:

Date Installed:

FBO Name: Address:

Engine Total Time: Inspection Results / Comments:

Signature:_______________________________________________

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 2004 Teledyne Continental Motors, Inc.

M O T O R S

A Teledyne Technologies Company

P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 2

CRITICAL SERVICE BULLETIN

CSB07-2

COMPLIANCE NECESSARY TO MAINTAIN SAFETY

Technical Portions FAA Approved

SUBJECT:

TURBOCHARGER WASTEGATE OIL INLET FITTING INSPECTION and REPLACEMENT

PURPOSE:

To provide instructions for the inspection of the turbocharger wastegate oil inlet fitting for possible chafing on the adjacent structure and to provide instructions for fitting replacement.

COMPLIANCE

Prior to the next aircraft flight.

MODELS AFFECTED:

TSIO-360-RB;LTSIO-360-R: See Serial Number Listing

GENERAL Teledyne Continental Motors (TCM) has received a report from the field of possible interference between the turbocharger wastegate oil inlet fitting and the adjacent airframe engine mount structure. Damage to the wastegate oil inlet fitting could lead to fitting fracture and subsequent loss of engine oil. WARNING Loss of engine oil could lead to internal engine damage, loss of engine power, engine failure, damage to the airframe, personal injury or death. All new TSIO-360-RB engines S/N 322761 to S/N 322793 and new LTSIO-360-RB engines S/N 322516 to 322546 that were shipped from the Teledyne Continental Motors factory to Piper Aircraft Inc. for installation in new aircraft must be inspected prior to further flight in accordance with the instructions contained in this Critical Service Bulletin. In addition: All new LTSIO-360-RB engines S/N 322526 to S/N 322555; All rebuilt LTSIO-360-RB engines S/N 819525 to S/N 819533 All new TSIO-360-RB engines S/N 322777 to S/N 322802 All rebuilt TSIO-360-RB engines S/N 819275 to S/N 819282 that were sold through an authorized TCM distributor for aftermarket installation must be inspected prior to further flight in accordance with the instructions contained in this Critical Service Bulletin. WARRANTY 1. TCM will reimburse the inspection portion of this bulletin for up to .5 hour labor per engine at the posted shop labor rate. Labor warranty may be filed through any TCM authorized distributor. 2. Parts, shipping and an additional 1.5 hours labor at the posted shop labor rate will be reimbursed under warranty for each engine requiring fitting replacement. ISSUED

REVISED

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© 2007 TELEDYNE CONTINENTAL MOTORS, INC.

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INSPECTION PROCEDURES 1. Using the airframe manufacturer’s maintenance instructions, open or disconnect each engine cowl flap to allow access to the wastegate actuator. (Reference Figure 1) 2. Inspect the oil inlet fitting of the wastegate actuator. 3. If the fitting is a one-piece 90° fitting as shown in Figure 2A, no further action is required. Reassemble the previously removed airframe components using the applicable airframe manufacturer’s maintenance instructions. Make engine log book entries for each engine inspected certifying compliance with this Critical Service Bulletin. 4. If the fitting is a two piece assembly (straight fitting and 90° fitting) as shown in Figure 2B, proceed to the fitting replacement instructions contained in this Critical Service Bulletin. FITTING REPLACEMENT 1. Using the airframe manufacturer’s maintenance instructions, open or disconnect the engine cowl flaps and remove the engine cowling as necessary to allow access to the wastegate actuator. (Reference Figure 1) 2. Disconnect the wastegate actuator oil inlet pressure hose P/N 646644S4S21.00 from the wastegate actuator by disconnecting hose from the wastegate oil inlet 90 degree fitting. Cap the hose to prevent contamination during the fitting replacement. 3. Remove the 90 degree fitting P/N MS51521B4, straight fitting MS51525B4, and O-ring seal P/N 630979-15 from the oil inlet on the wastegate and discard. (Reference Figure 3) 4. Inspect Hose P/N 646644S4S21.00 for any signs of chafing or damage to the fitting. Replace if any damage is noted. 5. Inspect the adjacent engine mount structure for any chafing damage from the wastegate actuator fitting or hose. If any damage to the engine mount structure is noted, inspect the damage per the applicable airframe manufacturer’s maintenance instructions or contact Piper Customer Service at 1-772-978-6573. 6. Install replacement 90 degree fitting P/N AN833-4 with new O-ring P/N 630979-15 (O-Ring P/N MS28778-4 is an approved alternate) and Jam nut P/N AN924-4. Lightly lubricate the Oring with clean 50W engine oil before installation. 7. Clock the P/N AN833-4 fitting to allow connection of wastegate oil pressure hose while maintaining sufficient clearance between the fitting and the airframe engine mount structure. While holding the fitting in position to ensure clearance between the fitting and the airframe engine mount structure, ensure that the o-ring is seated in the relief boss on the fitting. Screw ISSUED

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the jam nut finger tight against the fitting boss. Torque the jam nut to 85-105 inch-pounds while holding the correct fitting orientation. 8. Install the wastegate oil pressure supply hose P/N 646644S4S21.00 to the wastegate oil inlet 90 degree fitting. Using a back-up wrench, torque hose fittings in accordance with the instructions contained in the latest revision of TCM bulletin SB96-7. 9. Using the airframe manufacturer’s maintenance instructions, reassemble any removed airframe components and reinstall the cowling. 10. Perform an engine ground run using the airframe manufacturer’s pilots operating handbook. After the ground run check all engine lubricating system fittings for leaks and verify clearance was maintained between the wastegate oil inlet fitting and the engine mount structure. Repair any leaks found prior to further flight. 11. Make an engine logbook entry certifying compliance with this Critical Service Bulletin.

INSPECTION AREA

FIGURE 1 INSPECTION AREA

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646644S4S21.00 Hose Assembly

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A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

AN833-4 FITTING AN924-4 JAM NUT 630979-15 SEAL (Alternate Seal MS28778-4) PAGE NO REVISION

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FIGURE 2A NEW INSTALLATION

MS51521B4 FITTING (Discard)

MS51525B4 FITTING (Discard) 630979-15 SEAL (Discard)

FIGURE 2B OLD INSTALLATION

MS51525B4 FITTING 630979-15 SEAL REMOVE AND DISCARD

MS51521B4 FITTING REMOVE AND DISCARD

FIGURE FIGURE 2

3 FITTING REPLACEMENT DETAIL

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 2

CRITICAL SERVICE BULLETIN

CSB08-11 Technical Portions FAA Approved

COMPLIANCE NECESSARY TO MAINTAIN SAFETY SUBJECT: Kelly Aerospace® Power Systems Service Bulletin 033 PURPOSE :

To provide notification of Mandatory Replacement of Cooling Fan and Pulley Assemblies on TCM P/N 656872 , Kelly Aerospace P/N ES7024-11 and TCM P/N 657199 Kelly Aerospace ES7024-14 back-up alternators. Kelly Aerospace Mandatory Service Bulletin 033 is attached

COMPLIANCE: As required by Kelly Aerospace Service Bulletin 033 (Attached) MODELS AFFECTED: All IO550N and IOF550N engines equipped with the TCM 656872, ES2074-11 and TCM 657199, ES7024-14 GENERAL It has come to the attention of Kelly Aerospace Power Systems, that certain IO550N and IOF550N engines installed in Cirrus Design SR22 aircraft equipped with the backup alternators listed in the attached bulletin, may experience failure in the cooling fan of the backup alternator. This Service Bulletin is issued to mandate the replacement of both the fan and pulley assemblies on the 656872 ES7024-11 and 657199 ES7024-14 backup alternators listed in the attached bulletin. Announcement of the availability of a replacement alternator fan, part number 657582 and pulley, part number 657583 is included in this bulletin Serial numbers of affected alternators are included in attached Kelly Aerospace Service Bulletin 033.

. WARRANTY Warranty consideration in the compliance of this bulletin will be; Labor of 1.5 hours at posted shop rate and parts required for bulletin completion. All compliance to be performed by approved Cirrus Design Service Centers. All warranty consideration in the compliance with this bulletin will be provided by Teledyne Continental Motors through Cirrus Design.

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Original

Service Bulletin Compliance is Considered Mandatory

Bulletin No. 033

Issue Date: July 11, 2008

ES7024-11 (TCM P/N 656872) ES7024-14 (TCM P/N 657199) ALTERNATOR FAN AND PULLEY REPLACEMENT INTRODUCTION: It has come to the attention of Kelly Aerospace Power Systems, that certain Cirrus Design SR22 airplanes may experience failures in the cooling fan of the backup alternator. During normal operation of the ES7024-11 (TCM 656872) & ES7024-14 (TCM 657199) backup alternator, a variable resonance condition with the cooling fan currently installed, may result in the development of cracks in portions of the blades. This condition, left uncorrected, may lead to the loss of the entire fan assembly with the potential loss of alternator function. This Service Bulletin is being issued to mandate the replacement of both the fan and pulley assemblies on the existing ES7024-11 (TCM 656872) & ES7024-14 (TCM 657199) alternators and to announce the availability of an improved pulley assembly which when installed will remedy the above condition. COMPLIANCE: Within the next ten (10) hours time in service or at the next regularly scheduled maintenance event or annual inspection which ever occurs first. EFFECTIVITY: All Cirrus Design SR22 Airplanes utilizing a Kelly Aerospace Power Systems ES7024-11 or ES7024-14 backup alternator installed per the serial numbers listed below.

Suspect Serial Numbers - ES7024-11

New

F012805

F012806

F012807

F013887

F013888

F073050

G051889

G051890

G061199

G061200

G061201

G061202

G061203

H024787

H051538

H051539

H051540

H051541

I031197

I051109

I051110

I051111

I052679

Kelly Aerospace Power Systems Service Bulletin 033

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Suspect Serial Numbers - ES7024-14 H025905

H025906

H025907

H025908

H025909

H051542

H060577

H060578

H060579

H060580

H060581

H060582

H060583

H060584

H060585

I031198

I031199

I031200

I031201

I031202

I031203

I041577

I041578

I041579

I041580

I041581

I041582

I041583

I041584

I041585

I041586

I041587

I041588

I041589

I041590

I041591

I041592

I041593

I041594

I041595

I050132

I050133

I050134

I050135

I050136

I050137

I050138

I050139

I050140

I050141

I050142

I050143

I050144

I050145

I050146

I050147

I050148

I050149

I050150

I050151

I050507

I050508

I050509

I050510

I050511

I050512

I050513

I050514

I050515

I050516

I050517

I050518

I050519

I050520

I050521

I050522

I050523

I050524

I050525

I052606

I052607

I052608

I052609

I052610

I052611

I052612

I052613

I052614

I052615

I052616

I052617

I052618

I052619

I052620

I052638

I052639

I052640

I052641

I052642

I052643

I060752

I060753

I060754

I060755

I060756

I060757

I060758

I060759

I061324

I061325

I061326

I061730

I061731

I061732

I061733

I061734

I061735

I061736

I061737

I061738

I061739

I061740

I061741

I061742

I061743

I061744

I061745

I061746

I061747

I061748

I061749

I061750

I061751

I061752

I062099

I062100

I062101

I062102

I062103

I062104

I062105

I062106

I062107

I062108

I062109

I062110

I062111

I062112

I062113

I062569

I062570

I062571

I062572

I062573

I062574

I062575

I062576

I062577

I062578

I062601

I062602

I062603

I062604

I062605

I062606

I070067

I070068

I070069

I070070

I070071

I070072

I070073

I070265

I070266

I070267

I070268

PROCEDURE:

CAUTION:: This procedure must be performed by competent and qualified personnel familiar with engine and airframe maintenance that is specific to the electrical system.

CAUTION:: Do not depend on this Service Bulletin for gaining access to the aircraft or engine. This instruction requires that you use the applicable manufacturers maintenance manuals. In addition, any preflight or inflight operational checks require use of the appropriate AFM or POH.

Replacing Alternator Fan and Pulley 1.

Remove all electrical power from the aircraft before beginning work. Assure that the aircraft battery has been disconnected and that no external power is hooked up.

2. Access the aircraft backup alternator by removing the engine cowling as required in accordance with instructions contained in the Cirrus Design aircraft maintenance manual. 3. Loosen the alternator from the mount and slide the belt off. Retighten alternator to mount if fan and pulley are to be changed on the airplane. 4. Remove the alternator pulley nut, washer, pulley, and fan. The removal must be done using a nylon strap wrench (do not use rubber or chain). Apply a section of suitable alternator “V” belt of a length sufficient to wrap at least 320 degrees around and into the groove with the belt higher than the circumference of the pulley. To hold the pulley for the nut removal, place the strap wrench over the belt and pulley and tighten strap. This may be accomplished on or off the airplane.

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Kelly Aerospace Power Systems Service Bulletin 033

New

Replacing Alternator Fan and Pulley (cont’d) 5. Install a new TCM P/N 657582 fan, and new TCM P/N 657583 pulley as shown in Figure 1. Use the existing pulley nut and the locking washer. Take care when removing the locking washer as it is a special device which has two pieces. The sharp serrations must face outward while the shallow ramp must face each other. Using the strap wrench per instruction 4 above, torque the pulley nut to 35 to 45 ft-lbs. 6. Install the alternator belt (new or existing) on to the pulley and tension per instructions contained in the applicable manufacturers maintenance manual. 7. Perform an engine run to check the security and performance of the backup alternator installation and proceed to the “Return to Service” section.

Figure 1 - Alternator Part Replacement RETURN TO SERVICE: NOTE:: The alternator in question is only installed in Cirrus Design SR22 aircraft utilizing a backup alternator system. Check for the latest publication issued by Cirrus Design regarding aircraft model, serial number and warranty procedures. 1.

Utilizing the applicable aircraft and engine manufacturers maintenance manuals, install any portion of the aircraft removed to gain access.

2.

Upon successful completion of this service bulletin by repair of the alternator, make an appropriate log book entry of compliance.

New

Kelly Aerospace Power Systems Service Bulletin 033

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MATERIAL REQUIRED: One (1) each, fan, TCM part number 657582, and one (1) each, pulley, TCM part number 657583. AVAILABILITY OF PARTS: Parts to support this service bulletin must be obtained from an authorized Cirrus Design Service Center. WARRANTY STATEMENT: The sole warranty applicable to this service publication is related to the material listed in the “Material Required” section above provided the parts are obtained through an authorized Cirrus Design Distributor or Service Center. Other warranty may apply per the terms and conditions in the aircraft manufacturers Limited Warranty Policy. To qualify for warranty consideration, all work must be accomplished at an authorized Cirrus Design Service Center. All requests for labor related to this publication must be filed through the appropriate Cirrus Design Service Center. This publication does not imply or state any responsibility for the workmanship of any person or entity performing work or maintenance on the turbocharger, engine, or aircraft. CONTACT INFORMATION: If you have any questions concerning the instructions in this service bulletin, please contact Kelly Aerospace Power Systems Technical Support at 888-461-6077. Questions concerning aircraft service or operation must be forwarded to the applicable manufacturer of that product.

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Kelly Aerospace Power Systems Service Bulletin 033

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 2

CRITICAL SERVICE BULLETIN

CSB08-9A Technical Portions FAA Approved(Supersedes CSB08-9)

COMPLIANCE NECESSARY TO MAINTAIN SAFETY SUBJECT: Slick Service Bulletin SB3-08A

PURPOSE: Notification and support of the Mandatory Inspections Called for in SB3-08A COMPLIANCE: As listed in bulletin, time in service sensitive MODELS AFFECTED: Engines equipped with Slick 4300/6300 magnetos and Lasar™ 4700/6700 magnetos as designated in the bulletin

GENERAL Unison Industries has issued Slick Service Bulletin SB3-08A dated 09-11-2008, concerning inspections of specific magneto models as listed above. The affected magnetos may be installed on various TCM model engines. Inspections are considered Mandatory and must be accomplished as required by the attached bulletin.

WARNING FAILURE TO COMPLY WITH THE RECOMMENDED INSPECTIONS OF SLICK SERVICE BULLETIN SB3-08A MAY CAUSE INTERRUPTION OF ENGINE OPERATION DUE TO MAGNETO FAILURE. Questions? Contact Unison Piston Products Technical Support Hotline at 904-739-4081 Unison Technical Publications Web-site: www.unisonpubs.com Teledyne Technical Services 888-826-5465

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T e le d y n e C o n t in e n t a l M o t o r s, In c . P.O. BOX 90 MOBILE, AL 36601 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

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SB3-08A SLICK Service Bulletin UNISON PROPRIETARY INFORMATION The information contained in this document is Unison proprietary information and is disclosed in confidence. It is the property of Unison and shall not be used, disclosed to others or reproduced without the express written consent of Unison. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by U.S. export control laws. Unauthorized export or re-export is prohibited. TO: Aircraft manufacturers, distributors, dealers, engine overhaul facilities, owners and operators of Slick Aircraft Products aircraft magnetos. SUBJECT: Mandatory inspections on all Slick 4200/6200/4300/6300 and LASAR™ 4700/6700 magnetos MAGNETO MODELS AFFECTED: • Slick and LASAR™ magnetos with serial numbers beginning with 0409XXXX through 08080453. • Magnetos which have had carbon brush or distributor block assembly replaced with components packaged between September 1, 2004 and August 14, 2008. ENGINE MODELS AFFECTED: Engines utilizing Slick and LASAR™ magnetos. AIRFRAME MODELS AFFECTED: Aircraft utilizing Slick and LASAR™ magnetos. BACKGROUND INFORMATION: Field reports indicate operators have experienced premature carbon brush wear. Premature brush wear can lead to failure of the magneto to provide consistent spark and possible loss of engine power. This bulletin describes an inspection schedule for specific serial number ranges and magneto and brush operating times due to observed variations in premature wear rates. Bulletin SB3-08A supersedes bulletin SB3-08. The bulletin has been updated to ease the inspection schedule for low operating time magnetos, to provide an ending serial number for the affected range of magnetos, and to announce the availability of new design magnetos and replacement parts. Inspections that were carried out per the schedule originally recommended in SB3-08 should be considered when determining the need for additional inspections per this revised bulletin. For magnetos that require continued special inspections per this bulletin, Unison recommends replacement of the carbon brush, or distributor assembly, or magneto with new design parts as described in the Detailed Instructions to prevent the need for additional special inspections. ISSUED MO DAY YR

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Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 2008 Unison Industries, LLC

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SLICK Service Bulletin

SB3-08A

New Magnetos, manufactured after the ending serial number indicated, and new replacement Brush Kits, and Distributor Kits, manufactured after August 14, 2008, contain a new carbon brush material that is less susceptible to accelerated side-wear in the distributor gear shaft. The new material has successfully completed substantial bench and flight tests, accumulating extensive service time in both four and six cylinder engine applications. Design improvements have also been made to the distributor gear assembly, revising tolerances to reduce gear shaft end-play to help reduce brush side-wear, and to the distributor bearing support bar, adding ribs to effectively increase the distance across the insulating material surface. COMPLIANCE: •

For all magnetos with serial numbers 0409XXXX through 0611XXXX, and all magnetos that have had a carbon brush or distributor block replaced with components packaged between September 1, 2004 and November 30, 2006 perform Compliance Step 2 only. See Detailed Instructions for Service Bulletin ending compliance information.

•

For all magnetos with serial numbers between 0612XXXX and 08080453, and all magnetos that have had a carbon brush or distributor block replaced with components packaged between December 1, 2006 and August 14, 2008, perform Compliance Steps 1 or 2 as applicable based on magneto operating time. See Detailed Instructions for Service Bulletin ending compliance information.

COMPLIANCE STEPS *

Total magneto operating time is defined as magneto engine operating time since new or since carbon brush replacement, whichever is less.

1.

For magnetos with some operating time but less than 250 hours of engine operating time, if not previously inspected per SB3-08 initial issue, inspect within the next 25 hours of operation. Inspect again within the next 250 hours or at the 500 hour magneto service interval, whichever comes first. Subsequently follow the recommended inspection schedule in the applicable Unison or engine/airframe manufacturer’s Maintenance and Overhaul publications.

2.

For magnetos with greater than 250 hours of engine operating time that have not yet been inspected pursuant to this service bulletin, inspect the magneto within the next 50 hours or at next annual inspection, whichever occurs first. Subsequently, follow the recommended inspection schedule in the applicable Unison, or engine or airframe manufacturer's Maintenance and Overhaul publication(s). No further special inspections per this bulletin are required unless brush or distributor assembly is replaced. NOTE: If the distributor block assembly or carbon brush are replaced with parts packaged between September 1, 2004 and August 14, 2008, perform Service Bulletin requirements as applicable.

PROOF OF COMPLIANCE: Appropriate logbook entries.

UNISON PROPRIETARY INFORMATION – Subject to the restrictions on the cover or first page ISSUED MO DAY YR

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PARTS REQUIRED PER BULLETIN: As required by inspections described in this Service Bulletin, do one or more of the following: replace magneto, or distributor block (4-cylinder distributor Kit P/N K3822 or 6-cylinder distributor Kit P/N K3823), or carbon brush (Kit P/N K3215), or coil (Kit P/N K3975 or K5275) specified in Maintenance and Overhaul Manuals L-1037, L-1363, or L-1503 as applicable. TOOLS REQUIRED PER BULLETIN: Slick T-100 Tool Kit, magneto timing light, T-300 SynchroLASAR™ and standard shop tools as applicable. WEIGHT CHANGE: None. REQUIRED SERVICE LITERATURE: Refer to the following literature when performing the instructions listed below: Slick 4200/6200 Magneto Maintenance and Overhaul Manual L-1037 Slick 4300/6300 Magneto Maintenance and Overhaul Manual L-1363 LASAR™ 4700/6700 Magneto Maintenance and Overhaul Manual L-1503 Slick Service Bulletin SB2-08 - Magneto Breaker Cam Inspection WARRANTY INFORMATION: If damage or premature wear listed in this Service Bulletin is discovered during inspection, and the magneto is within Unison's 1-year warranty period, the magneto may be returned through your point of sale for warranty replacement. For magnetos outside the 1-year warranty period in which components listed in this bulletin have failed, those components may be returned under warranty through your point of sale. DETAILED INSTRUCTIONS: 1. Use lighted magnification (4X minimum) to inspect carbon brush for rough surface and possible tapering. REPLACE CARBON BRUSH THAT SHOWS ANY OF THE UNACCEPTABLE CONDITIONS SHOWN IN FIGURE 1 PER THE APPLICABLE MAINTENANCE AND OVERHAUL MANUAL. Undercut or nailhead

Smooth, semi-glossy surface

Acceptable

Rough surface

Tapering

Unacceptable

Undercut or nailhead

Rough surface

Tapering

Unacceptable

Carbon Brush Figure 1 UNISON PROPRIETARY INFORMATION – Subject to the restrictions on the cover or first page ISSUED MO DAY YR

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2. Inspect coil tab for carbon residue coating left by carbon brush. See Figure 2. REPLACE CARBON BRUSH PER THE APPLICABLE MAINTENANCE AND OVERHAUL MANUAL IF SUBSTANTIAL RESIDUE IS FOUND ON COIL TAB. Use a cotton swab and alcohol to remove residue from coil tab, or replace coil if tab cannot be cleaned. Also inspect high tension coil tab for wear caused by carbon brush. Wear is indicated by a visible depression in the tab. If tab is worn, replace coil.

Acceptable

Unacceptable Evidence of Improper Wear of Carbon Brush Figure 2

3. Inspect bearing bar for evidence of brush residue contamination, burning, or arcing. See Figure 3. REPLACE DISTRIBUTOR BLOCK ASSEMBLY PER THE APPLICABLE MAINTENANCE AND OVERHAUL MANUAL IF THERE IS ANY EVIDENCE OF ELECTRICAL ARCING OR BURNING. The new bearing bar can be identified by either the manufacturer-dated packaging, or visually by noting the dams.

Unacceptable (Developing bearing bar failure) Bearing Bar Figure 3 UNISON PROPRIETARY INFORMATION – Subject to the restrictions on the cover or first page ISSUED MO DAY YR

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4. If bearing bar does not show evidence of burning or arcing, clean and remove any normal residue per the applicable Maintenance and Overhaul Manual and reassemble into the magneto. CAUTION:

IF THE COIL TAB PROTRUDES ABOVE THE MAGNETO FRAME, IT CAN MAKE DIRECT CONTACT WITH THE DISTRIBUTOR GEAR AXLE AND CAUSE THE MAGNETO TO MALFUNCTION.

5. Prior to installing distributor block, make sure coil tab is parallel to and flush with frame mating surface to within 1/32 inch. See Figure 4.

Parallel and Flush To 1/32 Below Frame

Parting Surface Of Frame

Spring Loaded Carbon Brush

Coil Coil Tab

Coil Tab Positioning Figure 4 6. Service Bulletin ending compliance can be documented if existing magneto is replaced by new magneto with serial number 08080454 or later, or if the carbon brush and/or distributor block has been replaced by one manufactured after August 14, 2008, or if the magneto has accumulated 500 hours of engine operating time and has passed the Service Bulletin inspection requirements. Make an appropriate logbook entry. NOTE: Special provisions have been made with Unison Distributors for replacement kits. Visit www.unisonindustries.com/ourproducts/distributors.html for a list of Unison’s authorized distributors.

Unison Piston Products Technical Support Hotline: 904-739-4081 Unison Technical Publications Web-site: www.unisonpubs.com

UNISON PROPRIETARY INFORMATION – Subject to the restrictions on the cover or first page ISSUED MO DAY YR

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Warranty If your TCM engine is within the original full coverage warranty period as stated in your written warranty, contact TCM Technical Services at 1-888-826-5465, option 2 Beyond the full warranty coverage period, contact Unison Hotline for assistance.

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

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®

TELEDYNE CONTINENTAL IGNITION SYSTEMS

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety SUBJECT: REASON FOR BULLETIN:

CATEGORY 2

CSB641 FAA APPROVED

POSSIBLE OPEN CONDITION OF SC-20, SC-200 AND S-1200 SERIES MAGNETO CAPACITOR, P/N 10-349276 Quality assurance testing has revealed the potential for incomplete internal grounding circuits on magneto capacitors P/N 10-349276 delivered to TCM by a component supplier during the period of October through December, 1993. Although these capacitors originally passed acceptance test, the possibility exists for the ground to be lost with time due to operational vibration. In the interest of safety, TCM is recalling and replacing all capacitors P/N 10-349276 with date codes 93-40 and 93-42 and will cover the customer's cost of inspection and replacement. WARNING . . The propeller must not be moved by hand on engines that may contain affected capacitors until the inspection and/or replacement instructions set forth in this service bulletin are complied with. To do so could cause the engine to fire which may result in serious bodily injury or death.

EQUIPMENT AFFECTED:

1.

All new and rebuilt SC-20, SC-200 and S-1200 Series Magnetos (Part number series 10-500XXX-X, 10-600XXX-X and 10-349XXX-X, respectively) with manufacturing (serial) numbers: J2793XXX(R) through J3193XXX(R), K0193XXX(R) through K3093XXX(R), L0193XXX(R) through L2293XXX(R) inclusive, with capacitor P/N 10-349276 marked with date code 93-40 or 9342 installed, except magnetos identified as being already in compliance with this Bulletin as specified under IDENTIFICATION. NOTE . . . The "X" numbers in the part and serial numbers have no significance in determining affectivity. Only the first five digits are needed. The "(R)" at the end of the serial numbers indicates "rebuilt". The absence of an "(R)" indicates a "new" magneto. 2. All magnetos that have had spare capacitors P/N 10-349276 installed subsequent to October 27, 1993 identified with date codes 93-40 and 93-42.

3. COMPLIANCE:

1.

All spare capacitors, P/N 10-349276 identified with date codes 93-40 and 9342. All affected magnetos and magnetos that have had spare P/N 10-349276 capacitors installed subsequent to October 27, 1993 must be inspected and affected capacitors replaced within 25 operating hours or immediately if a "Hot Magneto" (no R.P.M. drop) is found to exist during a magneto drop check while performing an engine run-up. Return all capacitors that are replaced to

Teledyne Continental Motors Attention: Service Department 2000 9th Street Mobile, Al 36615 (205) 438-3411 Ext. 305 2.

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All spare capacitors P/N 10-349276 must be inspected and those identified with date codes 93-40 and 93-42 returned to TCM.

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in. lbs. torque to each of the four breaker cover retaining screws. When reinstalling "plead", apply 15 to 17 in. lbs torque to nut on stud terminal. Identify magneto as specified under IDENTIFICATION.

GENERAL INFORMATION: In P/N 10-349276 Capacitor Assemblies marked with date codes 93-40 and 93-42, an intermittent open circuit condition may exist between the internal thru-lead and the "p-lead" stud terminal. If this open circuit condition exists, the magneto cannot be shut off during magneto RPM drop-off check ("Mag drop check") or at engine shut down. A hazardous "Hot Magneto" condition exists under these conditions. Because of the intermittent nature of this open circuit condition, Teledyne Continental Motors is requiring return of all affected capacitors from the field. DETAILED INSTRUCTIONS: 1.

For affected magnetos and magnetos that have had spare P/N 10-349276 capacitor installed subsequent to October 27, 1993: Note . . . If access allows, the following procedures may be performed with the magneto installed on the engine. Otherwise, the magneto must be removed from the engine, the following procedures performed, and the magneto reinstalled on the engine following the Engine Manufacturer's latest published procedures.

1.1 Remove the two screws securing the capacitor to the magneto cover and gently slide the capacitor out just enough to view the ink stamped date code on the side. If the date code is other than 93-40 or 93-42, reinstall the capacitor, apply 8 to 12 in. lbs. torque to both capacitor securing screws, and identify the magneto as specified under IDENTIFICATION.

1.3 Make an engine logbook entry indicating compliance with this Service Bulletin. Include magneto part number and manufacturing (serial) number in the logbook entry. Return all capacitors marked with P/N 10-349276 and date codes 93-40 or 93-42 to TCM. 2.

For spare capacitors:

2.1 Return all spare capacitors marked with P/N 10-349276 and date codes 93-40 or 93-42 to TCM. IDENTIFICATION: Upon compliance with the Detailed Instructions of this bulletin, metal stamp the letter "E" approximately 1/8 inch high in the upper left corner of the magneto data plate, near the word "TYPE". WARRANTY CONSIDERATION: All affected equipment will be covered by the TCM Gold Medallion Warranty or Ignition Systems Warranty as applicable, subject to its terms and conditions. Warranty claims may be filed through any TCM Distributor. Up to 1.8 hours labor will be allowed per magneto installed on engine. Up to 1.0 hours labor will be allowed per magneto not installed on engine.

1.2 If the capacitor is marked with date code 93-40 or 93-42, remove breaker cover to allow full access to the capacitor flag terminal. Note capacitor lead routing and flag terminal orientation. Remove capacitor from magneto and remove o-ring packing from the capacitor. Install packing on a replacement capacitor and install replacement capacitor into cover. Apply 8 to 12 in. lbs. torque to both capacitor securing screws. Route lead and install capacitor flag terminal onto breaker in the same orientation as was noted upon removal. Reinstall breaker cover. For S-1200 series magnetos, apply 30 to 35 in. lbs. of torque to the cover securing screw. For SC-20 and SC200 Series magnetos, apply 20 to 25

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TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 2

CRITICAL SERVICE BULLETIN Compliance Necessary to Maintain Safety

CSB 662A Technical Portions FAA Approved SUBJECT:

TCM D-2000 AND D-3000 SERIES MAGNETO CAPACITORS, P/N’S 10-382807, 10-382681, AND 10-382681-1

PURPOSE:

To provide instructions for the replacement of affected capacitors, to revise overhaul replacement requirements for D-2000 and D-3000 capacitors, and to emphasize existing required safety practices.

BACKGROUND:

Investigation of field returns has revealed the potential for incomplete control terminal connections and internal connections to ground in some magneto capacitors, P/N’s 10-382807, 10-382681, and 10-382681-1, delivered to TCM prior to December 1999. Although these capacitors originally passed acceptance test, the possibility exists for the connections to be lost after a short time in service. In the interest of safety, TCM is requiring replacement of all capacitors P/N’s 10-382807, 10-382681, and 10-382681-1 marked with date codes up to and including 9942, and less than 200 hours. WARNING: THE PROPELLER MUST NOT BE MOVED BY HAND ON ENGINES THAT MAY CONTAIN AFFECTED CAPACITORS UNTIL THE REPLACEMENT INSTRUCTIONS SET FORTH IN THIS SERVICE BULLETIN ARE COMPLIED WITH. TO DO SO COULD CAUSE THE ENGINE TO FIRE WHICH MAY RESULT IN SERIOUS BODILY INJURY OR DEATH.

COMPLIANCE:

All affected magnetos, ignition systems, and magnetos that have had spare affected capacitors installed with less than 200 hours time in service must have affected capacitors replaced within the next 50 hours, or at the next scheduled maintenance event, whichever occurs first. All D-2000 and D-3000 series magneto capacitors must be replaced with new capacitors at the time of magneto overhaul.

EQUIPMENT AFFECTED:

1.

All new and rebuilt D4-3000 Series and D8-3000 Series magnetos and ignition systems prior to manufacturing number (Serial Number) L169901G(R) (which indicates a build date of December 16, 1999) with less than 200 hours, and all new and rebuilt D6-3000 magnetos and ignition systems prior to manufacturing number (Serial Number) K179901G(R) (which indicates a build date of November 17, 1999) with less than 200 hours, except magnetos identified as already in compliance as specified under IDENTIFICATION. Refer to TCM Ignition Systems Service Information Letter SIL642 to interpret manufacturing numbers.

2.

All D-2000 and D-3000 Series magnetos that have had spare capacitors P/N’s 10-382807, 10382681, and 10-382681-1 marked with date codes prior to and including 9942 with less than 200 hours, except magnetos identified as already in compliance as specified under IDENTIFICATION. Refer to GENERAL INFORMATION section of this bulletin to interpret capacitor date codes.

3. All TCM D-2000 and D-3000 Series spare capacitors P/N’s 10-382807, 10-382681, and 10382681-1 marked with date codes prior to and including 9942 with less than 200 hours. Refer to GENERAL INFORMATION section of this bulletin to interpret capacitor date codes.

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week of the year, etc.). Therefore, date code 0001 is newer than date code 9942. See figure 1.

GENERAL INFORMATION: Investigation of field returns has revealed that some affected D-2000 and D-3000 capacitors for 4, 6, and 8 cylinder applications may experience open circuit conditions within a short time after installation. Symptoms include (a) engine will crank but will not start, (b) engine will crank and start normally but have 0 (zero) RPM Magneto drop, (c) engine will crank and start normally but will have an excessive magneto drop. As always, the importance of the magneto drop-off check, as specified in the pilot’s operating handbook and TCM Ignition System Service Bulletin SB 653, in determining the airworthiness of the aircraft cannot be overemphasized. Indications exceeding the pilot’s operating handbook limits are cause for investigation and corrective action prior to further flight.

WARNING ZERO RPM MAGNETO DROP INDICATES AN UNAIRWORTHY CONDITION, INCLUDING THE POSSIBILITY OF A HOT MAGNETO WHICH MAY BE A PRELIMINARY SYMPTOM LEADING TO MAGNETO FAILURE. THIS CONDITION MUST BE CORRECTED PRIOR TO FURTHER FLIGHT, OTHERWISE INJURY, DEATH, OR DAMAGE TO PROPERTY MAY RESULT. IN THE EVENT OF A HOT MAGNETO, THE ENGINE MAY INADVERTENTLY EXPERIENCE IGNITION OR START-UP ANY TIME THE PROPELLER IS MOVED. INJURY, DEATH, OR DAMAGE TO PROPERTY MAY RESULT. PLACE A SIGN ON THE PROPELLER INDICATING “HOT MAGNETO”.

WARNING HIGH RPM MAGNETO DROP OR INOPERATIVE MAGNETO INDICATES AN UNAIRWORTHY CONDITION, WHICH MAY BE A SYMPTOM OF MAGNETO FAILURE OR A PRELIMINARY SYMPTOM LEADING TO MAGNETO FAILURE. EITHER OF THESE CONDITIONS MUST BE CORRECTED PRIOR TO FURTHER FLIGHT, OTHERWISE INJURY, DEATH, OR DAMAGE TO PROPERTY MAY RESULT.

All D-2000 and D-3000 capacitors must be replaced with new capacitors at the time of magneto overhaul. DETAILED INSTRUCTIONS: For affected magnetos, ignition systems, and magnetos that have had spare affected TCM 10-382807, 10382681, and 10-382681-1 capacitors installed: 1.

Remove all harness spark plug leads from the spark plugs. Obtain access to the magneto.

2.

Label and disconnect p-leads and any applicable retard or tachometer leads to the magneto.

3.

Disassemble four screws that secure harness cover to the magneto. Discard lockwashers, crushwashers, and self-locking screws. Remove and discard pressure gasket, if used.

4.

Remove nut and lockwasher from capacitor. Using a screwdriver or needle nose pliers, remove capacitor lead from breaker points. Remove capacitors from harness cover.

5.

Measure magneto-to-engine timing for both magnetos. If timing exceeds engine manufacturer’s limits, remove the magneto from the engine to inspect breaker points. Replace breaker assemblies if damage to the cam follower is evident. Adjust breaker points as necessary in accordance with D-2000 and D3000 Service Support manual, Form X42003 or later revision.

6.

Install new capacitors with date code 9943 or newer, and replace attaching hardware and gasket (if used) in accordance with D-2000 and D-3000 Service Support manual, Form X42003 or later revision, SB651, and SB653.

Capacitors are marked with a four-digit date code. The first two digits represent the year (99=1999, 00=2000), and the last two digits represent the week (01= first ISSUED

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IDENTIFICATION:

WARRANTY:

Identify magnetos in compliance with this bulletin by stamping or vibro-peening a letter W in the upper right corner of the magneto data plate. Make an engine logbook entry indicating compliance with this bulletin.

All affected equipment will be covered by the applicable TCM Ignition Systems warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. Up to 2.0 hours labor will be allowed per magneto.

DATE CODE

FIGURE 1 Capacitor date code marking.

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TELEDYNE CONTINENTAL ® IGNITION SYSTEM

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB 664 TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

MAGNETO CAPACITOR P/N 10-400558 REPLACEMENT.

PURPOSE:

TCM has identified a quantity of magneto capacitors part number 10-400558 that could have an open circuit, which would allow a hot magneto condition even when the ignition switch is in the “OFF” position. Critical Service Bulletin provides inspection and disposition instruction for service spare capacitors and magnetos that may contain these capacitors.

COMPLIANCE:

On receipt of this Critical Service Bulletin. Make certain that no one is allowed to move the propeller on an engine suspected of containing an affected capacitor. This could result in an engine start.

PARTS AFFECTED:

All New (10-) and Rebuilt (BL-) S20, S200 and S1200 Series magnetos of all part numbers manufactured, ordered or received between August 1, 2002 and August 31, 2002 identified within the following serial number sequences: D02HA001 through D02HA999, D02HA001R through D02HA999R E02HA001 through E02HA999, E02HA001R through E02HA999R F02HA001 through F02HA999, F02HA001R through F02HA999R All part number 10-400558 capacitors.

WARNING:

DO NOT MOVE THE PROPELLER OF ANY ENGINE CONTAINING AN AFFECTED MAGNETO CAPACITOR. THE ENGINE COULD START, REGARDLESS OF IGNITION SWITCH POSITION, CAUSING PERSONAL INJURY OR DEATH.

A. INSPECTION 1. Inspect the serial number stamped on the magneto data plate to determine if it falls within the sequences listed in “PARTS AFFECTED” above. Also, regardless of magneto serial number, determine if P/N 10-400558 capacitor has been installed. 2. If the magneto serial number is affected or capacitor P/N 10-400558 has been installed in any magneto and for all P/N 10-400558 in inventory, inspect the capacitor potting compound/insulator type. 3. If capacitor P/N 10-400558 potting/insulator material is black (reference Figure 1), the capacitor must be returned to TCM in accordance with Section D. 4. Any capacitor with red insulator material (reference Figure 2) does not require replacement in accordance with this Critical Service Bulletin. ISSUED MO 09

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CSB 664

10-400558 Capacitor with Black Potting

Capacitors with Red Insulator Not Affected

Compound

Figure 1 Affected Capacitor

Figure 2 Serviceable Capacitors

B. CAPACITOR REPLACEMENT INSTRUCTIONS – S20 AND S200 SERIES MAGNETOS 1. Remove airframe and engine components necessary to gain access to the magneto capacitor/contact point cover. 2. Remove 4 magneto cover screws. While removing the cover, carefully remove capacitor lead from contact points terminal, noting terminal placement and lead orientation for reassembly. 3. Remove 2 screws securing the capacitor to the cover and remove capacitor. Remove o-ring packing from affected capacitor. 4. Place o-ring on new capacitor (reference Table 1). Secure capacitor to magneto cover with 2 screws. Torque screws to 8 - 12 in lbs. 5. Attach serviceable replacement capacitor terminal to contact points terminal in accordance with instructions in the applicable Service Support Manual. 6. Attach magneto cover using 4 screws. Torque screws to 20- 25 in lbs. 7. As applicable, record the magneto serial number to be supplied to TCM distribution for warranty application. 8. As applicable, make a engine log book entry as to inspection and/or replacement of the part number 10-400558 capacitor in accordance with TCM Critical Service Bulletin CSB02-8.

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C. CAPACITOR REPLACEMENT INSTRUCTIONS – S1200 SERIES MAGNETOS 1. Remove airframe and engine components necessary to gain access to the magneto capacitor/contact point cover. 2. Remove 4 sets of hardware securing the ignition harness and remove the harness from the magneto. 3. Remove 1 magneto cover screw from the magneto cover. While removing the cover, carefully remove capacitor lead from contact points terminal, noting terminal placement and lead orientation for reassembly. 4. Remove 2 screws securing the capacitor to the cover and remove capacitor. Remove o-ring packing from affected capacitor. 5. Place o-ring on new capacitor (reference Table 1). Secure capacitor to magneto cover with 2 screws. Torque screws to 8 - 12 in lbs. 6. Attach capacitor terminal to contact points terminal in accordance with instructions in the applicable Service Support Manual. 7. Attach magneto cover using 1 screw. Torque screw to 30- 35 in lbs. Install ignition harness with attaching hardware and torque to 18 - 22 in lbs. 8. As applicable, record the magneto serial number to be supplied to TCM distribution for warranty application. 9. As applicable, make a engine log book entry as to inspection and/or replacement of the part number 10-400558 capacitor in accordance with TCM Critical Service Bulletin CSB02-8. TABLE 1 - SELECT REPLACEMENT CAPACITOR For New (10-) and Rebuilt (BL-) Magneto Part Numbers

Use Capacitor Part Number

10-500556-1, 10-500556-3, 10-500556-101, 10-500556-103, 10-600606-1, 10-600606-3, 10-600656-1, 10-600656-3, 10-600616-3

10-400604

All other magnetos

10-349276

D. WARRANTY AND PART DISPOSITION 1. Warranty coverage for inspection and replacement of capacitors is as follows: (a) Due to the simplicity of the capacitor inspection, there will be no labor allowance for inspection of service spare capacitors or magnetos in inventory. (b) Labor allowance for capacitor inspection of one or two affected magnetos installed on an engine – ½ hour total. (c) Labor allowance for capacitor replacement on a magneto installed on an engine – ½ hour per magneto. This includes capacitor inspection – 1.(b). 2. Affected capacitors must be returned to TCM as follows:

MO 09

ISSUED DAY YEAR 06

2002

MO

REVISED DAY YEAR

PAGE NO REVISION

3 of 4 P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

CSB 664

(a) Affected service spare capacitors in inventory – These will be returned to TCM by TCM distribution. Contact an authorized TCM distributor for return instructions and to order a replacement. (b) Affected capacitors removed from magnetos - Contact an authorized TCM distributor for warranty claim application and capacitor return instructions. Make certain that you provide the applicable magneto serial number to ensure proper warranty application. Contact TCM Technical Services at 888-826-5465 or 251-436-8299 or your regional TCM Service Representative if you have any questions concerning this Critical Service Bulletin.

MO 09

ISSUED DAY YEAR 06

2002

MO

REVISED DAY YEAR

PAGE NO REVISION

4 of 4 P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

CSB 664

TELEDYNE CONTINENTAL ® IGNITION SYSTEM

CATEGORY 2

CRITICAL SERVICE BULLETIN

CSB 665A

Compliance Necessary To Maintain Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

MAGNETO CAPACITOR P/N 10-400615 INSPECTION AND REPLACEMENT.

PURPOSE:

TCM has identified a quantity of magneto capacitors part number 10-400615 which may have ground stud (also referred to as the P-Lead stud) threads that do not meet specification. This may allow the ground wire (P-Lead) to come loose, resulting in a hot magneto.

COMPLIANCE:

On receipt of this Critical Service Bulletin. Make certain that no one is allowed to move the propeller on an engine suspected of containing an affected capacitor. This could result in an engine start.

PARTS AFFECTED:

All New (10-) and Rebuilt (BL-) S20, S200 and S1200 Series magnetos of all part numbers in the affected serial number ranges as listed in Table 1, with the exception of the serial numbers listed in Table 2 of this Bulletin.

All spare part number 10-400615 capacitors in the affected date code range. Any magneto which may have an affected capacitor installed as a spare part Between 10/01/2003 and the effective date of this bulletin. REASON FOR REVISION: To correct part number references WARNING:

DO NOT MOVE THE PROPELLER OF ANY ENGINE WHICH MAY CONTAIN AN AFFECTED MAGNETO CAPACITOR. THE ENGINE COULD START, REGARDLESS OF IGNITION SWITCH POSITION, CAUSING PERSONAL INJURY OR DEATH.

A. INSPECTION – AFFECTED CAPACITORS INSTALLED IN MAGNETOS 1. Remove engine cowlings as necessary to gain access to the magneto ground stud (P-Lead) connection. All airframe component removal and reinstallation should be accomplished in accordance with the latest revision of the applicable airframe maintenance manual. 2. Remove the P-Lead from the capacitor ground stud. (Reference Figure 1) 3. Reinstall the P-Lead retaining nut and washer. Using a properly calibrated and certified torque wrench, torque the retaining nut to 27 inch-pounds. 4. If the P-Lead retaining nut can be torqued to 27 inch-pounds without slippage, no further action is required. Remove the retaining nut and reinstall the P-Lead. Torque the retaining nut to 15-17 inch-pounds. Make a log entry in the engine and airframe logbooks stating compliance with this bulletin. 5. If the retaining nut cannot be torqued to 27 inch-pounds, the capacitor must be replaced. Refer to section C or D of this bulletin, as applicable, for capacitor replacement procedures. ISSUED

REVISED

PAGE NO REVISION TM

MO 06

DAY 18

YEAR 2004

MO 08

DAY 20

YEAR 2004

Teledyne Continental Motors, Inc. P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

© 2004 Teledyne Continental Motors, Inc.

1 of 5 CSB 665

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TABLE 1 Affected New (10-) and Rebuilt (BL-) Magneto Serial Number Ranges -S20 Series Magnetos D03JA001 through D04DA157 -S200 Series Magnetos E03JA001 through E04DA148 -S1200 Series Magnetos F03JA001 through F04DA237 Any –S20, -S200 and –S1200 series magneto which through maintenance records can be verified to have had a 10-400615 capacitor installed between October 1, 2003 and the effective date of this Critical Service Bulletin NOTE -20, –200, and –1200 series magnetos with serial numbers higher than those listed in table 1 may have capacitors installed within the affected date code range. These capacitors were tested by the factory prior to installation. TABLE 2 Magneto Serial Numbers On Which Compliance With This Bulletin Has Already Been Verified E04AA089 E04BA001 E04BA004 E04BA031 E04BA108 E04BA110 E04CA002 E04CA004 E04CA005 E04CA013 E04CA016 E04CA017 E04CA019 E04CA020 E04CA021 E04CA022 E04CA023 E04CA025 E04CA026 E04CA027 E04CA028 E04CA029 E04CA030 E04CA031 E04CA032 E04CA034 E04CA035 E04CA037

MO 06

ISSUED DAY YEAR 18

2004

E04CA041 E04CA042 E04CA043 E04CA044 E04CA045 E04CA047 E04CA048 E04CA053 E04CA054 E04CA055 E04CA057 E04CA058 E04CA059 E04CA079 E04CA081 E04CA083 E04CA084 E04CA086 E04CA089 E04CA092 E04CA094 E04CA098 E04CA107 E04CA120 E04CA159 E04CA198 E04CA215 E04CA217

MO 08

E04CA218 E04CA219 E04CA221 E04CA222 E04CA225 E04CA226 E04CA228 E04CA229 E04CA230 E04CA231 E04CA232 E04CA233 E04CA234 E04CA235 E04CA236 E04CA252 E04CA256 E04CA257 E04CA258 E04CA261 E04CA263 E04CA271 E04CA273 E04CA274 E04CA275 E04CA276 E04CA277 E04CA278

REVISED DAY YEAR 20

2004

E04CA279 E04CA280 E04CA281 E04CA282 E04CA283 E04CA284 E04CA285 E04CA286 E04CA287 E04CA288 E04CA289 E04CA290 E04CA291 E04CA292 E04CA314 E04CA315 E04CA328 E04CA329 E04CA330 E04CA332 E04CA333 E04CA334 E04CA335 E04CA336 E04CA337 E04CA338 E04CA340 E04CA341

E04CA342 E04CA343 E04CA344 E04CA345 E04CA346 E04CA347 E04CA356 E04CA357 E04CA360 E04CA361 E04CA363 E04CA365 E04CA369 E04CA371 E04CA372 E04CA374 E04CA375 E04CA376 E04DA122 E04DA123 E04DA124 E04DA125 E04DA126 E04DA127 E04DA129 E04DA130 E04DA131 F04AA150

F04AA154 F04AA158 F04AA180 F04AA183 F04AA184 F04AA187 F04AA240 F04AA242 F04AA243 F04AA244 F04AA246 F04AA247 F04AA248 F04AA249 F04AA250 F04AA252 F04AA316 F04AA320 F04AA321 F04AA323 F04AA324 F04AA325 F04BA113 F04CA368

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

2 of 5 CSB 665

A

Ground Stud

Figure 1

B. INSPECTION OF CAPACITORS IN SPARES STOCK. 1. Examine each 10-400615 capacitor in spares stock for the stamped date code. (Reference Figure 2) 2. Dates codes of 03-44 through 04-17 must be removed from stock and returned to Teledyne Continental Motors under warranty through the TCM authorized distributor from which the affected capacitors were purchased. 3. Capacitors with date codes not listed above are not affected by this bulletin and cannot be returned for warranty consideration under this bulletin. FIGURE 2 GROUND STUD

DATE CODE Example: 04 = Year 09 = Week

MO 06

ISSUED DAY YEAR 18

2004

MO 08

REVISED DAY YEAR 20

2004

PAGE NO REVISION TM

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3 of 5 CSB 665

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C. CAPACITOR REPLACEMENT INSTRUCTIONS – S20 AND S200 SERIES MAGNETOS 1. Remove airframe and engine components necessary to gain access to the magneto capacitor/contact point cover. Airframe component removals and installations must be accomplished in accordance with the applicable airframe maintenance manual. 2. Remove 4 magneto cover screws. While removing the cover, carefully remove capacitor lead from contact points terminal, noting terminal placement and lead orientation for reassembly. 3. Remove 2 screws securing the capacitor to the cover and remove capacitor. Remove o-ring packing from affected capacitor. 4. Place o-ring on new P/N 10-400615 capacitor. Secure capacitor to magneto cover with 2 screws. Torque screws to 8 - 12 in lbs. 5. Attach serviceable replacement capacitor terminal to contact points terminal in accordance with instructions in the applicable Service Support Manual. 6. Attach magneto cover using 4 screws. Torque screws to 20- 25 in-lbs. 7. Reinstall the airframe wiring harness. Torque the P-Lead retaining nut to 15-17 in.-lbs. 8. As applicable, record the magneto serial number to be supplied to TCM distribution for the warranty claim application. 9. As applicable, make a engine log book entry as to inspection and/or replacement of the part number 10-400615 capacitor in accordance with TCM Critical Service Bulletin CSB665. D. CAPACITOR REPLACEMENT INSTRUCTIONS – S1200 SERIES MAGNETOS 1. Remove airframe and engine components necessary to gain access to the magneto capacitor/contact point cover. Airframe component removal and installations must be accomplished in accordance the applicable airframe maintenance manual. 2. Remove 4 sets of hardware securing the ignition harness and remove the harness from the magneto. 3. Remove 1 magneto cover screw from the magneto cover. While removing the cover, carefully remove capacitor lead from contact points terminal, noting terminal placement and lead orientation for re-assembly. 4. Remove 2 screws securing the capacitor to the cover and remove capacitor. Remove o-ring packing from affected capacitor. 5. Place o-ring on new P/N 10-400615 capacitor. Secure capacitor to magneto cover with 2 screws. Torque screws to 8 - 12 in lbs. 6. Attach capacitor terminal to contact points terminal in accordance with instructions in the applicable Service Support Manual. 7. Attach magneto cover using 1 screw. Torque screw to 30- 35 in lbs. Install ignition harness with attaching hardware and torque to 18 - 22 in lbs. 8. Attach the P-Lead to the ground stud using the retained hardware. Torque the retaining nut to 15-17 in.-lbs.

MO 06

ISSUED DAY YEAR 18

2004

MO 08

REVISED DAY YEAR 20

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

4 of 5 CSB 665

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9. As applicable, record the magneto serial number to be supplied to TCM distribution for the warranty claim application. 10. As applicable, make a engine log book entry as to inspection and/or replacement of the part number 10-400615 capacitor in accordance with TCM Critical Service Bulletin CSB665.

D. WARRANTY AND PART DISPOSITION 1. Warranty coverage for inspection and replacement of capacitors is as follows: (a) Due to the simplicity of the capacitor inspection, there will be no labor allowance for inspection of service spare capacitors. (b) Labor allowance for capacitor inspection of one or two affected magnetos installed on an engine – 1 hour total. Magnetos not included in the serial number range in Table 1 but which can be verified through maintenance records to have had a capacitor replacement performed between October of 2003 and the effective date of this bulletin may qualify for warranty coverage for capacitor inspection / replacement. (c) Labor allowance for capacitor replacement on a magneto installed on an engine – 1 hour per magneto. This includes capacitor inspection – 1.(b). 2. Affected capacitors must be returned to TCM as follows: (a) Affected service spare capacitors in inventory – These will be returned to TCM by TCM distribution on a warranty claim. Contact the authorized TCM distributor from which the affected capacitors were purchased for return instructions and to order replacements. (b) Affected capacitors removed from magnetos - Contact an authorized TCM distributor for warranty claim application and capacitor return instructions. Make certain that you provide the applicable magneto serial number to ensure proper warranty application. Contact TCM Technical Services at 888-826-5465 or 251-436-8299 or your regional TCM Service Representative if you have any questions concerning this Critical Service Bulletin.

MO 06

ISSUED DAY YEAR 18

2004

MO 08

REVISED DAY YEAR 20

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. BOX 90 MOBILE ALABAMA 36601 • 251-436-8134

5 of 5 CSB 665

A

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB93-13 FAA APPROVED

SUBJECT:

CARBURETOR AIR INTAKE HOUSING ASSEMBLY INSPECTION

PURPOSE:

To provide an inspection procedure and replacement instructions for carburetor air intake housing assemblies.

COMPLIANCE:

Those carburetor air intake housing assemblies, repair kits and engines listed in the MODELS AFFECTED must be inspected within the next 10 hours and every25 hours thereafter until replaced with a current production assembly.

MODELS AFFECTED:

1) C85, C90, O200A & B, and O240 model engines Carburetor Air Intake Housing Assemblies and P/N 641689 Repair Kit Assemblies that were purchased from TCM between the dates of September 1, 1991, and June 30, 1993. The Carburetor Air Intake Housing Assembly part numbers which are affected are: CE11141, CE11142, 639814, 639815 and 641534 as identified in paragraph 2B of the Inspections Procedures set forth in this bulletin. 2) All new engines identified below.

The engines listed below must be inspected to determine if the affected assemblies are installed. Those that have affected assemblies installed must be inspected per the Inspection Procedures set forth in this bulletin.

MODEL

SERIAL NUMBER

NEW ENGINES O200A

256030 thru 256037

TCM has received reports that the affected carburetor air intake housing assemblies have experienced cracks in the air valve and in the welds which attach the air valve to the shaft. Therefore, it is necessary to inspect and replace the affected assemblies in accordance with the following instructions. Affected repair kits P/N 641689 must be replaced with current production kits.

ISSUED MO

DAY

08

12

REVISED YEAR 93

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 3

NONE

WARNING . . . Failure to replace any affected assembly that contains a crack may result in breakage of the air valve and/or separation of the air valve from its shaft and cause partial or total loss of engine power. INSPECTION PROCEDURE 1.

Remove engine cowling to gain access to the carburetor air intake housing assembly.

2.

Measure the exposed portion of the Teflon bearing. See Figure 1. A.

Those carburetor air intake housing assemblies having an exposed portion of the Teflon bearing which measures .062 (as shown in Figure 1 A) do not require replacement pursuant to this bulletin. However, such assemblies should be inspected thoroughly as part of each 100 hour inspection and any discrepancies corrected.

B.

Any carburetor air intake housing assembly having an exposed portion of the Teflon bearing which measures .250 - .282 (as shown in Figure 1 B) must be inspected in accordance with this bulletin, with repetitive inspections at 25 hour intervals until the assembly is replaced.

3.

Remove the air filter so that the air valve and the welds that attach the air valve to the shaft can be inspected.

4.

Inspect the entire carburetor air intake housing assembly for cracks. Using an inspection mirror and light, thoroughly inspect the welds that attach the air valve to the shaft and the areas of the air valve adjacent to the welds for cracks. See Figure 2. REPLACE THE COMPLETE CARBURETOR AIR INTAKE HOUSING ASSEMBLY BEFORE FURTHER FLIGHT IF CRACKS ARE FOUND ANYWHERE IN THE ASSEMBLY.

5.

Inspect the general condition of the entire carburetor air intake housing assembly. Inspect for wear on the bushings, shaft and lever. Verify that the air valve operates freely with no binding. CORRECT ALL DISCREPANCIES BEFORE FURTHER FLIGHT.

6.

After the initial inspection has been performed, the repetitive 25 hours inspections can in most cases be performed without removal of the engine cowling.

REPLACEMENT INSTRUCTIONS All affected carburetor air intake housing assemblies as identified under paragraph 2B above and P/N 641689 repair kit assemblies purchased between the dates of September 1, 1991 and June 30, 1993 must be replaced. Such assemblies may continue in service until replacement assemblies are obtained provided (1) they contain no cracks or other discrepancies and, (2) they continue to be inspected at 25 hour intervals in accordance with this bulletin. A replacement assembly must be ordered from TCM as soon as bulletin affectivity has been established. Orders will be filled as replacement assemblies become available. Teledyne Continental Motors will replace all carburetor air intake housing assemblies and repair kits affected by this bulletin (see paragraph 2B) at no charge on an exchange basis and will allow one (1) hour labor for removal and installation. Claims may be filed through any TCM distributor.

ISSUED MO

DAY

08

12

REVISED YEAR 93

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 • MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

2 of 3

NONE

FIGURE 1 DETAIL OF BEARING AND HOUSING

FIGURE 2 CROSS-SECTION OF AIRBOX

ISSUED MO

DAY

08

12

REVISED YEAR 93

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 • MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

3 of 3

NONE

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB94-1 FAA APPROVED

SUBJECT:

TELEDYNE CONTINENTAL MOTORS IGNITION SYSTEMS SERVICE BULLETIN – NO. CSB641

PURPOSE:

To advise TCM customers of the subject service bulletin.

COMPLIANCE: MODELS AFFECTED:

See attached TCM Ignition Systems Service Bulletin No. CSB641

All engine models that utilize the magneto part numbers listed in the attached service bulletin.

Teledyne Continental Motors requires that the attached TCM Ignition Systems Service Bulletin No. CSB641 be complied with as indicated.

ISSUED MO

DAY

02

01

REVISED YEAR 94

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 1

NONE

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CSB94-15 FAA APPROVED

SUBJECT:

CRANKCASE STUD INSPECTION

PURPOSE:

TCM Quality Control has identified crankcases that had certain .250"-20 stud mounting holes drilled slightly oversize prior to tapping. This can produce a stud thread fit that may allow the crankcase threads to strip when sufficient torque is applied. The following procedure provides inspection instructions to determine if the .250"-20 tapped holes in the front and rear of the crankcase are oversize. Oversize holes will require the installation of an .007" oversize stud kit in accordance with the instructions set forth in this bulletin. WARNING

Inadequate stud thread engagement may result in the loss of stud preload (torque), allowing accessories and/or related components to become loose. Such conditions could result in loss of engine oil and/or engine failure. COMPLIANCE: MODELS AFFECTED:

Within the next 25 hours of operation or six months from the date of issuance of this bulletin. O-470, IO-470, IO-520, IO-550, TSIO-520, TSIO-550, TSIOL-550 and GTSIO-520 model engines listed below and these engine models that contain affected service replacement crankcases.

1. All engines listed below must comply with the instructions set forth in this bulletin. NEW ENGINE MODELS O-470-R IO-470-L IO-520-BB IO-520-E IO-520-F IO-520-K IO-550-B

SERIAL NUMBER 446717 468588 578974, 578976 thru 578981. 556628, 556629. 579215. 557546. 675898 thru 675917, 675957. 682136 thru 682138, 682140 thru 682142, 682153. 676751 thru 676755, 676761 thru 676768, 676770 thru 676774, 676800 thru 676803, 676875, 676876, 676878. 680009. 681026, 681027.

IO-550-C

IO-550-D IO-550-E

MO 12

ISSUED DAY YEAR 02

94

MO

REVISED DAY YEAR

MODELS IO-550-G TSIO-520-BB TSIO-520-C TSIO-520-CE TSIO-520-M TSIO-520-NB TSIO-520-R TSIO-520-UB TSIO-550-B TSIOL-550-A

SERIAL NUMBER 679074 thru 679077, 679086. 526042 501629. 530161, 530162. 532021 thru 532024, 521654. 522670, 522671. 527202, 527204 thru 527208, 527217, 527218. 802053 thru 802056. 800584 thru 800586.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 8

REBUILT ENGINE MODELS O-470-J O-470-K O-470-L O-470-R

SERIAL NUMBER 202183-R 049458-R thru 049462-R. 069790-R, 069791-R, 069797-R. 288195-R, 288196-R, 288200-R, 288201R, 288204-R, 288206-R thru 288208-R, 288211-R thru 288214-R, 288219-R, 288223-R, 288226-R thru 288230-R, 288235-R thru 288238-R. 286822-R, 286823-R, 286825-R, 286829-R thru 286831-R, 286833-R thru 286839-R, 286844-R thru 286847-R. 242149-R. 295501-R, 295503-R. 088747-R. 089849-R thru 089853-R. 092942-R, 092943-R. 096588-R thru 096594-R, 096596-R thru 096598-R. 109350-R thru 109352-R. 171084-R, 171087-R, 171088-R, 171091R, 171092-R, 171094-R thru 171097-R. 112706-R, 112710-R, 112711-R, 112713R, 112716-R. 234764-R. 280941-R, 280944-R, 280950-R thru 280955-R, 280957-R thru 280961-R, 280964-R thru 280969-R. 285821-R, 285822-R, 285826-R, 285828R, 285829-R, 285831-R thru 285834-R, 285836-R thru 285838-R, 285840-R thru 285842-R, 285844-R, 285846-R, 285849R. 287233-R thru 287235-R, 287239-R thru 287249-R, 287251-R thru 287253-R, 287255-R thru 287258-R, 287260-R thru 287264-R, 287266-R thru 287269-R, 287271-R.

O-470-U

IO-470-C IO-470-E IO-470-F IO-470-K IO-470-N IO-470-S IO-470-V IO-520-A IO-520-B IO-520-BA

IO-520-BB

IO-520-C

MODELS IO-520-CB

IO-520-D

IO-520-E IO-520-F

IO-520-K IO-520-L

IO-520-M IO-520-MB IO-550-A IO-550-B

IO-550-C IO-550-D

IO-550-E IO-550-F

MO 12

ISSUED DAY YEAR 02

94

MO

REVISED DAY YEAR

SERIAL NUMBER 282436-R, 282438-R thru 282445-R, 282447-R thru 282453-R, 282456-R thru 282463-R, 282470-R, 282471-R. 282992-R, 282999-R. 293002-R thru 293006-R, 293008-R, 293009-R, 293012R, 293013-R, 293016-R thru 293020-R, 293024-R, 293025-R, 293027-R, 293028R, 293030-R thru 293036-R, 293038-R thru 293042-R, 293044-R thru 293046-R, 293048-R thru 293059-R, 293062-R. 215813-R. 291191-R thru 291193-R, 291195-R thru 291205-R, 291208-R, 291217-R, 291101R, 291102-R, 291106-R, 291109-R thru 291111-R, 291113-R, 291115-R, 291118R, 291120-R, 291122-R thru 291125-R, 291128-R, 291133-R, 291134-R, 291136R, 291137-R, 291139-R, 291141-R, 291146-R thru 291148-R, 291150-R thru 291152-R, 291154-R, 291157-R, 291158R, 291160-R, 291161-R, 291163-R, 291165-R thru 291167-R, 291169-R thru 291171-R, 291174-R, 291176-R thru 291178-R, 291180-R thru 291184-R, 291186-R thru 291188-R, 291190-R. 224082-R, 224084-R, 224085-R. 270478-R, 270479-R, 270482-R, 270484R, 270485-R, 270487-R, 270488-R, 270490-R, 270493-R, 270495-R thru 270499-R. 294501-R, 294504-R, 294506R, 294509-R, 294514-R thru 294521-R. 270872-R, 270873-R, 270876-R, 270880-R thru 270882-R, 270884-R thru 270891-R. 277486-R thru 277494-R. 280363-R thru 280366-R. 281937-R, 281940-R, 281942-R, 281943R, 281946-R, 281947-R, 281949-R thru 281966-R, 281968-R thru 281970-R. 271872-R, 271873-R, 271879-R thru 271882-R, 271884-R thru 271888-R. 284074-R, 284076-R thru 284082-R, 284084-R thru 284089-R, 284091-R thru 284093-R, 284095-R thru 284098-R. 283289-R, 283290-R, 283293-R thru 283298-R. 284591-R thru 284598-R, 284600-R, 284602-R.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 8

REBUILT ENGINES (cont’d) MODELS IO-550-L TSIO-520-AF TSIO-520-B TSIO-520-BB TSIO-520-BE TSIO-520-C TSIO-520-CE TSIO-520-D TSIO-520-DB TSIO-520-E TSIO-520-EB . TSIO-520-G TSIO-520-H TSIO-520-J TSIO-520-LB TSIO-520-M

TSIO-520-N TSIO-520-NB

SERIAL NUMBER 289031-R thru 289037-R. 245224-R. 176634-R, 176636-R, 176637-R, 176640R. 287529-R thru 287533-R. 273762-R, 273764-R, 273765-R. 178418-R thru 178429-R. 268548-R, 268550-R thru 268552-R. 180115-R. 242012-R. 275325-R, 275327-R, 275328-R, 275331-R thru 275334-R, 275336-R, 275337-R. 271284-R thru 271286-R. 216045-R. 217306-R, 217310-R, 217312-R thru 217314-R, 217316-R. 218963-R, 218964-R. 237280-R. 291536-R, 291537-R, 291540-R thru 291542-R, 291545-R, 291547-R, 291548R, 291550-R thru 291553-R, 291555-R thru 291564-R, 291566-R, 291567-R, 291570-R 291575-R, 291578-R. 228612-R thru 228614-R. 290647-R, 290649-R thru 290652-R, 290655-R, 290657-R thru 290665-R, 290670-R.

MODELS TSIO-520-P TSIO-520-R

TSIO-520-T TSIO-520-UB TSIO-520-VB

TSIO-520-WB GTSIO-520-D GTSIO-520-H GTSIO-520-L GTSIO-520-M GTSIO-520-N

SERIAL NUMBER 278672-R thru 278674-R, 278677-R thru 278680-R. 269989-R, 269992-R, 269994-R, 269996-R thru 269999-R. 293503-R, 293504-R, 293506-R thru 293511-R, 293513-R thru 293527-R, 293531-R. 239398-R thru 239402-R, 239404-R. 249040-R thru 249042-R. 290240-R, 290242-R, 290245-R thru 290248-R, 290250-R thru 290252-R, 290254-R, 290255-R, 290257-R, 290260-R thru 290265-R, 290267-R. 274286-R thru 274291-R, 274293-R, 274294-R. 219460-R. 267313-R, 267314-R, 267317-R, 267320R. 292009-R, 292019-R, 292022-R thru 292024-R. 276380-R thru 276385-R, 276388-R thru 276390-R, 276392-R, 276415-R. 277171-R thru 277174-R, 277176-R, 277177-R.

2. All affected part number and serial number service replacement crankcases listed below must comply with the instructions set forth in this bulletin. These crankcases were manufactured between February 1, 1994 and June 30, 1994. CRANKCASE PART NUMBER

SERIAL NUMBER

652538-4, 652538-4A1, 652539-1, 652539-1A1, 6525392A1, 652539-5, 652540-1, 652540-1A1, 652540-2, 652540-2A1, 652559, 652559A1, 652654

B019401XXX thru F309401XXX.

The letter suffixes (as indicated by XXX above) following the serial numbers are insignificant in determining affectivity. Use the letter prefix and subsequent numerals to determine crankcase effectivity.

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INSPECTION AND REWORK INSTRUCTIONS 1.

Open or remove the cowling necessary to gain access to the rear of the engine.

2.

Remove the two sets of nuts and washers from the idler gear support pin studs. These studs are positioned on the rear (accessory section) of the crankcase, just below the left and right accessory drives. See Figure 1. DO NOT remove the idler gear support pin.

3.

Measure the stud height extending out of the crankcase and record. Using a suitable stud remover or double nuts, remove the two .250" studs.

4.

Check these tapped holes in the crankcase to determine if they are oversize by using a #3 (.2130) drill bit. See Figure 2. This will be accomplished by first measuring the shank of the drill bit with a calibrated micrometer. The diameter of the shank must measure .210" - .212". Insert the shank end of the drill bit into the tapped .250"-20 hole. The shank should not extend into the tapped portion of the hole. If it does not, reinstall the two studs to the recorded height using Loctite Primer "N" and 271 Stud Lock. Allow at least 30 minutes for the Loctite to cure prior to the installation of the idler gear pin attaching hardware. Torque nuts to 90 - 110 inch pounds. Make a log book entry as to compliance with this service bulletin as no further action is required. If the shank of the drill bit extends into the tapped portion of the hole, proceed as follows.

5.

Refer to Table 1 and order the appropriate stud kit. Aircraft owner/FBO information must be provided to the TCM Distributor at the time the order is placed for tracking and warranty purposes. The TCM Distributor will forward this information to TCM. This information must include aircraft registration and serial number, make and model. Engine model and serial number(s), owner and FBO name, address and fax/phone number.

6.

Remove the engine from the aircraft in accordance with the applicable airframe manufacturer's service manual. This is necessary so that the oil pump can be removed and the .250"-20 through studs in the crankcase can be replaced with oversize studs.

7.

Remove the starter, starter adapter assembly (as necessary to remove oil pump) and oil pump and discard the gaskets. Remove the cam cover plate and prop reduction gear cover (GTSIO-520 models only) located on the front of the crankcase, below the crankshaft and discard gaskets. DO NOT remove the idler gear support pin.

8.

Measure all of the .250" stud extension heights and record their locations. See Figure 1. This is necessary for proper installation of the replacement studs. Remove all .250"-28 studs from the front and rear of the crankcase using an appropriate stud removal tool and record their lengths as they are removed so that the same length stud is installed in the same location. Discard the old studs.

9.

Add a small amount of clean grease to the 1/4-20 GH7 tap (supplied in the stud kit) to prevent aluminum material generated during tapping from entering the engine. Run the 1/4-20 GH7 tap into and then out of each .250" stud hole location (except the idler gear pin stud holes) indicated in Figure 1. Thoroughly clean grease and debris from the stud holes by saturating a clean cloth with Loctite Primer "N" and cleaning each hole until threads are clean. Final cleaning and preparation of the threads is accomplished by spraying a light film of Loctite Primer "N" into the stud holes.

10.

Using the studs contained in the appropriate kit listed in Table 1, apply a line of Loctite 271 along the .250"-20 threads of the studs. These studs are .007 oversize and are identified by being blue in color and a "L" shaped stamp on the .250"-28 end. See

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Figure 3. Use a .250"-28 stud driver and install the appropriate length studs in their proper locations, to the recorded extension heights. Allow at least 30 minutes for the Loctite to cure prior to component installation. Stamp the letters "OS" on each side of the crankcase split line using a 1/8" metal stamp. See Figure 1 for approximate location. 11.

Install the oil pump, prop reduction gear cover, (GTSIO-520 models only) and cam cover using new gaskets and attaching hardware. Torque .250"-28 nuts to 90 - 110 inch pounds. Install the remaining components that were removed and torque to the proper values.

12.

Install the engine in accordance with the airframe manufacturer's service manual. Run the engine to check for oil leaks. Repair any leaks prior to flight.

13.

Perform normal pre-flight inspections and engine instrument parameter checks, in accordance with the aircraft manufacturer's pilot's operating handbook, in preparation for flight. Fly the aircraft for one hour.

14.

While the engine is warm from flight, drain the engine oil and remove the oil filter or screen. Examine the contents of the filter/screen. Residual material (aluminum) that may not have been completely removed after the tapping operation will be contained in the filter/screen.

15.

Remove, inspect and replace/clean the oil filter/screen within the next 5 hours of engine operation. If the filter/screen is free of material, then resume normal oil and filter change intervals. If the filter/screen continues to contain metal particles, contact TCM Service Department at (205) 438-3411.

16.

Make a log book entry as to compliance with this service bulletin. TABLE 1 - KIT PART NUMBER TO ENGINE GUIDE

Determine which kit is appropriate for your engine model as listed in Table 1. This is accomplished by noting the engine model and specification number on the engine data plate. Example: IO-520-D35. (IO-520-D = Engine Model, 35 = Specification Number). Engine models listed below without specification numbers are considered to cover all model specifications unless noted otherwise. Review Table 1 carefully to insure that you order the appropriate kit for your specific engine model. PART NUMBER EQ6649

EQ6650 EQ6651 EQ6652

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ENGINE MODEL IO-520-B,-BA,-BB,-C,-CB,-M,-MB. IO-550-A,-B,-C,-G. TSIO-520-B,-BB,-BE,-D,-DB,-E,-EB,-J,-JB,-K,-KB,-L,-LB, N,-NB,-UB,-VB,-WB. TSIO-550-A,-B,-C. TSIOL-550-A. All GTSIO-520 Model Engines. O-470-G,-J,-L,-M,-R,-S,-U. IO-470-C,-D,-E,-F,-J,-K,-L,-M,-N,-S,-V,-U. O-470-U12,25,29,33,36,40. IO-520-A,-D,-E,-F,-J,-K,-L. IO-550-D,-F,-L. TSIO-520-AE,-AF,-C,-CE,-G,-H,-M,-P,-R,-T. LTSIO-520-AE. TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

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TABLE 2 - STUD KIT CONTENTS The kits listed in Table 2 will, in most cases, contain more studs and gaskets than are necessary to comply with the instructions set forth in this bulletin. This was necessary to consolidate a large number of crankcase studding differences into a smaller number of kits. Make certain that the studs removed are replaced with studs of the same length and the proper gaskets are used. QTY 1

PART NUMBER EQ6649

1 5 1 2 2 2 1 1 1

401968P007 401936P007 401962P007 401801P007 401804P007 401963P007 649949 653415 1/4-20 GH7

1

EQ6650

1 6 2 1 6 2 1 1 1 1

402165P007 402161P007 402129P007 401852P007 401804P007 401963P007 649969 653415 653388 1/4-20 GH7

DESCRIPTION Stud Kit, (includes the following) .Stud, 4.53" .Stud, 3.88" .Stud, 2.19" .Stud, 1.19” .Stud, 1.06" .Stud, 1.00" .Gasket, oil pump Gasket, cam cover .Bottom Tap Stud Kit, (includes the following) .Stud, 6.91" .Stud, 6.81" .Stud, 2.75" .Stud, 1.41" .Stud, 1.06" .Stud, 1.00" .Gasket, oil pump .Gasket, cam cover .Gasket, reduction gear cover .Bottom Tap

QTY 1

PART NUMBER EQ6651

5 2 4 3 1 2 1

402056P007 401886P007 401832P007 402129P007 401852P007 401870P007 649969

1

653387

1

1/4-20 GH7

1

EQ6652

3 5 2 4 2 1 1 2 1

402157P007 402158P007 402159P007 401832P007 402129P007 401841P007 401852P007 401870P007 649969

1

653387

1

1/4-20 GH7

DESCRIPTION Stud Kit, (includes the following) .Stud, 3.56" .Stud, 3.19" .Stud, 2.81" .Stud, 2.75" .Stud, 1.41" .Stud, 1.12" .Gasket, oil pump with screen housing .Gasket, oil pump with integral filter adapter .Bottom Tap Stud Kit, (includes the following) .Stud, 6.10" .Stud, 4.40" .Stud, 4.10" .Stud, 2.81" .Stud, 2.75" .Stud, 2.09" - 2.12" .Stud, 1.41" .Stud, 1.12" .Gasket, oil pump with screen housing .Gasket, oil pump with integral filter adapter .Bottom Tap

Warranty action required to comply with this bulletin is covered by the Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM Distributor. MAN-HOURS REQUIRED: Inspection only ........................... 2 Hours per engine, maximum. Stud replacement ....................... Average time 39 hours. However, most (includes engine removal) .......... installations will require less time

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB95-1A FAA APPROVED

SUBJECT:

INSPECTION AND REPLACEMENT OF DUKES INCORPORATED TURBOCHARGER OIL OUTLET CHECK VALVE PART NUMBER 367-00, (TCM P/N 641068).

PURPOSE:

TCM Quality Control has identified certain turbocharger oil outlet check valves manufactured by Dukes Incorporated (Dukes P/N 367-00) that do not meet their manufacturing specifications. The check valve is located in the turbocharger oil line, between the turbo and oil scavenge pump. TCM requires that all affected Dukes check valves be replaced prior to further flight in accordance with the instructions set forth in this bulletin. WARNING FAILURE TO REPLACE AFFECTED DUKES INC. CHECK VALVES CAN RESULT IN DAMAGE TO THE OIL SCAVENGE PUMP, INTERNAL ENGINE DAMAGE AND SUBSEQUENT LOSS OF ENGINE POWER.

COMPLIANCE: MODELS AFFECTED:

Prior to further flight. TSIO-360-E, EB, F, FB, G, GB, KB, LB and MB LTSIO-360-E, EB and KB. A. Any P/N 367-00 Dukes check valve (TCM P/N 641068) purchased between August 1, 1994 and March 20, 1995 must be inspected in accordance with the instructions set forth in this bulletin. B. The following engines must be inspected in accordance with the instructions set forth in this service bulletin. These engines were shipped from TCM between August 1, 1994 and March 23, 1995. NEW ENGINES

MODELS

SERIAL NUMBER

TSIO-360-FB TSIO-360-KB

318019 320223, 320229, 320233 thru 320235, 320239, 320242 thru 320250, 320254 thru 320259, 320261, 320262, 320264, 320266, 320292, 320293. 319226, 319232, 319235 thru 319237, 319241, 319244 thru 319246, 319248 thru 319253, 319257, 319258, 319260 thru 319268, 319270, 319271, 319273, 319297, 319322.

LTSIO-360-KB

REBUILT ENGINES MODELS

SERIAL NUMBER

TSIO-360-E TSIO-360-EB

225140-R. 265937-R, 265938-R, 265942-R thru 265944-R, 265946-R thru 265968-R, 265970-R thru 265973-R, 265975-R, 265977-R thru 265982-R.

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04

05

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A

REBUILT ENGINES (cont’d) MODELS

SERIAL NUMBER

LTSIO-360-E LTSIO-360-EB

225648-R. 266471-R, 266480-R, 266482-R, 266486-R, 266487-R, 266489-R thru 266495-R, 266497-R thru 266499-R, 807251-R thru 807254-R, 807256-R thru 807259-R, 807261-R thru 807265-R, 807267-R, 807268-R, 807271-R thru 807275-R, 807276-R. 232814-R thru 232817-R. 281183-R, 281187-R, 281189-R, 281190-R, 281193-R thru 281197-R, 281199-R, 299501-R thru 299523-R, 299525-R thru 299528-R, 299532-R. 268192-R, 268195-R thru 268201-R, 268205-R thru 268207-R. 268428-R, 268430-R, 268431-R, 268433-R, 268434-R, 268436-R, 268437-R, 268440-R thru 268445-R. 247257-R, 247259-R, 247260-R, 247262-R, 247267-R thru 247271-R, 247273-R thru 247275-R. 279245-R thru 279247-R, 279249-R, 279250-R.

TSIO-360-F TSIO-360-FB TSIO-360-KB LTSIO-360-KB TSIO-360-LB TSIO-360-MB

INSPECTION AND REPLACEMENT INSTRUCTIONS

A. All part number 641068 Dukes check valves in inventory and those purchased between August 1, 1994 and March 20, 1995 must be inspected as follows: 1. Check all P/N 641068 Dukes check valves for date codes A3Q94, A4Q94 and A1Q95. If the valve is identified with one of these date codes or the code is not readable, the valve must be replaced. 2. Contact your TCM Distributor for a warranty replacement. All affected Dukes valves must be returned for warranty replacements. B. Inspect affected engines prior to further flight as follows: 1. Remove the engine cowling necessary to gain access to the turbocharger oil outlet check valve P/N 641068. 2. Remove and replace check valves that are identified with a date code of A3Q94, A4Q94 or A1Q95. If the date code is not readable, the valve must be replaced. 3. If replacement is required as instructed in the preceding paragraph, order a warranty replacement valve P/N 641068 from your TCM Distributor. All affected valves must be returned for warranty replacements. 4. Install the replacement valve (date code A2Q95 or later) in the turbo oil outlet line, with the flow arrow on the valve body pointing in the direction of oil flow toward the scavenge pump. Perform a oil leak check run and repair any leak prior to flight. 5. Make an engine log book entry, "Complied with TCM service bulletin CSB95-1". WARRANTY: TCM will allow one hour labor at posted shop rate for the inspection and one hour for each valve replacement. All claims must be filed with a TCM Distributor, with affected Dukes valves accompanying each claim.

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TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB95-4 FAA APPROVED

SUBJECT:

INTAKE VALVE GUIDE SEAL P/N 646678 INSPECTION

PURPOSE:

Teledyne Continental Motors has received reports and investigated instances of intake valve guide seal damage on cylinder assemblies supplied from September 1, 1994 through April 30, 1995. This bulletin provides inspection procedures to determine if seal replacement on these cylinder assemblies is required.

COMPLIANCE:

Prior to further engine operation. 1. For cylinders that have accumulated more than 50 hours of operation accomplish the instructions set forth in section "A. INSPECTION INSTRUCTIONS". 2. For cylinders that have accumulated 50 hours of operation or less accomplish the instructions set forth in section "B. INSPECTION INSTRUCTIONS".

MODELS AFFECTED:

All IO-240, IO-360, TSIO-360 and LTSIO-360 model engines and cylinders listed below: 1. The following engines must be inspected as set forth in this service bulletin. NEW ENGINES

MODEL IO-240-A IO-360-ES TSIO-360-FB TSIO-360-KB

SERIAL NUMBER 806055 thru 806064, 806076, 806077, 806100, 806102 thru 806106, 806109 thru 806111. 357024 thru 357029, 357035 thru 357037. 318019. 320229, 320233 thru 320235, 320239, 320242 thru 320250, 320254 thru 320268, 320273 thru 320275, 320292 thru 320295. 319232, 319235 thru 319237, 319241, 319244 thru 319253, 319256 thru 319258, 319260 thru 319274, 319276, 319297 thru 319299, 319322, 319323.

LTSIO-360-KB

REBUILT ENGINES MODEL IO-360-A IO-360-C IO-360-CB IO-360-D IO-360-DB IO-360-G IO-360-GB IO-360-H

SERIAL NUMBER 020134-R. 060635-R, 060636-R, 060638-R, 060639-R. 236518-R. 062983-R thru 062990-R. 239789-R thru 239799-R. 244580-R thru 244582-R. 236687-R thru 236690-R. 226563-R thru 226565-R, 226567-R, 226568-R.

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REBUILT ENGINES (cont’d) MODEL IO-360-HB IO-360-J IO-360-K IO-360-KB TSIO-360-A TSIO-360-AB TSIO-360-C TSIO-360-CB TSIO-360-E TSIO-360-EB

SERIAL NUMBER 265186-R thru 265188-R. 238725-R. 240131-R, 240132-R, 240134-R. 288581-R thru 288584-R, 288586-R thru 288606-R, 288608-R. 197110-R. 237614-R. 283542-R, 283543-R. 236213-R thru 236220-R, 236222-R thru 236224-R. 225145-R. 265938-R, 265942-R thru 265944-R, 265946-R thru 265975-R, 265977-R thru 265984-R, 265986-R thru 265989-R, 265991-R. 232814-R thru 232818-R. 281183-R, 281190-R, 281193-R thru 281197-R, 281199-R, 299501-R thru 299523-R, 299525-R thru 299528-R, 299531-R thru 299533-R. 268195-R thru 268202-R, 268204-R thru 268207-R, 268209-R, 268210-R. 247257-R, 247259-R, 247260-R, 247262-R, 247267-R thru 247271-R, 247273-R thru 247275-R, 247277-R, 247279-R thru 247281-R. 279245-R thru 279247-R, 279249-R, 279250-R, 279252-R thru 279254-R. 266480-R, 266482-R, 266486-R, 266487-R, 266489-R thru 266495-R, 266497-R thru 266499-R, 807251-R thru 807254-R, 807256-R thru 807280-R, 807282-R thru 807284-R. 268431-R, 268433-R, 268434-R, 268436-R, 268437-R, 268440-R thru 268445-R, 268447-R, 268449-R.

TSIO-360-F TSIO-360-FB TSIO-360-KB TSIO-360-LB TSIO-360-MB LTSIO-360-EB LTSIO-360-KB

2. Cylinder assembly part numbers 649484CE-A1, 649484CE-A4, 649484CE-A5, 653450A1, 653450A2, 653450A4, 653450A5, 653450A7, 653450TC-A2, 653450TC-A3, 653450TC-A5, 653451A1, 653451A2, 653451A3 and 653451TC-A3 supplied by TCM from September 1, 1994 through April 30, 1995. 3. Any IO-240, IO-360, TSIO-360 and LTSIO-360 model engine, regardless of date of manufacture or total time in service, that exhibits seal material in the oil suction screen, oil screen, filter or oil sump must be inspected in accordance with the instructions set forth in section "B. INSPECTION INSTRUCTIONS". CAUTION Some early production cylinders contain intake valve guides that have an installed height of .885 - .905 inch above the valve spring retainer. Intake guide seals CANNOT be installed on cylinders containing these guides. Intake guide seals can only be installed on intake guides that have a measured installed height of .695 to .715 inch above the valve spring retainer. WARNING FAILURE TO INSPECT FOR AND REPLACE DAMAGED INTAKE VALVE GUIDE SEALS CAN RESULT IN A PARTIAL OR TOTAL LOSS OF OIL PRESSURE AND SUBSEQUENT LOSS OF POWER AND/OR ENGINE FAILURE. MO 08

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2 of 6 CSB95-4

A. INSPECTION INSTRUCTIONS (Cylinders that have accumulated more than 50 hours of operation) WARNING MAKE CERTAIN THAT THE AIRCRAFT MASTER AND MAGNETO SWITCH IS IN THE "OFF" POSITION AND THE MAGNETOS ARE GROUNDED PRIOR TO ACCOMPLISHING THE FOLLOWING INSTRUCTIONS. 1. Remove aircraft cowling, baffling and components in accordance with the airframe manufacturer's instructions to facilitate the removal of the oil suction screen and oil screen or filter. 2. Drain oil into a clean container and strain oil through a suitable filter and inspect for contamination. Remove the oil suction screen located on the lower left portion of the accessory case and the oil screen or filter located on the lower right portion of the accessory case. Inspect screens and filters for intake valve guide seal material. This would be evident by the existence of dark green rubber and/or small coil spring material. WARNING THE PRESENCE OF ANY MATERIAL OTHER THAN NORMAL AMOUNTS OF COMBUSTION BY-PRODUCTS AND WEAR MATERIALS REQUIRES INVESTIGATION TO DETERMINE ITS ORIGIN. ACCOMPLISH ANY NECESSARY REPAIRS PRIOR TO FURTHER ENGINE OPERATION. 3. If no material is present, clean and install oil suction screen and oil screen. Install new oil filter where used. Torque oil suction screen to 200-210 inch pounds. Torque the oil screen to 500-520 inch pounds. Torque oil filter to 192-216 inch pounds. Install oil drain plug and torque to 190-210 inch pounds. Safety wire oil suction screen, oil screen or filter and oil drain plug using approved methods as indicated in TCM Service Bulletin SIL93-15 or current revision as applicable. Replenish engine oil with the appropriate grade and quantity. No further action is required. 4. If seal material is present, proceed to section "C. SEAL REMOVAL AND INSTALLATION INSTRUCTIONS". B. INSPECTION INSTRUCTIONS (Cylinders that have accumulated 50 hours of operation or less) WARNING MAKE CERTAIN THAT THE AIRCRAFT MASTER AND MAGNETO SWITCH IS IN THE "OFF" POSITION AND THE MAGNETOS ARE GROUNDED PRIOR TO ACCOMPLISHING THE FOLLOWING INSTRUCTIONS. 1. Remove aircraft cowling, baffling and components in accordance with the airframe manufacturer's instructions to facilitate the removal of the intake rocker cover. Remove the top spark plug leads and spark plugs. 2. Remove intake rocker cover and gasket. Discard gasket. Rotate the propeller until the intake valve is on its seat. Disengage tab washers and remove rocker shaft nuts, tab washers and retainers. Discard tab washers. Remove intake rocker arm, thrust washer and shaft assembly. 3. Proceed to section "C" and accomplish steps 4 and 5 only.

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3 of 6 CSB95-4

4. Inspect the intake valve guide seal for damage to the seal lip and/or missing spring. Figure 1 shows an intact and properly seated intake guide seal. Repeat inspection on all cylinders. 5. If seal springs are intact and the seals do not exhibit any damage, make certain that the seal is completely seated on the valve guide by tapping the seal using a plastic mallet and installation tool. Figure 2 provides proper dimensions to produce an installation tool. Proceed to section "C", step 7 and reinstall the intake parts as instructed. 6. If seal springs are not intact or the seal is damaged, remove and inspect the oil suction screen and oil screen or oil filter. Drain engine oil. Proceed to section "C" and accomplish steps 6, 7, 8, 9 and 10. C. SEAL REMOVAL AND INSTALLATION INSTRUCTIONS 1. Remove aircraft cowling, baffling and components in accordance with the airframe manufacturer's instructions to facilitate the removal of the intake rocker covers. Remove the top spark plug leads and spark plugs. 2. Remove intake rocker cover and gasket. Discard gasket. Rotate the propeller until the intake valve is on its seat. 3. Disengage tab washers and remove rocker shaft nuts, tab washers and retainers. Discard tab washers. Remove intake rocker arm, thrust washer and shaft assembly. WARNING USE EXTREME CAUTION IN THE AREA OF THE PROPELLER WHILE PERFORMING THE FOLLOWING STEP. VERIFY THAT THE PISTON IS POSITIONED AT THE BOTTOM OF THE INTAKE STROKE PRIOR TO CONNECTING AIR PRESSURE SOURCE. 4. Rotate propeller until the piston is at the bottom of the intake stroke. Install deferential compression tester adapter in the top spark plug location. Connect a regulated air pressure source to the adapter and apply 80 to 100 PSI. 5. Install valve spring compressor (Kent Moore (Borroughs) P/N 3602 or equivalent) on the cylinder with rocker shaft P/N 648002 and nuts P/N 646605. Compress the valve springs and remove the valve keepers with a magnet. Slowly relieve spring compression and remove roto coil, inner and outer valve springs and spring compressor. 6. Remove the seal from the guide and valve stem. Coat new seal P/N 646678 and intake valve guide with clean 50 weight aircraft engine oil. Install seal over valve stem and into position on the valve guide by hand. Using the installation tool and a plastic mallet, see Figure 2, tap the seal onto the guide until seal is completely seated. Make certain that the seal is firmly seated on the guide. See Figure 1. 7. Install valve spring compressor on rocker shaft. Install inner P/N 625957 and outer P/N 625958 valve springs with coils in opposite directions into position in the valve spring retainer P/N 24026. Install roto coil P/N 631654 on valve springs and compress only deep enough to allow the installation of the valve keepers. Install two valve keepers P/N 627731 into position between the roto coil and valve stem and slowly relieve spring compression. Remove spring compressor, nuts and rocker shaft. Disconnect air source and remove adapter from spark plug port.

MO 08

ISSUED DAY YEAR 10

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

4 of 6 CSB95-4

8. Install intake rocker arm assembly P/N 639648, thrust washers P/N 653189 and retainers P/N 631996 onto rocker shaft P/N 648002 and position the assembly on the intake studs. Install new tab washers P/N 501867 and nuts P/N 646605. Turn propeller to position the piston at the top of the compression stroke. Torque nuts to 110-120 inch pounds. Bend washer tabs into position against nut flats. Install rocker cover with new gasket P/N 653195 and torque attaching hardware beginning with the two lower screws first to 55-65 inch pounds. Repeat the previous steps (2, 3, 4, 5, 6, 7 and 8) on each cylinder. 9. Install oil suction screen, oil screen or oil filter, oil drain plug and replenish oil as indicated in section "A", step 3. Install spark plugs and torque to 300-360 inch pounds. Install spark plug leads and torque 5/8-24 leads to 90-95 inch pounds and 3/4-20 leads to 110-120 inch pounds. Reinstall baffling and components that were removed in accordance with the airframe manufacturer's instructions. 10. Make a log book entry as to compliance with this service bulletin. WARRANTY TCM will reimburse the cost of the parts and labor to perform the inspection and (if necessary) the replacement of intake guide seals through December 15, 1995. After this date warranty coverage will be subject to the terms and conditions of the Gold Medallion Warranty Policy. Warranty claims must be filed with an authorized TCM Distributor.

MO 08

ISSUED DAY YEAR 10

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

5 of 6 CSB95-4

MO 08

ISSUED DAY YEAR 10

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

6 of 6 CSB95-4

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB96-1 FAA APPROVED

SUBJECT:

STARTER GEAR AND CLUTCH ASSEMBLY P/N 653575

PURPOSE:

TCM Quality Control has identified certain starter gear and clutch assemblies (P/N 653575) manufactured by Consolidated Fuel Systems Incorporated that may not meet heat treating specifications. TCM requires that all affected Consolidated Fuel Systems starter gear and clutch assemblies be inspected in accordance with the instructions set forth in this service bulletin and if required, replaced prior to further engine operation. WARNING FAILURE TO REPLACE AFFECTED CONSOLIDATED FUEL SYSTEMS STARTER GEAR AND CLUTCH ASSEMBLIES IN ACCORDANCE WITH THIS SERVICE BULLETIN CAN RESULT IN INTERNAL ENGINE DAMAGE AND SUBSEQUENT LOSS OF ENGINE POWER.

COMPLIANCE: MODELS AFFECTED:

Prior to further engine operation. O-200-A, O-200-B. O-240-A, O-240-B. IO-240-A, IO-240-B. O-300-A, O-300-B, O-300-C. (Key start equipped models only.) A. All P/N 653575 starter gear and clutch assemblies that were supplied by TCM beginning October 1, 1995 through February 28, 1996 for inventory or installation in an affected engine model must be inspected in accordance with the "INSPECTION INSTRUCTIONS" set forth in this service bulletin. B. The following engines must have the starter gear and clutch assembly P/N 653575 inspected prior to further engine operation in accordance with the "INSPECTION INSTRUCTIONS" set forth in this service bulletin. Replacement P/N 653575 gear and clutch assemblies can be purchased from any TCM Distributor. NEW ENGINES MODEL

SERIAL NUMBER

O-200-A .............................................. 256047. REBUILT ENGINES MODEL

SERIAL NUMBER

O-200-A .............................................. 285401-R thru 285409-R, 285411-R thru 285415-R. ISSUED MO 03

DAY 01

REVISED YEAR

MO

DAY

YEAR

96

 1996, TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 3 CSB96-1

INSPECTION INSTRUCTIONS - ASSEMBLIES IN INVENTORY. 1. Inspect the rear side of the large gear (see Figure 1) and verify the seven digit date code number. Assemblies identified with the date codes listed in Table 1 or any assemblies that do not have a visible date code may contain improperly heat treated gears and must be returned to a TCM Distributor for replacement. Table 1 - AFFECTED DATE CODES 9510002 thru 9511008, 9510010, 9511001 thru 9511003, 9511005 thru 9511036, 9601001 thru 9601012, 9601015 thru 9601031, 9601036 thru 9601098, 9601104, 9601108, 9601114, 9601115, 9601117, 9601118, 9601124, 9602001, 9602002, 9602005 thru 9602028, 9602032, 9602033, 9602038, 9602041, 9602042, 9602044, 9602055, 9602056, 9602058, 9602060, 9602062 thru 9602066, 9602068 thru 9602070, 9602073. NOTE: The date codes listed above indicate the group that must be inspected. It has been determined that only certain assemblies within this group do not meet heat treating specifications.

FIGURE 1. P/N 653575 GEAR AND CLUTCH ASSEMBLY

INSPECTION INSTRUCTIONS - ASSEMBLIES INSTALLED IN ENGINES. A. Affected engine models that have had P/N 653575 starter gear and clutch assemblies installed and accumulated LESS than 25 hours in service must be removed and inspected for an affected date code listed in Table 1. If the assembly is identified with an affected date code or does not have a visible date code, return the assembly to a TCM Distributor for replacement.

MO 03

ISSUED DAY YEAR 01

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MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 3 CSB96-1

B. Affected engine models that have had P/N 653575 starter gear and clutch assemblies installed and accumulated MORE than 25 hours in service must be inspected as follows. 1. Assure that the aircraft master switch and magneto switch is in the "OFF" position. Gain access to the starter assembly and remove the starter power cable in accordance with the Aircraft Manufacturer's Service Manual. 2. Remove the starter assembly attaching hardware and carefully remove the starter and the gear and clutch assembly from the accessory case. 3. Reference Figure 1. Inspect the small gear for tooth wear or damage. If the gear teeth exhibit wear or damage, contact your local TCM Field Service Representative or TCM Factory Customer Service at (334) 438-3411 for additional instructions. 4. Gear and clutch assemblies that do not exhibit tooth wear or damage may continue in service. 5. Install the serviceable or a replacement gear and clutch assembly and the starter. Install starter assembly attaching hardware. Torque nuts (3 each) to 180-220 in/lbs. Torque bolts (two each) to 155-175 in/lbs. 6. Reinstall starter power cable and engine cowling in accordance with the Aircraft Manufacturer's Service Manual. 7. Make a log book entry as to compliance with this service bulletin. PUBLICATIONS AFFECTED: NONE WARRANTY: Warranty action required to comply with this service bulletin is covered by the Gold Medallion Warranty or Service Parts Warranty, subject to its terms and conditions. All gear and clutch assemblies returned for replacement must be returned with the date code recorded on the warranty claim for proper processing.

MO 03

ISSUED DAY YEAR 01

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

3 of 3 CSB96-1

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB96-13 FAA APPROVED Supersedes M86-11 Rev.1

SUBJECT:

IO-360, TSIO-360 AND LTSIO-360 SERIES ENGINE CONNECTING ROD INSPECTION AND REPLACEMENT.

PURPOSE:

TCM Service Bulletin M86-11 Rev. 1 dated October 1, 1986 provided connecting rod inspection and replacement instructions for IO-360, TSIO-360 and LTSIO-360 model engines to be accomplished "at next engine overhaul, top overhaul or anytime the cylinders are removed for any reason". This required the replacement of forging number 626119 connecting rods that have a measured beam width below .625 inch. Field reports indicate that certain affected engines have yet to be inspected because of low aircraft utilization. Due to the potential for over stressed connecting rods associated with abnormal operating conditions or incidents, it is now required that connecting rod inspection and appropriate corrective action be accomplished on those engines that have not complied with M86-11 Rev. 1 prior to engine overhaul. Beam width inspection criteria for 360 series engine connecting rods has been a requirement of the IO-360 and L/TSIO-360 Overhaul Manuals since the November 1983 manual revision. 360 series engines that have been overhauled in accordance with November 1983 or later overhaul manual revisions were required to meet the connecting rod minimum beam width of .625 inch prior to returning the engine to service. Engines that have had a complete set of part number 646320 or 646321 rods installed or had all connecting rods inspected and verified to have a beam width above .625 inch are not affected by this service bulletin. Also, all factory new and rebuilt engines other than those listed in "MODELS AFFECTED" are not affected unless connecting rods were replaced without compliance with the inspection requirements set forth in this service bulletin.

COMPLIANCE:

MODELS AFFECTED:

Connecting rod inspection must be performed at the next 100 hour or annual inspection, but not later than one (1) year after the issue date of this service bulletin unless previous compliance with M86-11 Rev.1 has been accomplished.

1. The following engines must be inspected unless previous compliance with M86-11 Rev. 1 has been accomplished:

ISSUED MO

DAY

11

14

REVISED YEAR 96

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 5 CSB96-13

NEW - ENGINE MODEL IO-360-C

350035 thru 350075.

IO-360-D

351332 thru 351358.

IO-360-DB

351350 thru 351363.

IO-360-G

352646 thru 352799.

IO-360-GB

352777 thru 352887.

IO-360-H

353318 thru 353351.

IO-360-K

355258 thru 356561.

IO-360-KB

356003 thru 356561.

TSIO-360-C

300482 thru 300599.

TSIO-360-CB

300571 thru 300667.

TSIO-360-E

303850 thru 311546.

TSIO-360-EB

307391 thru 311612.

TSIO-360-F

305039 thru 310469.

TSIO-360-FB

305737 thru 310732.

TSIO-360-G

309000 thru 309002.

TSIO-360-GB

309004 thru 309433.

TSIO-360-H

308000 thru 308062.

TSIO-360-HB

308063 thru 308127.

TSIO-360-JB

313002 thru 313018.

LTSIO-360-E

304850 thru 306360.

LTSIO-360-EB

306382 thru 312567.

REBUILT - ENGINE MODEL

MO 11

SERIAL NUMBER

SERIAL NUMBER

IO-360-A

20114 thru 20128.

IO-360-C

60330 thru 60525.

IO-360-CB

236501 thru 236502.

IO-360-D

62709 thru 62829.

IO-360-DB

239601 thru 239609.

IO-360-G

224720 thru 224858.

IO-360-GB

236601 thru 236606.

IO-360-H

226502 thru 226508.

IO-360-J

238701 thru 238704.

ISSUED DAY YEAR 14

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

CSB96-13

2 of 5

REBUILT - ENGINE MODEL

SERIAL NUMBER

IO-360-K

230327 thru 230350.

IO-360-KB

235802 thru 235818.

TSIO-360-A

197057 thru 197087.

TSIO-360-AB

237601 thru 237609.

TSIO-360-C

224359 thru 230717.

TSIO-360-CB

236001 thru 236023.

TSIO-360-DB

238401.

TSIO-360-E

225002 thru 225086.

TSIO-360-EB

234551 thru 234638.

TSIO-360-F

232751 thru 232766.

TSIO-360-FB

237301 thru 237352.

TSIO-360-GB

237401 thru 237407.

TSIO-360-H

233251 thru 233253.

TSIO-360-HB

239952 thru 239956.

LTSIO-360-E

225501 thru 225596.

LTSIO-360-EB

233751 thru 233834.

2.

Any IO-360, TSIO-360 and LTSIO-360 model engine that has had a connecting rod or rods replaced with rods other than part number 646320 or 646321 that were not inspected in accordance with service bulletin M86-11 Rev. 1 where the rod beam width was not verified to be .625 inch or greater.

INSPECTION REQUIREMENTS 1. Remove all cylinders in accordance with the applicable TCM Overhaul Manual. 2. Inspect each connecting rod while it is positioned at its maximum stroke to allow clearance from the crankcase. Measure the beam width as indicated in Figure 1 and record the forging number. 3. Any connecting rod that has a beam width less than .625 inch must be replaced. See Figure 1. NOTE:

Connecting rods are supplied in pairs due to the maximum weight differential of 14 grams in opposing cylinder bays. Therefore, the opposite cylinder connecting rod will also require replacement. Reference Table 1 for the applicable replacement connecting rod kit.

4. Install and torque replacement connecting rods in accordance with the applicable TCM Overhaul Manual. Install cotter pins in accordance with Figure 2. 5. Reassemble the engine in accordance with the applicable TCM Overhaul Manual. Make a engine log book entry as to compliance with this service bulletin.

MO 11

ISSUED DAY YEAR 14

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

CSB96-13

3 of 5

Table 1 - Connecting Rod Kits Contact your TCM Distributor for special connecting rod exchange pricing. This pricing is only available to those customers who require replacement rods under the conditions set forth in this service bulletin. ENGINE MODEL

KIT PART NUMBER

QTY

KIT CONTENTS PART#

DESCRIPTION

IO-360-A,C,D,G,H,J,K TSIO-360-A,B,C,D,E,F,G,H. LTSIO-360-E.

(1) 646321A2

2 4 4

646321 639640 639292

CONNECTING ROD BEARING PIN, COTTER

IO-360-AB,CB,DB,ES,GB,HB,JB,KB. TSIO-360-AB,BB,CB,DB,EB,FB,GB, HB,KB,LB,MB. LTSIO-360-EB,KB.

(2) 646320A4

2 4 4

646320 642338 639292

CONNECTING ROD BEARING PIN, COTTER

(1) - This kit is for standard small bore diameter crankshafts. For .010" undersize small bore crankshafts, order connecting rod kit P/N 646321A2M010 which contains 4 each P/N 639640M010 bearings. (2) - This kit is for standard big bore diameter crankshafts. For .010" undersize big bore crankshafts, order connecting rod kit P/N 646320A4M010 which contains 4 each P/N 642338M010 bearings.

AFFECTED PUBLICATIONS: Insert a copy of this service bulletin into the appropriate section of the IO-360 and L/TSIO-360 Series Overhaul Manuals.

MO 11

ISSUED DAY YEAR 14

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

CSB96-13

4 of 5

MO 11

ISSUED DAY YEAR 14

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

CSB96-13

5 of 5

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN

CSB96-2

Compliance Necessary To Maintain Safety

FAA APPROVED

SUBJECT:

CRANKCASE OIL PASSAGE INSPECTION

PURPOSE:

TCM has verified a restricted crankcase oil passage on certain GTSIO-520 model engines. The following instructions are provided to determine if the oil passage to the front propeller shaft bearing is restricted. Only those engines and crankcases identified below are affected by this service bulletin.

COMPLIANCE:

Prior to further flight. WARNING OPERATION OF AN ENGINE WITH A RESTRICTED OIL PASSAGE CAN CAUSE LOSS OF LUBRICATION AND SUBSEQUENT ENGINE FAILURE.

MODELS AFFECTED:

GIO-550-A. GTSIO-520-C, D, F, G, H, K, L, M, N. NOTE: Compliance with this service bulletin is not required if previously accomplished by the instructions set forth in TCM "Special Service Instruction" SSI 1-96.

A. The following engines must be inspected INSTRUCTIONS" set forth in this service bulletin:

in

accordance

with

the

"INSPECTION

ENGINE MODEL

SERIAL NUMBER

GIO-550-A

6X, 7X, 8X, 9X, 10X, 11X, 12X.

GTSIO-520-H

267299-R thru 267304-R, 267306-R.

GTSIO-520-L

272489-R thru 272491-R, 272494-R, 292002-R, 292003-R, 292007-R thru 292009-R, 292019-R, 608754, 608756, 608758.

GTSIO-520-M

276352-R, 276357-R, 276364-R, 276369-R, 276378-R, 276380-R thru 276385-R, 613074.

GTSIO-520-N

277163-R, 277166-R, 277171-R, 277172-R, 277176-R.

ISSUED MO 03

DAY 21

REVISED YEAR

MO

DAY

YEAR

96

 1996, TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

276370-R,

PAGE NO REVISION

1 of 7 CSB96-2

B. New service crankcases purchased from TCM on or after July 1, 1993 that are identified with the serial numbers listed below must be inspected in accordance with the "INSPECTION INSTRUCTIONS" set forth in this service bulletin: CRANKCASE SERIAL NUMBERS D289302RS

A139405RS

J119310RS

A159404RS

J129307RS

A189407RS

A139401RS

A189409RS

NOTE: Crankcase serial numbers are stamped on the front of each crankcase half, just above the oil sump mount flange. C. If you have determined that your engine is affected by this service bulletin, contact your local TCM Field Service Representative or Teledyne Continental Motors (334-438-3411 ext. 299) to obtain special fittings required to perform the inspection and confirm compliance with this Service Bulletin. INSPECTION INSTRUCTIONS WARNING VERIFY MASTER SWITCH IS IN THE "OFF" POSITION AND MAGNETO SWITCHES ARE CONNECTED TO THE MAGNETOS, THAT THEY ARE IN THE "OFF" POSITION AND "P" LEADS ARE GROUNDED WHILE WORKING IN CLOSE PROXIMITY TO THE PROPELLER.

1. Remove engine cowling to allow access to the front and left (2-4-6) side of the crankcase. 2. Using a 5/32" allen wrench, remove the oil passage plug located in the front of the LEFT crankcase half between the propeller shaft and the reduction gear cover. See Figure 1. NOTE: If difficulty is experienced in the removal of the oil passage plug, contact your TCM Field Representative for further instructions. 3. Install and tighten the fitting and tube assembly (supplied by TCM for use in connection with this service bulletin) to the crankcase as shown in Figures 2 and 3. Attach a sufficient length of hose to the tubing assembly to allow personnel to be positioned well clear of the propeller arc. Connect a calibrated 0 - 100 P.S.I. gage to the hose. 4. Disconnect the aircraft oil pressure gage reference line and connect a length of hose and a calibrated 0 - 100 P.S.I. gage to the tee fitting. See Figure 4. The aircraft oil pressure gage CANNOT be used to record this reading. NOTE: This instruction (paragraph 4.) is provided specifically for the Cessna 421 aircraft. Other installations may vary. The important concern here is to reference the oil pressure at the 2-4-6 crankcase half oil passage. 5. Isolate and secure oil gage hoses to prevent damage to the hoses and adjacent components. It will be required to have one person to isolate and monitor the gages and one person to operate the aircraft.

MO 03

ISSUED DAY YEAR 21

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 7 CSB96-2

WARNING USE EXTREME CAUTION IN THE AREA OF THE PROPELLER ARC WHEN PERFORMING THE FOLLOWING STEPS TO PREVENT SERIOUS INJURY OR DEATH TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT. 6. Start the engine and allow the oil to warm-up to operating (green arc) temperature. With the engine operating at idle R.P.M., loosen the hose fitting at each gage only enough to bleed the air from the hose. Tighten each connection after all air has been bled from the lines. 7. With the propeller control in the "HIGH R.P.M." position and the mixture control in the "FULL RICH" position, increase the throttle control until an indication of 1900 R.P.M. is reached. 8. Allow the R.P.M. to stabilize for one minute and record the indicated oil pressure on the front and 2-4-6 oil passage gages. 9. Reduce the R.P.M. to 700 and repeat Step 8. Shut down the engine. 10. If the pressure DIFFERENTIAL between the two gage readings is greater than 10 P.S.I. at either the 1900 R.P.M. or 700 R.P.M. settings, contact TCM Customer Service at 334-4383411 or your local TCM Field Service Representative for instructions. 11. If the pressure differential is LOWER than 10 P.S.I., proceed as follows: 12. Remove the oil pressure gages, hoses, tube assembly and fitting. Install the aircraft oil pressure gage reference line and torque in accordance with the aircraft manufacturer's instructions. Apply a thin film of Loctite PST pipe sealant to the threads of the 1/16-27 plug and install in the front crankcase oil passage. Torque plug to 40 inch pounds. 13. Perform a leak check run and verify that no oil leaks exist at the front oil passage plug and the aircraft oil pressure gage reference line. Repair ANY fluid leaks prior to further engine operation. Install engine cowling. 14. Record compliance with this Service Bulletin in the engine log book. WARRANTY TCM will allow a maximum of 2 hours labor at the posted shop rate to perform the instructions set forth in this service bulletin. Warranty claims must be filed with a TCM Distributor.

MO 03

ISSUED DAY YEAR 21

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

3 of 7 CSB96-2

MO 03

96

ISSUED DAY YEAR 21

MO

REVISED DAY YEAR

FIGURE 1

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

4 of 7 CSB96-2

MO 03

96

ISSUED DAY YEAR 21

MO

REVISED DAY YEAR

FIGURE 2

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

5 of 7 CSB96-2

MO 03

96

ISSUED DAY YEAR 21

MO

REVISED DAY YEAR

FIGURE 3 TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

6 of 7 CSB96-2

FIGURE 4

MO 03

ISSUED DAY YEAR 21

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

7 of 7 CSB96-2

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB96-5 FAA APPROVED SUPERSEDES M93-6.

SUBJECT:

OIL PUMP DRIVE GEARS, P/N 649506 AND 649681

PURPOSE:

This bulletin supersedes M93-6. The inspection requirements and corrective actions that were mandated by Service Bulletin M93-6 have not been revised and are incorporated in this Service Bulletin. This Service Bulletin provides information on replacement oil pump drive gears for the affected engine models. Additional replacement gear information is provided in TCM Service Bulletin SB96-4.

COMPLIANCE: MODELS AFFECTED:

At next scheduled maintenance interval not to exceed 100 hours.

MODEL

SERIAL NUMBER

NEW ENGINES IO-360

DB HB KB

351388 thru 351392 353383 thru 353397 356742, 356743

TSIO-360

EB FB HB JB KB

311749, 311750 318016, 318017 308144, 308145 313034, 313035 320028, 320029, 320041 thru 320043, 320045 thru 320051, 320053 thru 320071, 320075 thru 320100, 320103, 320104, 320106 thru 320112 316130 317241 thru 317247

LB MB LTSIO-360

EB KB

312732 319026, 319027, 319030 thru 319052, 319054 thru 319070, 319074 thru 319078, 319080 thru 319100, 319103, 319104, 319106 thru 319112

REBUILT ENGINES O-300

ISSUED MO 04

DAY 11

A C D

REVISED YEAR

MO

DAY

YEAR

96

 1996, TELEDYNE INDUSTRIES, Inc.

16109D-R 230815-R thru 230818-R 25618D-R thru 25622D-R, 25624D-R thru 25627D-R 25356-R, 25363-R, 29723-R, 35774-R, 35977-R, 35978-R TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 5 CSB96-5

MODEL

SERIAL NUMBER

REBUILT ENGINES (cont’d) IO-360

A CB C DB D GB G HB H J KB K

TSIO-360

A CB C EB E FB F HB KB LB MB

LTSIO-360

EB E KB

MO 04

ISSUED DAY YEAR 11

96

MO

REVISED DAY YEAR

020131-R 236516-R 060602-R thru 060610-R 239661-R thru 239666-R, 239668-R thru 239670-R, 239675R, 239676-R, 239683-R, 239689-R thru 239692-R 062921-R thru 062929-R, 062931-R, 062932-R, 062937-R, 062938-R, 062940-R thru 062948-R 236665-R thru 236671-R 226545-R, 244555-R thru 244557-R, 244559-R thru 244562R 265161-R thru 265169-R, 265171-R thru 265178-R 226537-R thru 226544-R, 226546-R thru 226548-R 238720-R thru 238723-R 235962-R thru 235972-R, 235974-R thru 235983-R 235985-R thru 235993-R 240102-R thru 240107-R, 240109-R, 240110-R 197100-R thru 197102-R 236097-R, 236106-R thru 236122-R, 236124-R thru 236153R, 236155-R, 236156-R, 236158-R thru 236164-R 230801-R, 230802-R, 283501 thru 283507-R, 283509-R thru 283512-R 265734-R, 265736-R, 265740-R thru 265755-R, 265757-R thru 265763-R, 265765-R thru 265779-R, 265781-R thru 265801-R, 265803-R thru 265808-R, 265810-R 225132-R thru 225134-R, 225136-R 281023-R thru 281025-R, 281027-R thru 281030-R, 281032R thru 281055-R, 281057-R thru 281062-R, 281064-R thru 281070-R, 281072-R thru 281078-R, 281080-R, 281081-R 232804-R, 232805-R 239964-R thru 239969-R 268086-R, 268088-R thru 268093-R, 268095-R thru 268105R, 268108-R thru 268110-R, 268112-R thru 268126-R, 268128-R, 268129-R 247163-R, 247164-R, 247166-R thru 247195-R 279211-R thru 279225-R 266257-R, 266261-R thru 266282-R, 266284-R thru 266326R, 266345-R, 266347-R, 266348-R, 266351-R, 266352-R 225637-R, 225640-R thru 225642-R, 225644-R 268318-R thru 268366-R

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 5 CSB96-5

MODEL

SERIAL NUMBER

OVERHAUL ENGINES O-300

D

25179-H, 27903-H, 29712-H, 29899-H

IO-360

CB C D GB G H J KB EB

60475-H, 236505-H 060088-H 056217-H, 056495-H, 062900-H 244523-H 244514-H, 352152-H 353252-H 238710-H 256240-H, 355032-H, 355303-H, 355315-H, 355554-H 233760-H, 233849-H, 233876-H, 233882-H, 233906-H, 233907-H, 233926-H, 233938-H, 266113-H, 266127-H, 266129-H, 266131-H, 304546-H, 304623-H, 306072-H, 306334-H, 306607-H, 306927-H, 306965-H, 312145-H, 312214-H, 312345-H, 312376-H, 312538-H, 312575-H 304596-H, 304646-H, 304708-H, 304899-H 314041-H, 314052-H, 314096-H, 314100-H, 314150-H, 314153-H, 314180-H, 314204-H, 314206-H, 314273-H, 314276-H, 314295-H, 314307-H, 314491-H, 314570-H, 314618-H, 314850-H

LTSIO-360

E KB

TSIO-360

EB

E FB

F GB KB LB

MO 04

ISSUED DAY YEAR 11

96

MO

REVISED DAY YEAR

225091-H, 234598-H, 234668-H, 265582-H, 265591-H, 265607-H, 265630-H, 265683-H, 303127-H, 303616-H, 303881-H, 306318-H, 307451-H, 307582-H, 307679-H, 311034-H, 311188-H, 311283-H, 311407-H, 311455-H, 311525-H, 311549-H 303017-H 305070-H, 305238-H, 305398-H, 305402-H, 305933-H, 305950-H, 310104-H, 310207-H, 310219-H, 310228-H, 310356-H, 310555-H, 310723-H, 310758-H, 310762-H, 310844-H, 310848-H 305067-H, 305448-H 309254-H, 309807-H 268026-H, 311592-H, 314055-H, 314135-H, 315038-H, 315227-H, 315255-H, 315274-H, 315300-H, 315449-H 316026-H, 316065-H, 316094-H, 316103-H

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

3 of 5 CSB96-5

All O-300, IO-360, TSIO-360 & LTSIO-360 engines having one of the subject gears installed at engine overhaul or oil pump repair in the field, if the gear was purchased from TCM within the dates listed below. MODEL

GEAR P/N

PURCHASE DATE

O-300, IO-360, TSIO-360

649506

March 27, 1990 - Dec. 1, 1991

LTSIO-360

649681

Nov. 6, 1989 - Dec. 1, 1991

TCM has determined that a number of oil pump drive gears, P/N 649506 and 649681, may be susceptible to a cracking condition related to improper heat treatment. These gears may have been installed in the O-300, IO-360, TSIO-360 and LTSIO-360 engines listed above or these model engines having the gear replaced in the field within the dates listed above. Current information is that none of the affected gears have experienced crack propagation or mechanical failure as a result of this condition. TCM has also conducted tests which indicate that the condition will not prevent the gears from performing to overhaul. TCM requires that the subject gears be removed and replaced on all affected engines. The new oil pump drive gear part numbers are 654210 for right hand rotating engines and 654210-1 for left hand rotating engines. The new gear is identified by a groove across the threaded end of the shaft and two slots located in the gear face. See Figure 1 and NOTE 2. The part number 653236 and 653237 gears will only have the groove across the threaded end of the shaft. Oil pump drive gears P/N 634010, 640926 and 632550 are not affected by this bulletin and may remain in service. These usable gears can be identified by a woodruff key slot on the gear shaft if the part number is not legible. The subject gears P/N 649506 and 649681 must be removed from service and replaced with the current part number gears as shown in Table 1. Reference the appropriate TCM Engine Overhaul Manual for the proper disassembly and assembly procedures necessary to comply with this service bulletin. NOTE...Reference appropriate parts catalog for proper accessory case and oil pump drive gear combination. Table 1 ENGINE MODEL

GEAR TO BE REPLACED

REPLACEMENT GEARS

O-300'S IO-360'S and TSIO-360'S

649506

654210, 653813 (See Note2), 653236, 634010 or 632550 (See Note 1).

LTSIO-360'S

649681

654210-1, 653813-1 (See Note 2), 653237 or 640926.

NOTE 1:

MO 04

Oil pump drive gear P/N 632550 has an overall length 1.90" (0.60" shorter than the other gears listed in this table). It may be used as a replacement for P/N 649506 only if after positioning into the pump assembly, there exists .24" minimum length of threaded protruding from the oil pump drive gear to which the nut can be attached.

ISSUED DAY YEAR 11

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

4 of 5 CSB96-5

NOTE 2:

Installation of oil pump drive gear part numbers 654210, 654210-1, 653813 and 653813-1 will require the replacement of the oil pump gear. Current production engines incorporate oil pump drive gear part number 654210 or 654210-1. TCM recommends that the current production part number gears be used. See TCM Service Bulletin SB96-4.

Make appropriate log book entry of compliance with this Service Bulletin. AFFECTED PUBLICATIONS: Insert a copy of this service bulletin into the appropriate section of the following TCM manuals: Form # X30013, O-300 Overhaul Manual. Form # X30594A, IO-360 Overhaul Manual. Form # X30596A, L/TSIO-360 Overhaul Manual. WARRANTY: Teledyne Continental Motors will allow labor allowance per the TCM Approved Labor Allowance Schedule. The parts and labor will be prorated on actual engine hours rather than the standard Gold Medallion prorata warranty of forty (40) hours per month since the date in service. Warranty claims may be filed through any TCM distributor.

MO 04

ISSUED DAY YEAR 11

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

5 of 5 CSB96-5

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CATEGORY 2

CSB96-8 FAA APPROVED

SUPERSEDES M92-16.

SUBJECT:

REPLACEMENT OF AIRMELT (NON-VAR) CRANKSHAFTS

PURPOSE:

Provide replacement requirements and identification methods for crankshafts. This Service Bulletin supersedes M92-16 to incorporate additional engine models and expand the IO-520-F serial number affectivity. Additionally, clarification regarding inspection, identification and replacement criteria has been provided.

COMPLIANCE:

Engine overhaul or whenever the crankshaft is removed or made accessible by crankcase disassembly.

MODELS AFFECTED:

New, rebuilt and overhauled: IO-360-A, AB, C, CB, D, DB, ES, G, GB, H, HB, J, JB, K, KB. TSIO-360-A, AB, B, BB, C, CB, D, DB, E, EB, F, FB, G, GB, H, HB, JB, KB, LB, MB, RB. LTSIO-360-E, EB, KB, RB. IO-520-A, B, BA, C, D, E, F, J, K, L, M, P. LIO-520-P. TSIO-520-AE, AF, B, C, D, E, G, H, J, K, L, M, N, P, R, T, U. LTSIO-520-AE.

ACTION REQUIRED:

Inspect affected engine model crankshafts to determine if they are vacuum arc remelted (VAR) forgings whenever the crankshaft is removed or made accessible by crankcase disassembly. If the crankshaft cannot be identified as a VAR forging as set forth in the "IDENTIFICATION OF CRANKSHAFT" section of this Service Bulletin, it must be replaced with a new or serviceable VAR crankshaft.

BACKGROUND INFORMATION In 1978 TCM began using VAR process steel in the forging of crankshafts for use in a number of its engines. The VAR process material produces a forging with fewer impurities providing the greatest reliability and resistance to unusual operating circumstances.

Field service data analysis suggests it is prudent to require replacement of all non-VAR crankshafts utilized in the affected engine models set forth in this Service Bulletin with VAR crankshafts. This replacement must be accomplished at engine overhaul or whenever the crankshaft is removed or made accessible by crankcase disassembly. DO NOT USE NON-VAR CRANKSHAFTS IN ANY ENGINE NOT AFFECTED BY THIS SERVICE BULLETIN UNLESS IT CAN BE SUBSTANTIATED THAT IT HAS NOT PREVIOUSLY OPERATED IN AN AFFECTED ENGINE.

ISSUED MO 06

DAY 25

REVISED YEAR

MO

DAY

YEAR

96

1996 TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 6 CSB96-8

IDENTIFICATION OF CRANKSHAFT Crankshafts made from VAR process steel are identified with the raised letters VAR forged into the crankshaft. The VAR forging identification is on the number 3, 7 or 9 crankshaft cheek depending on the crankshaft part number. The VAR forging identification may have been partially removed during the balancing process. If the crankshaft is identified as VAR, vibroetch the crankshaft flange with the letter "V". This "V" should follow the serial number and heat code. Make an appropriate entry in the engine log book.

FIGURE 2

MO 06

ISSUED DAY YEAR 25

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 6 CSB96-8

FIGURE 3 All crankshafts with the following serial number sequences were manufactured using VAR steel and are not affected by this bulletin. The serial number is stamped into the flange of the crankshaft. IMPORTANT...The absence of a serial number impression on the crankshaft flange indicates a non-VAR crankshaft and the crankshaft must be removed from service at engine overhaul or whenever the crankshaft is removed from the crankcase. If a serial number stamped on the flange is different than described below, the crankshaft must be examined at next overhaul or when removed or made accessible by crankcase disassembly to determine whether the VAR identification is present on the number 3, 7 or 9 cheek. If no serial number or VAR identification is present the crankshaft must be replaced. S/N A001M1 and subsequent. (1981 through 1984) S/N 850001 and subsequent. (1985 through 1989) S/N A019001N and subsequent. (1990 and subsequent) SERIAL NUMBER INTERPRETATION 1981 thru 1984

S/N

Alpha-numerical sequential number for units produced. Begins with A001 each January 1st (A002M1, A003M1) 1985 thru 1989

S/N

Year of Manufacture (1985)

MO 06

ISSUED DAY YEAR 25

96

MO

REVISED DAY YEAR

A001

M 1 & Subsequent

Mobile Manufacture

85

Year of Manufacture (1981)

0001 & Subsequent

Sequential number for units produced that year (0001, 0002, 0003)

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

3 of 6 CSB96-8

1990 Forward

S/N

A

01 90

01

N

New Manufacture Month A-Jan B-Feb C-Mar

Day of Month

Year (1990)

Sequential number for units. Begins with 01 each day.

REFERENCE INFORMATION The following information is provided for reference only. All affected engine models must be inspected in accordance with the "ACTION REQUIRED" paragraph of this Service Bulletin. A. All TCM NEW ENGINES built on or after January 1, 1981, were originally manufactured with VAR crankshafts. B. All TCM REBUILT ENGINES with the following serial numbers and higher were originally manufactured with VAR crankshafts. MODEL

MO 06

ISSUED DAY YEAR 25

96

SERIAL NUMBER

IO-360-A

020132-R

IO-360-C

060619-R

IO-360-CB

236518-R

IO-360-D

062961-R

IO-360-DB

239737-R

IO-360-ES

All

IO-360-G

244566-R

IO-360-GB

236675-R

IO-360-H

226557-R

IO-360-HB

265182-R

IO-360-J

238725-R

IO-360-K

240114-R

IO-360-KB

288506-R

TSIO-360-A

197105-R

TSIO-360-AB

237602-R

TSIO-360-C

283519-R

TSIO-360-CB

236179-R

TSIO-360-DB

238403-R

LTSIO-360-E

225646-R

TSIO-360-E

225137-R

LTSIO-360-EB

266368-R

TSIO-360-EB

265830-R

TSIO-360-F

232810-R

TSIO-360-FB

281111-R

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

4 of 6 CSB96-8

MODEL

MO 06

ISSUED DAY YEAR 25

96

SERIAL NUMBER

TSIO-360-GB

237428-R

TSIO-360-H

233267-R

TSIO-360-HB

239971-R

LTSIO-360-KB

268382-R

TSIO-360-KB

268148-R

TSIO-360-LB

247215-R

TSIO-360-MB

279230-R

TSIO-360-RB

All

LTSIO-360-RB

All

IO-520-A

112667-R

IO-520-B

234762-R

IO-520-BA

280802-R

IO-520-C

287054-R

IO-520-D

282793-R

IO-520-E

215782-R

IO-520-F

286302-R

IO-520-J

216519-R

IO-520-K

224073-R

IO-520-L

270349-R

IO-520-M

270799-R

IO-520-P

All

LIO-520-P

All

LTSIO-520-AE

246612-R

TSIO-520-AE

246113-R

TSIO-520-AF

245218-R

TSIO-520-B

176607-R

TSIO-520-C

178375-R

TSIO-520-D

180097-R

TSIO-520-E

275248-R

TSIO-520-G

216043-R

TSIO-520-H

217281-R

TSIO-520-J

218956-R

TSIO-520-K

224602-R

TSIO-520-L

241936-R

TSIO-520-M

283174-R

TSIO-520-N

228590-R

TSIO-520-P

278614-R

TSIO-520-R

269856-R

TSIO-520-T

239382-R

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

5 of 6 CSB96-8

C. All TCM FACTORY OVERHAULED engines with a serial number higher than S/N 901203-H were originally supplied with VAR crankshafts. NOTE:

Engines listed in A, B and C may have been overhauled or repaired after shipment from TCM and a non-VAR crankshaft installed.

Owners and operators are encouraged to regard the parameters which may affect crankshaft reliability. FAA advisory circular AC20-103 dated March 7, 1978, discusses these conditions and details preventive measures. CRANKSHAFT EXCHANGE POLICY TCM will accept serviceable non-VAR crankshafts for new VAR crankshafts on an exchange basis for the affected engine models set forth in this Service Bulletin. Non-VAR crankshafts that require replacement due to damage or wear are not eligible for exchange pricing. Contact your TCM Distributor for exchange pricing information. AFFECTED PUBLICATIONS: Insert a copy of this Service Bulletin into the appropriate section of the following manuals: •

Form # X30594A, IO-360 Overhaul Manual.

•

Form # X30597A, TSIO-360 Overhaul Manual.

•

Form # X30039A, IO-520 Series Overhaul Manual.

•

Form # X30574A, TSIO-520 Permold Series Overhaul Manual.

•

Form # X30575A, TSIO-520 Sandcast Series Overhaul Manual.

MO 06

ISSUED DAY YEAR 25

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

6 of 6 CSB96-8

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN Compliance Necessary to Maintain Safety

CSB97-10A FAA APPROVED

SUBJECT:

PISTON PIN PLUG WEAR.

PURPOSE:

To notify owners, operators and maintenance facilities of the possibility of abnormal wear to the aluminum piston pin plug when installed in certain manganese phosphated cylinders.

COMPLIANCE:

Within the next ten (10) hours of operation from the date of issuance of this bulletin, inspect each affected IO-240, IO-360, TSIO-360, LTSIO-360, IO-520, TSIO-520, LTSIO-520, GTSIO-520, IO-550, TSIO-550 and TSIOL-550 series engine and cylinder in accordance with PART 1 of this bulletin. If elected, an optional method of compliance may be performed in accordance with PART 2 of this bulletin. ALL AFFECTED E-SERIES, O-470 AND IO-470 ENGINES AND CYLINDERS MUST BE INSPECTED AS SOON AS POSSIBLE (BUT NO LATER THAN THE NEXT 10 HOURS OF OPERATION) IN ACCORDANCE WITH PART 2 OF THIS BULLETIN.

MODELS AFFECTED:

Refer to Table 1 and Table 2 of this bulletin.

GENERAL INFORMATION In August, 1996 Teledyne Continental Motors (TCM) began using a manganese phosphate coating on the cylinder bore of certain cylinders to provide resistance to corrosion during the first hours of operation. TCM has identified accelerated wear in a small number of aluminum piston pin plugs removed from these cylinders. This wear has been attributed to a bore surface that was rougher than that specified for the cylinder bore believed to be due to extended exposure to the manganese phosphate treatment. TCM believes only a small number of manganese phosphate coated cylinders would cause accelerated piston pin plug wear. Cylinders that are affected by this bulletin are listed by part number in Table 2.

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

 1997 TELEDYNE INDUSTRIES INC.

To insure that piston pin plugs utilized in coated cylinders are not experiencing accelerated wear, perform the inspection detailed in PART 1 or PART 2.

WARNING FAILURE TO IDENTIFY ABNORMAL PISTON PIN PLUG WEAR MAY LEAD TO SUBSEQUENT PISTON DAMAGE AND RESULTING CATASTROPHIC ENGINE FAILURE.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

1 of 11 CSB97-10

A

INSPECTION INSTRUCTIONS PART 1 - PROGRESSIVE INSPECTION 1. Inspect the part number on the side of the cylinder base flange to determine if cylinder inspection is required. Only those cylinders that are identified with the part numbers listed in Table 2 are affected by this bulletin. NOTE: All factory new IO-550-B, IO-550-C and TSIO-520-UB engines provided in the new serial number listing of Table 1 must be inspected in accordance with Part 1 or Part 2 of this bulletin, regardless of cylinder part number. 2. If oil analysis has been performed prior to the date of this service bulletin, review the analysis report(s) for findings of high or abnormal amounts of aluminum. 3. If possible, review inspection results of previous oil filter element or screen examinations for content of fine aluminum material. 4. If high or abnormal amounts of aluminum were noted in the oil analysis or fine aluminum material was present in the oil filter element or screen, comply with PART 2 of this bulletin. 5. For all affected engines or cylinders listed in Table 1 or Table 2 regardless of previous history, the progressive inspection sequence below must be conducted. This includes a special oil analysis program. TCM will provide three (3) oil analysis kits and analyses at no charge. Contact TCM at 1-334-438-3411 ext. 81 to arrange immediate shipment of these kits. Please be prepared to provide the following information: •

ENGINE MODEL NUMBER.

•

TOTAL CYLINDER HOURS.

•

OWNER'S NAME, ADDRESS, PHONE NUMBER.

•

"SHIP TO" ADDRESS ANALYSIS KITS.

ISSUED MO

DAY

06

19

AND

SERIAL

FOR

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

OIL

a. After operation of the engine and while the engine oil is hot, drain oil and take an oil sample in accordance with the instructions contained in the oil analysis kit. Mail sample for analysis. b. Remove oil filter or screen. For oil filters, cut open the filter canister and remove the filter element. Allow the excess oil to drain from the filter element or screen and examine it for debris. Unless the amount of debris contained in the filter element or screen is more than typical for the total hours, reinstall and tighten the screen or new oil filter to the specified torque value and service the engine with the approved type, grade and quantity of oil. Record the findings of filter or screen inspection. c. Perform a borescope inspection of each affected cylinder paying particular attention to the 3 o'clock and 9 o'clock positions in the bore for signs of excessive piston pin plug contact. Reference Figures 1, 2, 3 and 4. Record inspection results for each cylinder. 6. Two additional oil analysis samples, oil filter examinations and borescope inspections must be performed at intervals of 25 and 50 hours after the initial inspection if results reveal no abnormalities. 7. Record results of each oil analysis, filter/screen examination and borescope inspection in the engine log book. 8. If any abnormal oil analysis trends, borescope inspections or oil filter/screen examinations are discovered, inspection in accordance with PART 2 will be required. 9. If upon completion of the three (3) inspections no abnormalities have been noted, compliance with the requirements of this bulletin is satisfied. Make a log book entry as to compliance with service bulletin CSB97-10.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

2 of 11 CSB97-10

A

PART 2 CYLINDER REMOVAL, INSPECTION AND REASSEMBLY. This inspection method will require the removal of each affected cylinder for inspection of the cylinder bore surface finish and piston pin length by TCM.

•

Cylinder Part Number.

•

Cylinder Position, (#1, #2, etc.). c. Carefully preserve and package each cylinder and piston pin separately in a manner that will avoid shipping damage. Ship to TCM in accordance with Appendix A for inspection.

NOTE: This is the required inspection method for affected 470 series engines listed in Table 1 that have affected part number cylinders installed as NOTE: International customers must contact TCM at 1listed in Table 2. All E-Series and 470 series 334-438-3411 for special instructions. engines that have had replacement cylinders 2. Reassembly Instructions. installed as listed in Table 2 must also be removed and returned to TCM for inspection. a. Reassemble all parts in accordance with the applicable TCM Overhaul Manual. Torque 1. Cylinder Removal and Shipping Instructions. all hardware in accordance with the latest a. Remove the cylinder in accordance with the revision of TCM Service Bulletin SB96-7. applicable TCM Overhaul Manual. WARRANTY b. Record and tag each cylinder and piston pin The action required to comply with this bulletin is with the following information: covered by the Gold Medallion Warranty or Service • Aircraft Registration Number. Parts Warranty, subject to its terms and conditions. • Engine Model. •

Engine Serial Number.

•

Total Cylinder Hours.

TABLE 1 - AFFECTED NEW AND REBUILT ENGINES ENGINE MODEL

NEW ENGINE - SERIAL NUMBER

IO-240-B

806823, 806828 thru 806832, 806929, 806930.

TSIO-360-JB

313036, 313037.

TSIO-360-MB

317269 thru 317275.

TSIO-360-RB

321359, 321360

TSIO-360-SB

321611, 321612

O-470-R

466727.

IO-470-N

458162 thru 458171.

IO-520-BB

580053 thru 580055, 580057, 580058.

IO-520-CB

576319, 576320.

IO-520-D

575926 thru 575928.

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

3 of 11 CSB97-10

A

ENGINE MODEL

NEW ENGINE - SERIAL NUMBER

IO-520-F

579240.

IO-550-B See Note 1.

682287 thru 682304, 682361 thru 682364, 682537, 682608 thru 682634, 682769, 682770, 682787 thru 682797, 682952, 682953, 913001, 913008.

IO-550-C See Note 1.

676987, 676989 thru 676998, 683102 thru 683107, 683171, 683172, 683263, 683272, 683346 thru 683350, 683401 thru 683419, 683532 thru 683535, 683545, 683550 thru 683557, 683696, 683697.

IO-550-F

679516, 679517.

IO-550-G

679271 thru 679278, 679281, 679283, 679293.

TSIO-520-CE

530166.

TSIO-520-M

532068 thru 532073.

TSIO-520-R

522690 thru 522693.

TSIO-520-UB See Note 1.

527249 thru 527252, 527297, 527299 thru 527303, 527329, 527330.

TSIO-520-VB

529108, 529109.

GTSIO-520-M

613077 thru 613079.

TSIO-550-C

802557 thru 802560, 802562 thru 802564.

TSIO-550-E

803037.

TSIOL-550-A

800637.

Note 1 – New IO-550-c, IO-550-B and TSIO-520-UB engines must comply with this service bulletin regardless of cylinder part number. ENGINE MODEL

REBUILT ENGINE - SERIAL NUMBER

IO-360-A

020138-R.

IO-360-C

060664-R.

IO-360-D

063013-R, 063014-R.

IO-360-DB

808773-R thru 808778-R.

IO-360-G

244595-R, 244597-R.

IO-360-JB

292505-R.

IO-360-K

240138-R.

IO-360-KB

288686-R thru 288688-R, 288690-R thru 288693-R.

TSIO-360-A

197116-R.

TSIO-360-C

283553-R, 283554-R.

TSIO-360-CB

236238-R, 236239-R.

TSIO-360-E

225150-R.

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

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4 of 11 CSB97-10

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ENGINE MODEL

REBUILT ENGINE - SERIAL NUMBER

TSIO-360-EB

809123-R, thru 809126-R, 809128-R thru 809132-R.

TSIO-360-FB

299628-R thru 299638-R.

TSIO-360-KB

811279-R, thru 811282-R.

TSIO-360-LB

247326-R, 247327-R.

TSIO-360-MB

279280-R, 279281-R.

LTSIO-360-E

225660-R.

LTSIO-360-EB

807408-R, 807410-R thru 807418-R, 807422-R.

LTSIO-360-KB

812012-R, 812013-R.

O-470-G

070702-R.

O-470-J

202205-R, 202206-R.

O-470-K

049485-R, 049487-R thru 049490-R.

O-470-L

069866-R thru 069872-R.

O-470-R

811818-R thru 811857-R, 811859-R, 811861-R, 811862-R.

O-470-S

269420-R, 269422-R thru 269428-R

O-470-U

809972-R, 809974-R thru 809983-R, 809985-R thru 809990-R, 809992-R, 809993-R, 809995-R thru 810000-R, 813254-R, 813255-R, 813257-R, 813259-R, 813262-R, 813264-R.

IO-470-C

295543-R.

IO-470-D

105635-R.

IO-470-E

088761-R.

IO-470-F

089905-R, 089906-R.

IO-470-K

092982-R, 092984-R.

IO-470-L

297703-R thru 297717-R, 297720-R thru 297723-R, 297728-R thru 297730-R, 297732-R, 297733-R.

IO-470-N

096683-R, 096685-R thru 096689-R.

IO-470-S

109376-R.

IO-470-V

171171-R thru 171178-R.

IO-520-A

112795-R thru 112801-R.

IO-520-B

234778-R thru 234781-R.

IO-520-BA

807193-R, 807194-R, 807196-R thru 807199-R, 807201-R thru 807207-R, 807209-R thru 807234-R, 807236-R.

IO-520-BB

809694-R, 809695-R, 809701-R, 809703-R, 809704-R, 809706-R, 809707-R, 809709-R, 809710-R, 809713-R thru 809727-R, 809729-R thru 809738-R

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

5 of 11 CSB97-10

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ENGINE MODEL

REBUILT ENGINE - SERIAL NUMBER 809741-R, 809742-R, 809744-R thru 809746-R, 809748-R thru 809750-R.

IO-520-C

810845-R thru 810851-R, 810853-R thru 810878-R, 810881-R thru 810885-R, 810888-R thru 810895-R, 810897-R thru 810900-R.

IO-520-CB

298839-R thru 298854-R, 298856-R thru 298867-R, 298869-R thru 298885-R, 298888-R, 298889-R.

IO-520-D

293491-R thru 293500-R, 812751-R thru 812763-R, 812765-R thru 812771-R, 812773-R thru 812780-R, 812782-R, 812783-R, 812785-R thru 812788-R, 812791-R thru 812795-R, 812797-R thru 812811-R.

IO-520-E

215870-R thru 215888-R.

IO-520-F

812255-R, 812278-R, 812279-R, 812293-R, 812295-R, thru 812297-R, 812299R thru 812311-R, 812313-R thru 812327-R, 812329-R thru 812332-R, 812334R thru 812337-R, 812339-R, 812340-R, 812342-R thru 812345-R, 812347-R thru 812354-R, 812356-R thru 812371-R, 812373-R, 812376-R, 812377-R, 812379-R thru 812385-R, 812388-R thru 812391-R.

IO-520-J

216529-R.

IO-520-K

224118-R thru 224122-R.

IO-520-L

294769-R, 294770-R, 294772-R thru 294777-R, 294779-R thru 294799-R, 294801-R, 294802-R, 294804-R, 294805-R, 294809-R.

IO-520-M

811535-R thru 811540-R, 811544-R thru 811554-R, 811556-R thru 811558-R, 811560-R thru 811562-R, 811565-R thru 811567-R.

IO-520-MB

277607-R, 277612-R, 277614-R, 277615-R, 277618-R thru 277620-R, 277623R thru 277640-R, 277643-R, 277644-R.

IO-550-A

280446-R thru 280453-R, 280455-R, 280458-R thru 280461-R.

IO-550-B

296928-R, 296939-R thru 296967-R, 296969-R thru 296971-R, 296975-R.

IO-550-C

810363-R thru 810404-R, 810406-R, 810408-R.

IO-550-D

284242-R thru 284244-R, 284246-R thru 284256-R.

IO-550-E

283360-R, 283364-R thru 283373-R.

IO-550-F

284787-R, 284790-R thru 284804-R.

IO-550-L

289113-R thru 289121-R.

TSIO-520-AE

246153-R thru 246155-R.

TSIO-520-AF

245240-R.

TSIO-520-B

176711-R, 176714-R thru 176726-R, 176730-R.

TSIO-520-C

178506-R thru 178510-R.

TSIO-520-CE

268568-R, 268569-R, 268570-R.

TSIO-520-E

812506-R thru 812513-R, 812515-R thru 812521-R, 812524-R, 812525-R, 812528-R, 812529-R.

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

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ENGINE MODEL

REBUILT ENGINE - SERIAL NUMBER

TSIO-520-EB

271449-R thru 271452-R, 271455-R thru 271469-R, 271472-R thru 271474-R.

TSIO-520-G

216050-R.

TSIO-520-H

217380-R thru 217382-R, 217384-R thru 217387-R.

TSIO-520-J

218983-R, 218984-R.

TSIO-520-JB

237183-R, 237184-R.

TSIO-520-LB

237295-R, 237296-R.

TSIO-520-M

291823-R thru 291850-R, 291852-R thru 291857-R, 291861-R thru 291863-R, 291865-R, 291868-R, 291869-R.

TSIO-520-NB

290966-R, 290967-R, 290969-R thru 290974-R, 290978-R, 290979-R, 290981-R thru 290989-R, 290992-R, 290993-R, 290995-R, 290996-R, 290998-R, 290999-R, 813501-R.

TSIO-520-P

278774-R, 278776-R thru 278781-R, 278785-R thru 278790-R.

TSIO-520-R

293845-R thru 293847-R, 293849-R thru 293861-R, 293863-R thru 293869-R, 293872-R thru 293875-R, 293877-R.

TSIO-520-T

239436-R thru 239445-R.

TSIO-520-UB

809316-R, 809317-R.

TSIO-520-VB

811061-R, 811065-R, 811067-R thru 811073-R, 811075-R, 811076-R, 811079R thru 811083-R, 811085-R, 811087-R thru 811095-R, 811097-R thru 811104R, 811107-R thru 811111-R, 811114-R, 811116-R.

TSIO-520-WB

274376-R, 274379-R thru 274393-R, 274395-R, 274396-R, 274398-R.

LTSIO-520-AE

246654-R.

GTSIO-520-H

267443-R thru 267449-R, 267451-R, 267454-R.

GTSIO-520-L

292234-R thru 292239-R, 292241-R, 292243-R thru 292246-R, 292248-R thru 292257-R, 292259-R, 292260-R, 292262-R, 292264-R thru 292270-R.

GTSIO-520-M

810560-R thru 810562-R, 810564-R thru 810570-R, 810573-R thru 810576-R, 810579-R, 810580-R, 810582-R thru 810587-R.

GTSIO-520-N

808289-R, 808292-R, 808293-R, 808295-R, 808296-R.

TSIO-550-C

802557-R thru 802560-R, 802562-R thru 802564-R.

TSIOL-550-A

800636-R thru 800638-R, 800642-R.

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

7 of 11 CSB97-10

A

TABLE 2 - AFFECTED CYLINDERS The following table contains cylinder part numbers affected by this bulletin and the engine models on which they are utilized. Any 240, 360, 520 or 550 cylinder identified with the affected part number that was shipped from TCM within the dates listed must be inspected in accordance with the instructions set forth in PART 1 or PART 2 of this bulletin. All E-Series and 470 series cylinders identified below must be inspected in accordance with PART 2 of this bulletin NOTE: Cylinders that are identified with the letter "M" or "P" steel stamped after the cylinder position number are not affected by this bulletin. The cylinder position number is located at the 12 o'clock position on the cylinder mounting flange.

TABLE 2 - AFFECTED CYLINDERS ENGINE MODEL

AFFECTED DATES

(1) Affected Cylinder P/N

All IO-240, IO-360-ES, TSIO-360-MB

3-11-97 to 6-9-97

654702

All IO-360, TSIO-360 & LTSIO-360

3-11-97 to 6-9-97

654701

All E-Series

3-13-97 to 6-9-97

654761

O-470-A, E & J, IO-470-J & K

2-20-97 to 6-9-97

654657

O-470-G, GCI, K, L, M, R & S, IO-470-C

3-7-97 to 6-9-97

654649

O-470-U, IO-470-D, E, F, H, L, M, N, S, U, V & VO

3-7-97 to 6-9-97

654650

All IO-520, TSIO-520-AF, CE & UB, IO-550-A, B & C

1-7-97 to 6-9-97

654651

IO-550-D, E, F & L

2-18-97 to 6-9-97

654653

TSIO-520-B, BB, C, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, VB, WB

1-15-97 to 6-9-97

654652

IO-550-G, TSIO-520-BE, GTSIO-520-F & K

2-12-97 to 6-9-97

654656

TSIO-520-AE, LTSIO-520-AE

3-6-97 to 6-9-97

654658

TSIO-550-A, B, C, E

3-13-97 to 6-9-97

654659

TSIOL-550-A, B

3-13-97 to 6-9-97

654648

GTSIO-520-C, D, H

2-12-97 to 6-9-97

654655

GTSIO-520-L, M, N

1-21-97 to 6-9-97

654654

(1) This will include all suffixes of these numbers; i.e. 654651A5.

ISSUED MO

DAY

06

19

REVISED YEAR 97

MO

DAY

YEAR

07

15

97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

8 of 11 CSB97-10

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Appendix A - Instructions For Returning Removed Cylinders For Inspection. Contact the TCM Customer Service Desk at (334) 438-3411, Ext. 81, for packing material and shipping labels. Please be prepared to provide the following information. Engine Model and Serial Number Shipping Address 1. Using the shipping labels provided; a. Complete a Return Tag for each cylinder and attach to the cylinder. b. Complete a Return Tag for each piston pin and attach to the piston pin. c. Complete a shipping label for each cylinder and attach to the outside of the box. d. Complete a return shipping label for each cylinder and place inside the box. (This label will be used for returning the cylinder to you.) 2. Ship all packages to TCM as follows. a. Ship via Emery 2nd Day Air, Inbound Collect. On the Airbill, reference: Account #545519019 Consignee Reference #75970400

Ship To:

Teledyne Continental Motors 2000 Ninth Street Mobile, AL 36615 Attn. Cylinder Inspection Program

ISSUED MO

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06

19

REVISED YEAR 97

MO

DAY

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TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

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DAY

06

19

REVISED YEAR 97

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07

15

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TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

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06

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TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

11 of 11

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

CSB97-10

A

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN

CSB97-9

Compliance Necessary To Maintain Safety

FAA APPROVED Supersedes SB 94-14A

SUBJECT:

GTSIO-520 CRANKCASE INSPECTION

PURPOSE:

PROVIDES INSTRUCTIONS FOR CRANKCASE INSPECTION AND REMOVAL OF NUMBER 5 CYLINDER 7TH STUD RETAINING BRACKET

COMPLIANCE: MODELS AFFECTED:

WITHIN NEXT 25 HOURS OF OPERATION AND EVERY 50 HOURS FOR THE NEXT 500 HOURS OF OPERATION ALL GTSIO-520 SERIES ENGINES INCORPORATING 7TH CYLINDER DECK STUD CONFIGURATION

GENERAL INFORMATION

b) remove the aircraft cowling

Inspection of engines and crankcases returned to TCM has identified the possibility of a crankcase crack developing in the area of the number 5 cylinder 7th stud and aft (9 o’clock) alternator mounting stud.

c) remove engine baffling to allow access to the alternator and number 5 cylinder area

Within the next 25 operating hours after the effective date of this bulletin and every 50 hours for the next 500 hours of operation perform a visual and dye penetrant inspection of the engine crankcase at the number 5 cylinder 7th stud location. Refer to Figure 1 for area to be inspected. All new and Rebuilt engines shipped from TCM after May 20, 1997 will not incorporate the number 5 cylinder 7th stud. CAUTION.....Engines that have complied with this Critical Service Bulletin will not have the number 5 cylinder 7th stud bracket P/N 653867 or nut P/N 646312; however, the 7th stud P/N 646140-3 will remain installed in the crankcase. PRE-INSPECTION: 1. Following the aircraft manufacturer’s instructions perform the following:

d) disconnect electrical wiring from the alternator. Identify terminal locations on wiring to aid installation 2. Remove and discard the number 5 cylinder 7th stud nut and bracket. The nut and bracket will not be reinstalled after inspection. 3. Remove alternator mounting hardware and remove alternator from the engine. Discard lock washers. CRANKCASE INSPECTION: 1. Clean the area around and adjacent to the number 5 cylinder 7th stud and alternator (Refer to Figure 1) with an approved cleaner. 2. Perform a visual and dye penetrant inspection of the area, with specific attention to the area between the number 5 cylinder 7th stud and the aft (9 o’clock) alternator mount stud (Refer to Figure 1).

a) disconnect aircraft battery ISSUED MO

DAY

05

28

REVISED YEAR

MO

DAY

YEAR

97

 1997 TELEDYNE INDUSTRIES INC.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

1 of 3 CSB97-9

3. If a crack is identified, the crankcase or engine must be replaced prior to further operation. 4. If no crack is identified, comply with the following instruction prior to returning the engine to service. ALTERNATOR STUD INSTALLATION: On engines incorporating the aft (9 o’clock) alternator mount stud,follow the instructions contained in the ALTERNATOR INSTALLATION section of this bulletin. Engines that do not have the alternator aft (9 o’clock) mounting stud installed will require installation of this stud. 1. Prior to installation of the P/N 401885 stud, thoroughly clean the stud hole in the crankcase with Loctite “Primer N”. 2. Apply Loctite “271” to the course threads of the stud and install to a stud height of .950 inches. Allow a minimum of 30 minutes for the Loctite “271” to cure. ALTERNATOR INSTALLATION: 1. Reinstall alternator using a new gasket, P/N 649978. Lubricate stud threads with clean 50 weight engine oil. Install 4 each of the following; flat washers, new lock washers and nuts. Torque alternator attaching nuts 150 to 180 inch pounds. AFFECTED PUBLICATIONS:

DAY

05

28

REVISED YEAR 97

a) install engine removed

baffling

previously

b) reconnect electrical wiring at alternator c) reinstall engine cowling d) reconnect aircraft battery POST INSPECTION / INSTALLATION OPERATIONAL VERIFICATION: Perform a complete engine ground run up in accordance with the aircraft manufacture’s instructions. Verify that alternators perform and function correctly. 1. After engine shut down, inspect engine for oil and fuel leaks. 2. Correct any discrepancies noted prior to returning the engine and aircraft to service. 3. Make log book entries indicating compliance with this Critical Service Bulletin. Entry must include the next required inspection interval. WARRANTY: The actions required by this bulletin are covered by TCM’s Gold Medallion Warranty, subject to its terms and conditions.

We recommend that you make the appropriate annotations to applicable manuals to call attention to this service bulletin.

ISSUED MO

1. Following the aircraft manufacturer’s instructions perform the following:

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

2 of 3 CSB97-9

VISUAL AND DYE PENETRANT INSPECT THIS AREA

CRITICAL INSPECTION AREA

Figure 1

ISSUED MO

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REVISED YEAR 97

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TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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3 of 3 CSB97-9

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 2

CRITICAL SERVICE BULLETIN Compliance Necessary To Maintain Safety

CSB98-1B TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

INTAKE AND EXHAUST VALVE INSPECTION

PURPOSE:

Teledyne Continental Motors (TCM) has recently investigated and confirmed reports of abnormal wear on the hardened wear tip of seven (7) valves. These seven (7) valves are from the approximately 200,000 valves manufactured by TRW, Inc. for TCM between January 1, 1996 and March 31, 1998. In each instance the abnormally worn valve exhibited signatures indicative of improper heat treatment of the valve wear tip during the manufacturing process. During our investigation, valves in stock at TCM and its distributors (approximately 8,000 valves) were checked for hardness of the wear tip and a total of 43 valves in stock were found to be below minimum specifications for hardness. While these valves represent a very small portion of the valves received by TCM during the time period in question, TCM is committed to insuring high levels of quality, product integrity and safety and is, therefore, issuing this service bulletin. While no engine failures have been reported to TCM to date as a result of this condition, the possibility of accelerated valve tip wear leading to engine damage or failure does exist. This bulletin requires the inspection of each valve, cylinder assembly, and engine supplied by TCM during the time periods designated in Table 1 of the COMPLIANCE section of this service bulletin, as well as any engine that has been overhauled or repaired using a valve or cylinder assembly supplied by TCM during the designated time periods. Although TCM believes that the probability of significant numbers of valves with improperly heat treated wear tips in the field is low, it is essential that such valves be found and removed from service. This service bulletin provides the compliance requirements and inspection procedures for inspecting all valves, cylinder assemblies and engines manufactured, overhauled, or repaired utilizing valves supplied during the time periods designated in Table 1 of the COMPLIANCE section of this service bulletin. TCM will furnish parts and labor in accordance with the Cost Reimbursement section of this service bulletin. Complete the Valve Inspection Reimbursement Form on page 13 of this bulletin and submit directly to TCM for payment.

WARNING Any valve with tip hardness below minimum specification is subject to accelerated wear which could result in engine damage or failure.

ISSUED MO

DAY

06

01

REVISED YEAR 98

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

CSB98-1B

An Allegheny Teledyne Company

1 of 14

B

COMPLIANCE:

As designated in Table 1

NOTE: The following cylinder assemblies (cylinders with part numbers suffixed by the letter “A” and a number, e.g..: 654928 A 3) are in compliance with this service bulletin. Part number: 654928, 654958, 954959, 654960, 654961, 654962, 654963, 654965, 654966, 654967,654968, 654969, 654970, 654971, 654974. TABLE 1 This service bulletin affects valves, cylinders assemblies and engines (listed by engine model) purchased from TCM during the time periods designated in the following table. Refer to Table 2 under Models Affected for serial number effectivity for TCM new and rebuilt engine. VALVE TIP INSPECTION REQUIRED BY ENGINE MODEL AND PURCHASE DATE ENGINE MODEL PURCHASE DATE OF ENGINE MODEL PURCHASE DATE OF AFFECTED VALVE, AFFECTED VALVE, CYLINDER ASSEMBLY CYLINDER ASSEMBLY OR ENGINE OR ENGINE C-75, 85,90 1/1/96 to 5/15/98 IO-470-ALL 1/1/96 to 3/31/98 O-200-A & B O-240-ROLLS-ROYCE 1/1/96 to 5/15/98 TSIO-470-ALL 1/1/96 to 3/31/98 O-300-A,B,C, & D 1/1/96 to 5/15/98 IO-520-ALL 1/1/96 to 3/31/98 GO-300-ALL 1/1/96 to 5/15/98 TSIO-520-ALL 1/1/96 to 3/31/98 IO-240-A & B 1/1/96 to 5/15/98 LTSIO-520-ALL 1/1/96 to 3/31/98 IO-346-A 1/1/96 to 3/31/98 GTSIO-520-ALL 1/1/96 to 3/31/98 IO-360-ALL 1/1/96 to 5/15/98 IO-550-ALL 1/1/96 to 3/31/98 TSIO-360-ALL 1/1/96 to 5/15/98 TSIO-550-ALL 1/1/96 to 3/31/98 LTSIO-360-ALL 1/1/96 to 5/15/98 TSIOL-550 1/1/96 to 3/31/98 E-Series 1/1/96 to 3/31/98 GIO-550-ALL 1/1/96 to 3/31/98 O-470-ALL 1/1/96 to 3/31/98 CAUTION:

Any affected engine or any engine which has been overhauled or repaired utilizing an affected valve or cylinder assembly experiencing audible valve lifter clatter must comply with Part 3 of this service bulletin within the next 10 hours of engine operation. Valve lifter clatter may be the result of increased clearances resulting from valve tip wear. 1.

Service spare valves and cylinder assemblies in inventory must be inspected on receipt of this bulletin. Comply with Part 1 or Part 2 as applicable.

2.

New and rebuilt affected engines and engines that have been overhauled or repaired utilizing affected valves or cylinder assemblies with more than 200 hours total time in service but less than 400 hours total time in service must be inspected within the next 100 hours of operation, but not later than the next annual inspection. Comply with Part 3 and Part 4. NOTE: Due to the variations in wear rates of improperly heat treated valve tips, unless audible valve lifter clatter is noted or reported, do not inspect affected engines with less than 200 hours of operation. ISSUED MO

DAY

06

01

REVISED YEAR 98

MO

DAY

YEAR

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PAGE NO REVISION

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

CSB98-1B

An Allegheny Teledyne Company

2 of 14

B

3.

New and rebuilt affected engines and engines that have been overhauled or repaired utilizing affected valves or cylinder assemblies with more than 400 hours total time in service must be inspected within the next 50 hours of operation. Comply with Part 3 and Part 4.

4.

MODELS AFFECTED:

Overhauled and repaired cylinders installed on any engine incorporating valves purchased from TCM during the time period designated in Table 1 must be inspected in accordance with the criteria stated in item 2 or 3 above, as applicable. Comply with Part 3 and Part 4. ALL AS SPECIFIED IN TABLE 1 and TABLE 2. TABLE 2

ENGINE MODEL

REBUILT S/N

NEW S/N

ENGINE MODEL

REBUILT S/N

NEW S/N

O-200-A

285406-285499 814000-841020

256046-256051

IO-360-DB IO-360-ES

808760-808788 NONE

O-300-A,, O-300-C, O-300 D

016112 230830; 230831 025676-025692.

NONE NONE NONE

IO-240-A IO-240-B

NONE NONE

NONE 806166, 806167; 806508; 806509 806565;806686806689;806693; 806695-806714; 806814-806832; 806843-806848; 806851;806900; 806930-806933; 806937-806939; 806942;806944; 806951-806955;

IO-360-G IO-360-GB

244585-244603 236694-236699 813001-813011 226575-226581 265191-265195 238726-238731 292504, 292505 240135-240139 288634-288712

351394 357049;357051; 357053-357068; 357070;357083; 357087-357093; 357097-357109 NONE 352962; 352964; 352967; 352968 NONE 358021-358024 NONE NONE NONE 356747-356751

197112-197120 237615-237616 283546-283558 236230-236246 225147-225150 809002;809036809208 232819 299572-299688

NONE NONE NONE 300673-300676 NONE 311753-311754 NONE NONE 318021-318022

IO-360-A IO-360-C IO-360-CB IO-360-D

020136-020139 060645-060684 236523-236526 062999-063027

ISSUED MO

DAY

06

01

NONE NONE NONE NONE

REVISED YEAR 98

MO

DAY

YEAR

IO-360-H IO-360-HB IO-360-J IO-360-JB IO-360-K IO-360-KB TSIO-360-A TSIO-360-AB TSIO-360-C TSIO-360-CB TSIO-360-E TSIO-360-EB TSIO-360-F TSIO-360-FB

TELEDYNE CONTINENTAL MOTORS

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CSB98-1B

An Allegheny Teledyne Company

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TABLE 2 (CONTINUED) ENGINE MODEL

REBUILT S/N

NEW S/N

ENGINE MODEL

REBUILT S/N

NEW S/N

TSIO-360-H TSIO-360-HB TSIO-360-JB TSIO-360-KB

233273-233278 239976-239982 NONE 268237-268249 811251-811309

NONE NONE 313036; 313037 320336-320339; 320342-320344; 320348-320349; 320351;320353320355;320357320363;320366320367;320371320380 NONE 317257; 317258; 317260;317268317279 321325-321330; 321349-321363; 321406-321460 321753-321758; 321761-321770; 321773-321774; 321777-321778

O-470-S O-470-U

269375-269458 809770-809999 810000 813254-813355

464587 470755-470758

IO-470-C IO-470-D IO-470-E IO-470-F IO-470-H IO-470-J IO-470-K IO-470-L

295529-295549 105630-105641 088756-088763 089873-089915 087343 089123-089126 092971-092990 297605-297797

IO-470-M IO-470-N IO-470-S IO-470-U IO-470-V

094591 096638-096703 109363-109385 118450-118453 171138-171197; 171199

NONE NONE NONE NONE NONE NONE NONE 468598-468600; 468602-468605 NONE 458162-458171 NONE NONE NONE

IO-520-A IO-520-B IO-520-BA

112768-112818 234771-234782 807099-807250 814256-814298 809556-809750 813755-813850 287426 287498 810751-810970 298637-298986; 298988-298993 293314-293499 812751-812879; 812891-812944 215849-215907 810025-810250 812212-812500 814250-814790 216526-216532 224115-224134 294670-294875; 294877-294888 270967-270999 811501-811598 277561-277693

TSIO-360-LB TSIO-360-MB

247300-247349 279268-279288

TSIO-360-RB

NONE

TSIO-360-SB

NONE

LTSIO-360-E LTSIO-360-EB LTSIO-360-KB

225656-225660 807320-807479; 807481-807485

NONE 312735-312736

812001-812044 268471-268499

319343-319346; 319351-319353; 319355;319358319359;319361; 319363-319371; 319374;319378319385; 321576-321581; 321601-321615; 321658-321712

LTSIO-360-RB

NONE

O-470-G O-470-J O-470-K O-470-L O-470-M O-470-R

070701-070703 202196-202209 049478-049496 069829-069882 054154 288418-288499 811751-811969

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IO-520-BB

NONE NONE NONE NONE NONE 466721-466729

98

MO

DAY

IO-520-CB IO-520-D IO-520-E IO-520-F IO-520-J IO-520-K IO-520-L IO-520-M IO-520-MB

REVISED YEAR

IO-520-C

YEAR

NONE NONE NONE 580048-580062 NONE 576319-576321 575921-575934 NONE 579231;579233; 579234-579242; 579244; 579245; NONE NONE 577222-577230 NONE 575059; 575060

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CSB98-1B

An Allegheny Teledyne Company

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TABLE 2 (CONTINUED) ENGINE MODEL

REBUILT S/N

NEW S/N

ENGINE MODEL

LTSIO-520-AE

246643-246666

524341

TSIO-520-UB (continued)

TSIO-520-AE TSIO-520-AF TSIO-520-B TSIO-520-BB TSIO-520-BE TSIO-520-C TSIO-520-CE TSIO-520-D TSIO-520-DB TSIO-520-E

246136-246163 245232-245247 176681-176753 287565-287592 273790-273809 178478-178536 268563-268577 180103-180109 242013-242014 275430-275499 812502-812582; 812584 271380-271499 815001-815009; 815011-815014 216048-216052 217360-217404 218976-218987 237177-237184 224607 245710-245712 241963-241970 237288-237300 291706-291950

NONE 525102 NONE 526043-526044 NONE 501634 530166-530167 NONE NONE NONE

TSIO-520-EB TSIO-520-G TSIO-520-H TSIO-520-J TSIO-520-JB TSIO-520-K TSIO-520-KB TSIO-520-L TSIO-520-LB TSIO-520-M

TSIO-520-N TSIO-520-NB

TSIO-520-T TSIO-520-UB

ISSUED MO

DAY

06

01

98

MO

DAY

GTSIO-520-C GTSIO-520-D GTSIO-520-H GTSIO-520-K GTSIO-520-L GTSIO-520-M

507070 506893 NONE NONE NONE NONE NONE NONE 532050;532051; 532053-532055; 532057-532065; 532067-532081 521659-521661; 521664;521665

290434-290499 811001-811193; 811195-811228 274339-274424

YEAR

518933-518934 NONE NONE 607109-607110 NONE 608764-608765 613077-613080; 613083 NONE

IO-550-A IO-550-B

280416-280473 296777-296999 297000-297053

NONE 682133; 682134; 682225;682233682237; 682248; 682249; 682250; 682252-682304; 682356-682364; 682385-682391; 682536; 682537; 682609-682634; 682768-682770; 682787-682826; 682952-682959; 682962-683001; 683003; 683005 683938-683945;

IO-550-B (33) IO-550-C

NONE 271983-271989 810281-810500 815251-815258

913001;913008 676870; 676937; 676938; 676946-676999 683101-683107; 683130; 683131; 683168-683172;

513920 522684-522696 515438; 515439 527242;527243; 527246-527252 527260; 527265; 527266;527284 527297; 527299; 527300-527303; 527329-527335; 527360-527363

NEW S/N

527365;527366; 527393; 527417; 527418 529107-529113

155564-155565 219468-219475 267387-267479 226133,226135 292131-292315 276491-276499 810501-810626 808268-808318

GTSIO-520-N

REVISED YEAR

TSIO-520-WB

510838-510842

228625-228639 290853-290999 813501-813571; 813573-813589 278735-278810 293705-293955; 293957-293975 239424-239464 249092-249100 809301-809335

TSIO-520-P TSIO-520-R

TSIO-520-VB

REBUILT S/N

TELEDYNE CONTINENTAL MOTORS

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CSB98-1B

An Allegheny Teledyne Company

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TABLE 2 (CONTINUED) ENGINE MODEL

REBUILT S/N

NEW S/N

ENGINE MODEL

REBUILT S/N

NEW S/N

TSIO-550-A TSIO-550-B

NONE NONE

NONE 802088;802111-

IO-550-D

284181-284278

683178; 683179; 683196-683200; 683263; 683272; 683344-683352; 683401-683419; 683532-683535; 683545;683550683581;683696683701;683706683741;683866683867;684159684166 680015-680016

IO-550-E

283327-283381

681028; 681036;681037

IO-550-C (continued)

IO-550-F

284717-284849

IO-550-G

MO

DAY

06

01

679165-679169; 679174-679175; 679183;679189; 679190;679192 679195;679199679201;679209679213;679218679220;679236; 679238;679239; 675245-679256; 679262-679294; 679297-679314; 679316-679319; 679323-679325; 679340; 679341

289083-289130 NONE

ISSUED

98

MO

DAY

814501-814502

TSIO-550-E

NONE

TSIOL-550-A

809255;809256

802529;802531; 802533-802581; 803004-803021; 803023-803054; 803056;803057; 803059;803061; 803062

TSIOL-550-C

NONE

800609-800616; 800620-800623; 800626;800627; 800632;800633; 800637;800640

GIO-550-A

NONE

NONE

916003 672000-672001

NONE 683351-683352

REVISED YEAR

TSIO-550-C

679515-679518; 679520

808503-808507

IO-550-L IO-550-N

802113;802118; 802123;802124

YEAR

TELEDYNE CONTINENTAL M OTORS

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CSB98-1B

An Allegheny Teledyne Company

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NOTE: The following cylinder assemblies (cylinders with part numbers suffixed by the letter “A” and a number, e.g..: 654928 A 3) are in compliance with this service bulletin. Part number: 654928, 654958, 954959, 654960, 654961, 654962, 654963, 654965, 654966, 654967,654968, 654969, 654970, 654971, 654974. GENERAL INFORMATION: NEW ENGINES INSTALLED IN NEW AIRCRAFT HAVE BEEN INSPECTED BY ACTUAL HARDNESS TESTING OF THE VALVE WEAR TIP AND ARE IN COMPLIANCE WITH THIS SERVICE BULLETIN. REFER TO THE ENGINE LOG BOOK FOR COMPLIANCE, NO “V” HAS BEEN STAMPED ON THE CYLINDER FLANGES. CYLINDERS IDENTIFIED WITH A 1/8 TH INCH HIGH LETTER “V” STEEL STAMPED AT THE 12 O’CLOCK POSITION ON THE CYLINDER FLANGE ARE IN COMPLIANCE WITH THIS SERVICE BULLETIN. REFER TO FIGURE 3. THESE CYLINDERS DO NOT REQUIRE ANY ADDITIONAL INSPECTION. PART 1

PART 2

UN-INSTALLED VALVES:

UN-INSTALLED SERVICE SPARE CYLINDERS ASSEMBLIES:

Inspect all un-installed valves purchased between January 1, 1996 and March 31, 1998 for the following characteristics. 1. Date code roll-stamped or vibro-etched on the valve stem between the valve keeper groove and the top of the valve. Refer to Figure 1 for location of date code. The date code will be either a two digit numerical (e.g. 3-98, etc.) or a two digit alpha (e.g. A-U, B-U, etc.) code. Valves with roll-stamped or vibro-etched date codes as herein described have been inspected by TRW, Inc. and are in compliance with this service bulletin. Valves in inventory that do not have roll-stamped or vibro-etched date codes between the valve keeper groove and the top of the valve must be returned to TCM. Contact your TCM distributor for detailed instructions on returning these items.

Using the following procedure inspect valve (s) for a date code roll-stamped or vibro-etched on the valve stem between the valve keeper groove and the top of the valve stem. Refer to Figure 1 for location of date code. 1. Mount the cylinder in a valve spring compressing fixture. 2. Compress the intake and exhaust valve springs individually and remove each set of valve keepers, retainer (intake side), roto-coil (exhaust side), outer and inner valve springs. 3. Visually inspect the intake and exhaust valve for the existence of a date code. The date code will be either a two digit numerical (e.g. 3-98, etc.) or two digit alpha date (e.g. A-U, B-U, etc.) code. 4. Valves with roll-stamped or vibro-etched date codes as herein described have been inspected by TRW, Inc. and are in compliance with this service bulletin. 5. Intake and exhaust valves that are not identified with a two-digit numerical or alpha

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date code as herein described must be returned to TCM. Contact your TCM distributor for detailed instructions on returning these items. 6. Order new valves from a TCM Distributor to replace valves that do not have a roll-stamped or vibro-etched date code as herein described. Insure replacement valves are identified with a roll-stamped or vibro-etched date code as herein described. Refer to Figure 1. 7. Assemble cylinder(s) with valves having rollstamped or vibro-etched date code as herein described in accordance with the applicable TCM Overhaul Manual. Mark cylinder flange in accordance with Figure 3, using a 1/8 th inch high letter “V”. PART 3 INSPECTION OF NEW AND REBUILT AFFECTED ENGINES AND ENGINES THAT HAVE BEEN OVERHAULED OR REPAIRED UTILIZING AFFECTED VALVES OR CYLINDER ASSEMBLIES

NOTE BEFORE PERFORMING ANY INSPECTION REVIEW ENGINE LOGBOOK FOR ENTRY OF COMPLIANCE WITH CSB98-1 (ANY REV.) OR INSPECT CYLINDER BASE FLANGE FOR PRESENCE OF LETTER “V” STAMPED AT 12 O’CLOCK POSITION. CYLINDERS STAMPED WITH LETTER “V” HAVE BEEN INSPECTED AND ARE IN COMPLIANCE WITH THIS SERVICE BULLETIN Refer to the COMPLIANCE section of this bulletin for specific compliance requirements.

DETAILED INSPECTION: To perform the required inspection remove the engine cowling to gain access to the engine. Remove engine baffling as required to facilitate removal of cylinder(s) rocker covers. With rocker cover(s) removed from cylinder(s) and the rocker arms removed, visually and dimensionally inspect the intake and exhaust valve wear tips for evidence of abnormal wear. Refer to Figure 1 and 2, and Table 3. Perform a dimensional inspection in accordance with the following instructions. 1. Using a calibrated depth micrometer or vernier caliper, measure and record the distance from the upper surface of the valve tip to the top of the valve keepers. Refer to Figure 2 2. Refer to Table 3 and determine the minimum and nominal dimension “X” for the specific engine. 3. Cylinder assemblies having valves with measurements less than the minimum dimension “X” specified in Table 3 or showing rolled material on the outer edge of the wear tip must be removed from the engine. Refer to the applicable TCM engine Maintenance or Overhaul Manual for specific instructions on cylinder removal. 4. On valves requiring replacement, inspect rocker arms foot for abnormal wear. Rocker arms exhibiting abnormal wear to the foot surface must be repaired or replaced. Refer to the applicable TCM engine Maintenance or Overhaul Manual for specific inspection, repair or replacement instructions. 5. Assemble cylinder(s) with valves having rollstamped or vibro-etched date code as

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described in Part 1 in accordance with the applicable TCM Overhaul Manual. Mark cylinder flange in accordance with Figure 3, using a 1/8 th inch high letter “V”.

engine, engine nacelle and adjacent areas for evidence of flammable fluid leaks. Correct any discrepancies noted before returning the engine and aircraft to service.

6. Install cylinder assemblies incorporating valves with roll-stamped or vibro-etched date codes as described in Part 1 in accordance with the applicable TCM engine Maintenance or Overhaul Manual.

Make a log book and maintenance record entry indicating compliance with this service bulletin.

NOTE: Refer to the latest revision of TCM Service Bulletin SB96-7 for fastener Torque Limits and torqueing procedures. 7. Cylinder assemblies having valves with measurements greater than specified in Table 2 meet the inspection requirements of this service bulletin and may be continued in service. Using new gaskets and seals reassemble the engine in accordance with the applicable TCM engine Maintenance or Overhaul Manual. 8. Mark the cylinder with a 1/8 th inch high letter “V” at the 12 o’clock position on the cylinder base flange, indicating compliance with this service bulletin. Refer to Figure 3. Re-install all engine baffles in accordance with the instructions provided by the aircraft manufacturer. Re-install any aircraft or engine mounted accessories removed to facilitate the inspection in accordance with the aircraft manufactures instructions. Re-install the engine cowling in accordance with the aircraft manufacturer’s instructions.

Cost Reimbursement 1. TCM will allow a maximum of 10 minutes for inspection of each un-installed cylinder. 2. A maximum of 10 minutes will be allowed for replacement of each valve in an un-installed cylinder. 3. TCM will allow maximum of 45 minutes for inspection of each cylinder affected by this service bulletin installed on an engine. 4. A maximum of 2 hours labor for the first cylinder removed on each side of the engine and 1 hour for each additional cylinder removed from the same side will be allowed for cylinder (s) that have been confirmed to have measurements less than the minimum specified dimension “X” in Table 3. A maximum of 10 minutes per valve in each affected cylinder will be allowed for valve removal and replacement. 5. Claims may be submitted directly to Teledyne Continental Motors P.O. Box 90 Mobile, Al. 36601, ATTN: Warranty Administration CSB98-1. Complete the attached Valve Inspection Reimbursement Form and include a copy of the repair work order. 6. All valves that do not comply with the

PART 4 Perform a complete engine ground run verifying the engine meets all performance criteria mandated by the aircraft manufacturer. Inspect the

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inspection requirements of this service bulletin must be returned to TCM with the Valve Reimbursement Form to receive payment.

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CSB98-1B

An Allegheny Teledyne Company

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DATE CODE LOCATION DIMENSION “X”

VALVE KEEPERS

FIGURE 1

TABLE 3 VALVE TIP TO KEEPER DIMENSIONS VALVE TIP TO KEEPER DIMENSION

VALVE TIP TO KEEPER DIMENSION

DIMENSION “X” ENGINE MODEL

EXHAUST

DIMENSION “X”

INTAKE

MIN

NOM

MIN

NOM

C-75, 85,90 O-200-A & B 0-300-A, B & C

.070

.093

.060

.093

.070

.093

.060

GO-300-ALL

.070

.093

0-240 & IO-240-ALL

.052

IO-346-A

ENGINE MODEL

EXHAUST

INTAKE

MIN

NOM

MIN

NOM

IO-470-ALL

.110

.132

.100

.132

.093

TSIO-470-ALL

.110

.132

.100

.132

.060

.093

IO-520-ALL

.110

.132

.100

.132

.076

.052

.076

TSIO-520-ALL

.110

.132

.100

.132

.110

.132

.100

.132

LTSIO-520-ALL

.110

.132

.100

.132

IO-360-ALL

.052

.076

.052

.076

GTSIO-520-ALL

.110

.132

.100

.132

TSIO-360-ALL

.052

.076

.052

.076

IO-550-ALL

.110

.132

.100

.132

LTSIO-360-ALL

.052

.076

.052

.076

TSIO-550-ALL

.110

.132

.100

.132

E-Series

.110

.132

.100

.132

TSIOL-550-ALL

.110

.132

.100

.132

O-470-ALL

.110

.132

.100

.132

GIO-550-ALL

.110

.132

.100

.132

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An Allegheny Teledyne Company

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FIGURE 2 MEASURING VALVE TIP TO VALVE KEEPER DIMENSION

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LETTER “V” MUST BE STAMPED AT THE 12 O’CLOCK POSITION IN THE CENTER OF THE FLANGE MID DISTANCE BETWEEN THE ADJACENT CYLINDER DECK STUD HOLES CYLINDERS THAT ARE IN COMPLIANCE WITH THIS SERVICE BULLETIN WILL HAVE THE LETTER “V” STAMPED IN THIS LOCATION

FIGURE 3 LOCATION OF COMPLIANCE MARKING

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TELEDYNE CONTINENTAL  AIRCRAFT ENGINE VALVE INSPECTION REIMBURSEMENT FORM CSB98-1 DATE

PREPARED BY

REPAIR AGENCY ADDRESS CITY

STATE

PHONE

ZIP CODE FAX

SERVICE MANAGER / D.O.M. AIRCRAFT OWNER ADDRESS CITY

STATE

ZIP CODE

PHONE

FAX

AIRCRAFT MAKE

AIRCRAFT MODEL

AIRCRAFT REGISTRATION

AIRCRAFT S/N

ENGINE MODEL:

LEFT

RIGHT

ENGINE SERIAL NUMBER:

LEFT

RIGHT

TOTAL TIME OF ENGINE OR CYLINDER:

LEFT

RIGHT

TYPE OF ENGINE OR SPARE CYLINDER(S). Mark all that apply: NEW

REBUILT

OVERHAULED

REPLACEMENT CYLINDERS

NOTE: A copy of the shop work order with the engine or cylinder total time since installation, and detailing the labor and materials used to comply with this service bulletin must be attached to this form. Attach additional forms detailing the labor and materials used if not contained on the work order. Return all valves removed with this form.

Total Amount Requested For Performance Of This Service Bulletin: $ Indicate To Whom Check Is to Be Mailed To: AIRCRAFT OWNER Mail Completed Forms To:

ISSUED MO

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TELEDYNE CONTINENTAL MOTORS P.O. BOX 90 MOBILE, AL 36601 ATTN: WARRANTY ADMINISTRATOR

REVISED YEAR 98

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INTENTIONALLY LEFT BLANK

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE CATEGORY 1

MANDATORY SERVICE BULLETIN The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

MSB 00-5D TECHNICAL PORTIONS FAA APPROVED

SUBJECT: CRANKSHAFT MATERIAL INSPECTION PURPOSE FOR REVISION “D” : Revision D of MSB 00-5 identifies engines and crankshafts that have not complied with previous issues of MSB 00-5. See Section 1 for non-compliant engines and crankshafts. Additional suspect engine and crankshafts have been identified and added to Sections 1,2,3 and 4 of this MSB. Teledyne Continental Motors strongly recommends that you review these sections to determine if your engine or crankshaft or if an engine or crankshaft in your possession or under your care has been added to this MSB.

BACKGROUND: Teledyne Continental Motors (TCM) has identified the cause of 14 crankshaft fractures which have occurred in the connecting rod journals on straight drive engines manufactured in 1998 and 1999. The cause of the fractures has been identified as composition and processing deficiencies during several discrete periods of steel production and/or forming operations by suppliers. The fractures have occurred in new, rebuilt and field overhauled engines with operational times varying from 15 to 1257 hours. TCM has worked closely with its suppliers and added additional procedures to insure future production integrity. TCM has developed an inspection process to identify and replace any other crankshafts potentially affected by this problem. This will be accomplished by means of a metallurgical inspection of two small core samples removed from the crankshaft propeller flange. Review of Teledyne Continental Motors manufacturing processes, nitride characteristics, and dimensional characteristics have not identified any other contributing causes. This Mandatory Service Bulletin Revision is issued to specifically identify crankshafts that have not complied with previous revisions. It also includes additional affected crankshafts that have been determined to be suspect since the last revision. ISSUED

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CONTINENTAL MOTORS

© 2001 TELEDYNE TECHNOLOGIES, INC.

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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This Mandatory Service Bulletin has been divided into Sections. Section 1 of this Bulletin lists specific crankshafts affected by this Mandatory Service Bulletin that have not complied with the inspection requirements of this Mandatory Service Bulletin or AD 2000-23-21. Affected crankshafts are listed as follows: 1. Crankshafts installed in Factory New or Rebuilt engines, by engine model, engine serial number, crankshaft serial number and heat code. 2. Crankshafts sold as service spares. First by crankshaft part number, serial number and heat code. Then by crankshaft serial number, heat code and part number. Section 2 of this Bulletin lists all affected crankshafts installed in Factory New or Rebuilt engines by engine model, engine serial number, crankshaft serial number and heat code. Section 3 of this Bulletin lists all affected crankshafts by crankshaft part number, crankshaft serial number and heat code. Section 4 of this Bulletin lists all affected crankshafts by crankshaft serial number, crankshaft part number and heat code. Section 5 of this service bulletin provides inspection procedures and warranty coverage. PURPOSE: To provide instructions for the removal of crankshaft core samples for metallurgical evaluation. WARNING The inspection required by this service bulletin is intended to detect metallurgical anomalies which if present and left uncorrected can result in engine failure. This inspection requires the removal of the aircraft spinner, propeller and spinner bulkhead to provide access to the crankshaft propeller flange. Two equally sized core samples will be taken from the propeller flange 180 degrees from each other using a customized tool provided by Teledyne Continental Motors. The removed core samples will be placed into a plastic, zip closure bag and identified by engine model, engine serial number and crankshaft serial number. These core samples must be returned to Teledyne Continental Motors for evaluation.

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COMPLIANCE: For affected engines or crankshafts this inspection must be performed within the next 10 hours of operation. Uninstalled service spare crankshafts of the affected serial number range must be inspected prior to installation in any engine. ENGINES and/or CRANKSHAFTS AFFECTED: IO-360, TSIO-360, LTSIO-360, O-470, IO-470, TSIO-470, IO-520, TSIO520, LTSIO-520, IO-550, TSIO-550 and TSIOL-550 series new and rebuilt direct drive engines assembled utilizing a crankshaft that was manufactured from April 1, 1998 through March 31, 2000. Affected engine serial numbers are specified below. Any preceding series engines that have had a replacement crankshaft installed during field overhaul or repair. Affected replacement crankshaft serial numbers are specified below. Refer to the Crankshaft Serial Number Identification below for identification of affected crankshafts. Note: If your engine has recently had a crankshaft installed that may have been manufactured from April 1, 1998, through March 31, 2000, the crankshaft serial number must be examined to determine if this inspection procedure applies. TCM’s website at www.tcmlink.com will provide our customers with real-time service information regarding MSB 00-5. Customers may determine if their engine or crankshaft is subject to the required inspection by completing the customer contact information and entering an engine or crankshaft serial number. If you do not have access to www.tcmlink.com, contact TCM service department at 1-888-200-7565. For International customers who do not have access to the Internet and TCM’s website, you may contact TCM’s Service Department via one of the International toll free numbers listed below or by dialing our direct number 251-438-3411 extension 5100.

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CRANKSHAFT SERIAL NUMBER IDENTIFICATION Each crankshaft is identified by a serial number steel stamped on the O.D. of the propeller flange that reflects its manufacturing date. Crankshafts produced prior to January 6, 2000 may be identified as follows: Crankshafts produced beginning January 6, 2000 may be identified as follows:

 To determine month of manufacture use the following alpha code: A= January B= February C= March D= April E= May F= June

G= July H= August I= September J = October K= November L= December

Month 

Day

Year

Sequence

Denotes Crankshaft

AXX98XXN

Denotes Crankshaft

Year

Month Serial Number N 00

XX

XXX

 To determine month of manufacturer use the following alpha code: (X)- is a production alpha code for internal use. A(X)= January G(X)= July B(X)= February H(X)= August C(X)= March I(X) = September D(X)= April J(X) = October E(X)= May K(X) = November F(X)= June L(X) = December

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SECTION 1 AFFECTED ENGINE MODELS NO RECORD OF COMPLIANCE WITH MSB00-5 OR AD 2000-23-21 LISTED BY ENGINE MODEL, ENGINE SERIAL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE ENG. MODEL SERIAL# C/S - S/ N 0-470-M 54156 F239814N

H/C KOL

0-470-R 0-470-R 0-470-R 0-470-R 0-470-R 0-470-R

815931 815852 466730 815834 811987 811988

F139007N A279921N F239802N L029811N D179812N D179807N

KON KPL KOL KPM KOL KOL

0-470-S 0-470-S 0-470-S 0-470-S

269464 464588 269482 269465

F029803N J129904N I039810N H269905N

KOL KRN KOL KRN

0-470-U 0-470-U

820007 813382

H259930N D179816N

KRN KOL

ENG. MODEL SERIAL# C/S - S/ N I0-520-F 814857 F119805N I0-520-F 814818 D239808N I0-520-F 814856 F129802N I0-520-F 814836 F059804N I0-520-F 814874 H049805N I0-520-F 814987 C119912N I0-520-F 814835 F099801N I0-520-F 818824 F239915N I0-520-F 814839 F169809N

H/C KON KOL KOL KOL KOL KPL KOL KRN KOL

I0-520-L I0-520-L I0-520-L

294915 295006 295003

F089801N G299929N G269903N

KOL KRN KRN

I0-550-B

684022

K239803N

KOP

I0-550-C I0-550-C

684254 815311

J249807N J269803N

KOR KOM

I0-550-D I0-550-D

284284 284286

D249814N D249815N

KOL KOL

I0-360-D

63038

J029809N

KPC

I0-470-C

295555

H249812N

KOM

I0-470-D

105643

F099813N

KOL

I0-470-E

88766

H039807N

KOL

I0-550-E I0-550-E

283384 283387

D249813N D259802N

KOL KOL

I0-470-L I0-470-L

297825 297882

F259802N E079802N

KOM KOM

I0-550-F I0-550-F

284851 284874

D249810N D279812N

KOL KOL

I0-470-N

96721

H259808N

KOM

I0-550-L I0-550-L

289136 289140

G229809N G229810N

KOL KOL

I0-520-C

816776

J299801N

KOP IO-550-E

283404

A050009N

KRN

LTSI0-360-KB

812065

K069808N

KPC

TSI0-360-KB

811331

K099810N

KPC

TSI0-520-C

178571

I039903N

KRN

I0-520-D I0-520-D I0-520-D I0-520-F I0-520-F I0-520-F

816565 816665 816711

L059806N G279919N G269920N

814848 579260 818767

ISSUED

F109806N G149906N D098803N

KOL KRN KRN KOL KPL KPL

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NON-COMPLIANT AFFECTED ENGINE MODELS NO RECORD OF COMPLIANCE WITH MSB00-5 OR AD 2000-23-21 LISTED BY ENGINE MODEL, ENGINE SERIAL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE

ENG. MODEL SERIAL# C/S - S/ N TSI0520E 812635 D019905N

H/C KPM

TSI0520H

217433

I099902N

KRP

TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M TSI0520M

291962 532093 291955 291970 818033 818047 818062 818063 818073 818023 532092 818026 818028 532083 532109 818075 532088 291967

F059803N C119906N D169807N F189804N F229904N G239913N G299912N H259909N I039919N D089913N D249901N D269906N E019912N F049809N L029909N I099906N L109804N F159801N

KOL KPL KOL KOL KRN KRN KRN KRN KRN KPL KPM KPM KPL KON KRN KRP KPK KOL

TSI0520NB

813621

I189808N

KOM

TSI0520R TSI0520R TSI0520R TSI0520R TSI0520R

522707 522702 522703 294096 293985

H209920N A259912N E039918N G279913N F059805N

KRN KPK KPM KRN KOL

TSI0520T TSI0520T

515440 515441

F099815N F159802N

KOL KOL

ISSUED

ENG. MODEL SERIAL# C/S - S/ N TSI0520VB 816046 K189807N TSI0520VB 816080 D149910N TSI0520VB 816081 D149906N TSI0550E

803070

REVISED

I179801N

H/C KOR KPM KPM KOR

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NON-COMPLIANT AFFECTED SERVICE SPARE CRANKSHAFTS BY PART NUMBER NO RECORD OF COMPLIANCE WITH MSB00-5 OR AD 2000-51-19

PART # SERIAL # 646623 A309907N 646623 D179910N 646623 D179912N 646623 D249812N 646623 D279811N 646623 G169909N 646623 G229809N 646623 G239808N 646623 J049913N 649133 D239803N 649133 D239815N 649133 G269911N 649134 A229913N 649134 B179903N 649134 C129905N 649134 C149913N 649134 D089903N 649134 D099901N 649134 D209807N 649134 D209809N 649134 D209810N 649134 D209811N 649134 D229808N 649134 D229809N 649134 D229812N 649134 D229817N 649134 D229819N 649134 D229821N 649134 D229822N 649134 D239801N 649134 D239811N 649134 D239813N 649134 D239816N 649134 D239818N 649134 D239824N 649134 D239902N 649134 D249801N 649134 D249803N 649134 D249804N 649134 D249910N 649134 D249914N

H/C KPL KPK KPK KOL KOL KRN KOL KOL KRP KOL KOL KRN KPK KOL KPL KPL KPL KPL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KPL KOL KOL KOL KPM KPM

ISSUED

PART # SERIAL # 649134 E039907N 649134 E039911N 649134 F089811N 649134 F109804N 649134 F109818N 649134 F119803N 649134 F119807N 649134 F129804N 649134 F129807N 649134 F129808N 649134 F129812N 649134 F159805N 649134 F159812N 649134 F169814N 649134 F179801N 649134 F179809N 649134 F179812N 649134 F229919N 649134 F269911N 649134 G099930N 649134 G269902N 649134 G279907N 649134 G279915N 649134 G279916N 649134 G289901N 649134 G289902N 649134 G289919N 649134 G289925N 649134 G289926N 649134 G309919N 649134 H049810N 649134 H049814N 649134 H049816N 649134 H059804N 649134 H099819N 649134 H109804N 649134 H119811N 649134 H239913N 649134 H239914N 649134 H249901N 649134 H249908N

H/C KPM KPL KOL KON KON KON KON KOL KOL KOL KOL KOL KOL KON KOL KOL KON KRN KPL KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KOL KOL KOL KOL KOL KON KOL KRN KRN KRN KRN

PART # SERIAL # 649134 H249915N 649134 H249923N 649134 H259910N 649134 H259918N 649134 H259919N 649134 H259920N 649134 I019801N 649134 I029804N 649134 I039917N 649134 I039920N 649134 I079903N 649134 I079921N 649134 I089915N 649134 I089916N 649134 J079912N 649134 J079914N 649134 J119901N 649134 L039903N 649134 L039907N 649134 L049803N 649134 L069806N 649134 L069808N 649134 L079802N 649134 L089903N 649134 N00AA189 649134 N00CA144 649135 H039802N 649138 A289913N 649138 D209804N 649138 F039818N 649138 H149804N 649141 C159909N 649141 D179810N 649141 D189908N 649141 E199920N 649141 F049805N 649141 F209802N 649141 H139809N 649141 H139815N 649141 H259934N 649141 H269901N

REVISED

H/C KRN KRN KRN KRN KRN KRN KOL KOL KRN KRN KRN KRP KRP KRP KRP KRP KRP KRN KRN KPK KOL KOL KOL KRP KRP KRP KOL KPL KOL KOL KON KPK KOL KOL KPL KON KON KON KON KRN KRN

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NON-COMPLIANT AFFECTED SERVICE SPARE CRANKSHAFTS BY PART NUMBER NO RECORD OF COMPLIANCE WITH MSB00-5 OR AD 2000-23-21

PART # SERIAL # 649141 I029809N 649141 I039808N 649141 I039811N 649141 I039812N 649141 I099923N 649141 J119919N 649895 A249808N 649895 B119906N 649895 B119908N 649895 B119910N 649895 I119811N 649895 J089810N 649895 J099808N 649895 L019808N 649896 K309804N 649898 A139915N 649898 A159915N 649898 A169901N 649898 A209913N 649898 B019907N 649898 B019909N 649898 B039904N 649898 C099906N 649898 C269908N 649898 E019903N 649898 I169815N 649898 L189808N 649900 C059915N 649900 C069904N 649900 C269904N 649900 I219820N 649900 J039809N 649900 J249808N 649900 K229803N 649900 K229807N 652006 E079822N 652009 F259801N 652009 F259804N 652010 B209904N 652010 E079805N 652010 F259806N

H/C KOL KOL KOL KOL KRN KRP KPM KPM KPM KPM KOM KOM KOM KPH KOM KPM KPM KOR KOR KPH KPH KPH KPM KPH KPH KOM KOM KOR KPH KPM KOP KOR KOR KOR KPM KOM KOM KOM KPH KOM KOM

ISSUED

PART # SERIAL # 652010 H259818N 652010 K049919N 652010 K059911N 652010 L089813N 652011 B189914N 652011 E079806N 652011 J189905N 653129 I309803N 653136 I239808N 653136 I239809N 653136 K079810N 654432 A189912N 654432 C059909N 654432 I229804N

H/C KOM KPH KPH KPH KPL KOM KPH KPC KPC KPC KPC KPM KOR KOM

REVISED

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NON-COMPLIANT AFFECTED SERVICE SPARE CRANKSHAFTS BY SERIAL NUMBER NO RECORD OF COMPLIANCE WITH MSB00-5 OR AD 2000-51-19

SERIAL # A139915N A159915N A169901N A189912N A209913N A229913N A249808N A289913N A309907N B019907N B019909N B039904N B119906N B119908N B119910N B179903N B189914N B209904N C059909N C059915N C069904N C099906N C129905N C149913N C159909N C269904N C269908N D089903N D099901N D179810N D179910N D179912N D189908N D209804N D209807N D209809N D209810N D209811N D229808N D229809N D229812N

H/C KPM KPM KOR KPM KOR KPK KPM KPL KPL KPH KPH KPH KPM KPM KPM KOL KPL KPH KOR KOR KPH KPM KPL KPL KPK KPM KPH KPL KPL KOL KPK KPK KOL KOL KOL KOL KOL KOL KOL KOL KOL

SERIAL # D229817N D229819N D229821N 229822N D239801N D239803N D239811N D239813N D239815N D239816N D239818N D239824N D239902N D249801N D249803N D249804N D249812N D249910N D249914N D279811N E019903N E039907N E039911N E079805N E079806N E079822N E199920N F039818N F049805N F089811N F109804N F109818N F119803N F119807N F129804N F129807N F129808N F129812N F159805N F159812N F169814N F179801N

PART # 649898 649898 649898 654432 649898 649134 649895 649138 646623 649898 649898 649898 649895 649895 649895 649134 652011 652010 654432 649900 649900 649898 649134 649134 649141 649900 649898 649134 649134 649141 646623 646623 649141 649138 649134 649134 649134 649134 649134 649134 649134

ISSUED

H/C KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KPL KOL KOL KOL KOL KPM KPM KOL KPH KPM KPL KOM KOM KOM KPL KOL KON KOL KON KON KON KON KOL KOL KOL KOL KOL KOL KON KOL

PART # 649134 649134 649134 649134 649134 649133 649134 649134 649133 649134 649134 649134 649134 649134 649134 649134 646623 649134 649134 646623 649898 649134 649134 652010 652011 652006 649141 649138 649141 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134

SERIAL # F179809N F179812N F209802N F229919N F259801N F259804N F259806N F269911N G099930N G169909N G229809N G239808N G269902N G269911N G279907N G279915N G279916N G289901N G289902N G289919N G289925N G289926N G309919N H039802N H049810N H049814N H049816N H059804N H099819N H109804N H119811N H139809N H139815N H149804N H239913N H239914N H249901N H249908N H249915N H249923N H259818N

REVISED

H/C KOL KON KON KRN KOM KOM KOM KPL KRN KRN KOL KOL KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KOL KOL KOL KOL KOL KOL KON KOL KON KON KON KRN KRN KRN KRN KRN KRN KOM

PART # 649134 649134 649141 649134 652009 652009 652010 649134 649134 646623 646623 646623 649134 649133 649134 649134 649134 649134 649134 649134 649134 649134 649134 649135 649134 649134 649134 649134 649134 649134 649134 649141 649141 649138 649134 649134 649134 649134 649134 649134 652010

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NON-COMPLIANT AFFECTED SERVICE SPARE CRANKSHAFTS BY SERIAL NUMBER NO RECORD OF COMPLIANCE WITH MSB00-5 OR AD 2000-23-21

SERIAL # H259910N H259918N H259919N H259920N H259934N H269901N I019801N I029804N I029809N I039808N I039811N I039812N I039917N I039920N I079903N I079921N I089915N I089916N I099923N I119811N I169815N I219820N I229804N I239808N I239809N I309803N J039809N J049913N J079912N J079914N J089810N J099808N J119901N J119919N J189905N J249808N K049919N K059911N K079810N K229803N K229807N K309804N L019808N

H/C KRN KRN KRN KRN KRN KRN KOL KOL KOL KOL KOL KOL KRN KRN KRN KRP KRP KRP KRN KOM KOM KOP KOM KPC KPC KPC KOR KRP KRP KRP KOM KOM KRP KRP KPH KOR KPH KPH KPC KOR KPM KOM KPH

PART # 649134 649134 649134 649134 649141 649141 649134 649134 649141 649141 649141 649141 649134 649134 649134 649134 649134 649134 649141 649895 649898 649900 654432 653136 653136 653129 649900 646623 649134 649134 649895 649895 649134 649141 652011 649900 652010 652010 653136 649900 649900 649896 649895

ISSUED

SERIAL # L039903N L039907N L049803N L069806N L069808N L079802N L089813N L089903N L189808N N00AA189 N00CA144

H/C KRN KRN KPK KOL KOL KOL KPH KRP KOM KRP KRP

PART # 649134 649134 649134 649134 649134 649134 652010 649134 649898 649134 649134

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SECTION 2 AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model O-470-G O-470-J

Eng. S/N C/S S/N H/C 817751 H249809N KON 202210 H139808N KON 202213 G319918N KRN 202214 J139911N KRP

O-470-K

49500 F039805N 49501 F249801N 49502 I039804N 49505 A299903N 49506 B199910N 49507 D129904N 49508 D139901N 49509 D129901N 49511 H269903N

KOL KON KOL KPK KPL KPL KPL KPL KRN

O-470-L

69885 D179813N 69887 F029807N 69888 H269904N 69889 F249804N 69890 F049806N 69893 I029807N 69894 H129807N 69895 A279923N 69896 H149805N 69897 E199926N 69900 A289907N 69902 A289903N 69903 A289912N 69904 B189912N 69906 C169912N 69907 D139904N 69910 G319907N 69911 G319915N 69912 B189911N 69914 J149901N 69915 J149903N 69916 J139921N

KOL KOL KRN KOL KON KOL KON KPL KON KPL KPL KPK KPL KPL KPL KPL KRN KRN KPL KRN KRP KRP

ISSUED

Engine Model O-470-L

Eng. S/N C/S S/N H/C 69917 J139916N KRP 69920 K049903N KRP

O-470-R

466730 F239802N 466733 B189909N 466734 D129905N 466737 J139910N 811967 F239812N 811983 D179805N 811984 D209806N 811986 D179809N 811987 D179812N 811988 D179807N 811990 F029805N 811991 F029801N 811992 F029804N 811993 F039808N 811994 F039803N 812000 F049802N 815752 F039802N 815753 F029808N 815754 F029810N 815755 F029811N 815756 F029809N 815757 F249802N 815758 F249805N 815759 F039801N 815760 F029802N 815763 F209805N 815764 F209806N 815767 F209811N 815772 F039810N 815773 F239817N 815774 F199806N 815775 F209807N 815778 F239803N 815794 I019807N 815807 I039806N 815808 I029815N

REVISED

KOL KPL KPL KRP KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

11 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model O-470-R

Eng. S/N C/S S/N 815820 I039801N 815825 F209809N 815851 A289906N 815852 A279921N 815853 A289904N 815855 A299911N 815857 A299904N 815858 A289910N 815859 A289911N 815860 L029813N 815861 B199904N 815862 B199908N 815863 B199907N 815864 B199911N 815865 C159914N 815866 C159917N 815867 C179905N 815868 C169906N 815869 C169903N 815871 C179903N 815872 C179901N 815873 C159911N 815874 C169905N 815875 C169907N 815876 C169911N 815877 D129903N 815878 D129909N 815880 D129910N 815881 C159916N 815882 C169908N 815884 C169904N 815886 E199923N 815889 H139801N 815890 F249909N 815892 C759909N 815901 I039802N 815909 G319911N 815910 G319914N 815911 G319913N 815912 I109904N

ISSUED

H/C KOL KOL KPK KPL KPK KPK KPK KPL KPK KPK KPL KPH KPL KPL KPK KPL KPL KPL KPL KPK KPK KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KON KRN KPL KOL KRN KRN KRN KRP

Engine Model O-470-R

Eng. S/N C/S S/N 815913 G319909N 815914 G319921N 815915 G319903N 815917 G319906N 815919 H259928N 815920 H259932N 815921 H259929N 815923 H269910N 815924 H259937N 815925 I099928N 815926 I099920N 815927 I109905N 815928 I099918N 815929 I099921N 815930 I099924N 815931 F139007N 815932 I099926N 815933 I109911N 815936 F199804N 815940 J139914N 815943 J149907N 815944 J139901N 815946 J159903N 815953 J139906N 815954 J119911N 815958 J159905N 815959 J139908N 815986 J139912N 815990 N00CA182 815992 N00CA197 815993 N00CA177

H/C KRN KRN KRN KRN KRN KRN KRN KRN KRN KRP KRP KRP KRN KRP KRP KON KRP KRP KON KRP KRP KRP KRP KRN KRP KRP KRN KRP KRP KRP KRP

269465 H269905N 269415 D179803N 269461 D179806N 269462 D179801N 269463 D179814N 269464 F029803N 269466 F039807N 269467 F039806N

KRN KOL KOL KOL KOL KOL KOL KOL

O-470-S

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

12 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model O-470-S

Eng. S/N C/S S/N 269468 F239816N 269469 F209810N 269470 D209805N 269471 E319807R 269472 F239801N 269473 F199802N 269474 F199805N 269475 F239813N 269476 F239806N 269478 H129810N 269479 I029816N 269480 I029808N 269482 I039810N 269487 L039803N 269489 I039803N 269490 A279920N 269491 A279922N 269494 C169901N 269496 B199906N 269497 C149904N 269498 C149902N 269499 C179904N 464588 J129904N 819001 C169910N 819005 F259903N 819006 F259917N 819008 G319901N 819009 G319904N 819010 G319916N 819011 G319902N 819012 G319905N 819013 H259935N 819014 G319919N 819015 H259933N 819017 J149902N 819018 J149911N 819019 J119909N 819021 J129915N 819023 H269909N 819026 J139904N 819034 N00CA185

ISSUED

H/C KOL KON KOL KPL KOL KON KOL KOL KOL KON KOL KOL KOL KPK KOL KPL KPL KPL KPL KPK KPK KPK KRN KPL KPM KPL KRN KRN KRN KRN KRN KRN KRN KRN KRP KRP KRP KRN KRN KRN KRP

Engine Model O-470-U

Eng. S/N C/S S/N 470759 A299901N 470763 J139905N 470764 J139915N 470765 J139923N 470767 J139924N 470769 K049916N 470776 N00CA183 470778 N00CA173 813375 D179804N 813377 D179811N 813380 D169818N 813381 D179802N 813382 D179816N 813390 D209803N 813395 F029812N 813396 F049801N 813398 F239804N 813400 F239818N 813401 F239815N 813402 F239809N 813405 F239811N 813409 I029813N 813413 H149801N 813415 H149803N 813418 H149806N 813420 H149802N 813427 L039806N 813440 L039804N 813442 L039810N 813445 L039805N 813450 A289909N 813452 A299910N 813453 A299902N 813455 A299916N 813458 A289902N 813462 C149905N 813463 C159906N 813464 C159910N 813467 C159915N 813468 C159908N

REVISED

H/C KPL KRN KRP KRP KRP KRP KRP KRN KOL KOL KOL KOL KOL KOL KOL KON KOL KOL KOL KOL KOL KOL KON KON KON KON KPK KPK KPK KPK KPL KPK KPK KPK KPL KPK KPK KPK KPL KOL

PAGE NO REVISION TM

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18

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

13 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model O-470-U

Eng. S/N C/S S/N 813469 C159913N 813472 D139903N 813474 D139902N 813475 D129908N 813476 D129912N 813478 D129907N 813482 C159912N 813486 E199921N 813490 F239810N 820006 H269906N 820007 H259930N 820010 H269907N 820012 H259931N 820013 H269902N 820014 I109909N 820016 H269908N 820019 I099927N 820023 I109910N 820024 I109908N 820030 J129902N 820032 J129906N 820033 J129911N 820034 J139913N 820035 J119908N 820036 H259936N 820037 J139919N 820038 K049905N 820053 J119912N 820068 N00CA184

H/C KPK KPL KPL KPL KPL KPL KPL KPL KOL KRN KRN KRN KRN KRN KRN KRN KRP KRN KRN KRN KRN KRP KRP KRP KRN KRP KRP KRN KRP

IO-360-C

060688 J059805N KPC

IO-360-D

063038 J029809N KPC 063039 J059804N KPC 063040 J059801N KPC

IO-360-DB

351396 I259805N 351397 K049814N 351399 K109817N 808799 I249807N 808801 K049817N 808802 K109802N

ISSUED

KPC KPC KPC KPC KPC KPC

Engine Model IO-360-ES

Eng. S/N C/S S/N 357114 I259804N 357115 I299804N 357116 I249806N 357151 A219910N

H/C KPC KPC KPC KPK

IO-360-G

244612 J059808N KPC 244613 J029808N KPC

IO-360-KB

288733 I249801N 288734 I259808N 288736 I259806N 288739 K099801N 288740 K109807N

KPC KPC KPC KPC KPC

IO-470-C

295552 E079819N 295553 F249811N 295554 F259803N 295555 H249812N 295556 L089802N 295557 B199917N 295558 C189903N 295559 E079906N 295560 H029903N 295561 J189901N 295562 J189902N 295563 K059915N 295564 J159911N 295565 K059906N 295566 K059909N 295567 A030005N 71122 H259805N

KOM KOM KOM KOM KPH KPH KOM KPH KPH KPH KPH KPH KPH KPH KPH KPH KON

IO-470-D

105642 D239810N 105643 F099813N 105644 F179805N 105645 F099806N 105648 J079910N 105649 J049918N

KOL KOL KON KOL KRP KRP

IO-470-E

088765 H039804N KOL 088766 H039807N KOL 088768 J089924N KRP

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

14 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-470-E

Eng. S/N C/S S/N H/C 088770 K029911N KRP

IO-470-F

89918 D239802N 89920 F109815N 89929 C159918N 89930 E199909N 89934 G269915N 89935 G279921N 89936 I079901N 89937 I099901N

IO-470-H

87344 F249812N KOM

Eng. S/N C/S S/N 297824 F249810N 297825 F259802N 297826 H259802N 297827 H249813N 297828 H259812N 297830 H249810N 297833 H249808N 297835 H259806N 297836 F249813N 297837 H259816N 297838 H259807N 297839 H259804N 297841 H259815N 297842 F249809N 297843 F249807N 297844 H259809N 297845 H259813N 297846 H249814N 297847 L089811N 297848 L089822N 297851 L089812N 297852 L089815N 297854 L089810N 297856 L089805N 297857 L089804N 297861 B199916N 297862 B209903N 297863 B209902N 297866 C189906N 297868 C189902N 297869 C189909N 297870 C189905N 297872 B209901N 297873 C189904N 297877 E079902N 297878 E069911N 297879 E079901N 297880 E069909N 297881 E079905N 297882 E079802N

KOL KON KPL KPL KRN KRN KRN KOR

IO-470-K

092995 E059810N 092997 F289908N 092998 H249816N 092999 F289902N 093000 L089809N 818504 E079903N 818505 H019902N 818508 H019904N 818510 J189903N 818511 K059910N 818512 L169908N

KOM KPM KON KRN KPH KPH KPH KPH KPH KPH KPH

IO-470-L

297803 E079807N 297804 E079813N 297807 E059811N 297809 E079820N 297810 E079815N 297811 E079821N 297812 E079810N 297813 E069908N 297814 E069805N 297815 E059807N 297816 E059812N 297817 E079816N 297818 E079817N 297819 E079904N 297823 F249806N

KOM KOM KOM KOM KOM KOM KOM KPH KOM KOM KOM KOM KOM KPH KOM

ISSUED

Engine Model IO-470-L

REVISED

H/C KOM KOM KON KOM KOM KOM KOM KON KOM KOM KOM KOM KOM KOM KOM KOM KOM KOM KPH KPH KPH KPH KPH KPH KPM KPH KPH KPK KOM KOM KOM KPH KPH KOM KPH KPH KPH KPH KPH KOM

PAGE NO REVISION TM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

15 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-470-L

Eng. S/N C/S S/N 297883 E079803N 297884 E079808N 297885 F289901N 297886 F289915N 297887 F289912N 297888 F289914N 297889 F289916N 297890 E079818N 297893 H029905N 297894 H029906N 297895 H019903N 297896 H019905N 297898 H029901N 297900 H019906N 297901 J189908N 297903 F289903N 297907 J189909N 297908 J189906N 297909 J189911N 297910 J189907N 297911 J189904N 297912 J159910N 297916 K049920N 297917 K049922N 297918 K059912N 297919 K059905N 297921 K059914N 297922 K059908N 297923 K049923N 297924 K059916N 297925 J159912N 297927 K059901N 297928 K059913N 297929 K059917N 297930 K049921N 297931 L169912N 297932 L169907N 297933 L239901N 297934 L239912N

ISSUED

H/C KOM KOM KPH KPH KPH KPH KPH KOM KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH

Engine Model IO-470-L

Eng. S/N C/S S/N 297935 L239911N 297936 A030007N 297937 A030010N 297938 A030006N 297939 L239907N 297940 A030008N 297941 L239909N 297942 L239908N 297950 L239910N 297953 A030011N 468607 E059808N 468608 E079823N 468611 E079812N 468613 L169910N

H/C KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KOM KOM KOM KPH

96705 E079809N 96707 E069804N 96708 E069810N 96710 E059809N 96711 E069802N 96712 F249815N 96713 E079825N 96714 E079814N 96715 E069808N 96716 F249808N 96717 F249814N 96718 F249816N 96720 H259814N 96721 H259808N 96721 H259803N 96722 H259817N 96724 L089807N 96725 L089816N 96726 L089806N 96727 L089801N 96728 B199914N 96729 B199912N 96730 B209905N 96732 E069910N 96734 C189901N

KOM KOM KOM KOM KOM KOM KOM KOM KOM KOM KOM KOM KOM KOM KON KOM KPH KPH KPH KPH KPH KPH KPH KPH KOM

IO-470-N

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

16 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-470-N

Eng. S/N C/S S/N 96735 H019901N 96736 J189910N 96737 J159909N 96738 J159907N 96739 K059902N 96741 L239902N 96742 L239904N 96743 A030003N 96745 L239906N 458174 K059904N 458175 K059907N

H/C KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH

IO-470-S

109389 C119908N 109390 D089912N 109391 E019915N 109393 G289914N 109394 G269912N 109397 J089922N 109398 K019913N

KPK KPL KPM KRN KRN KRP KRP

IO-470-V/VO

171198 F239907N 171207 L089819N 171213 C159905N 171214 D099907N 171216 E019914N 171217 E019917N 171218 E039904N 171219 E049917N 171220 E049913N 171222 I089930N 171225 E039910N 171227 G289913N 171228 I099905N 171229 I079910N 171231 J079911N 171232 F109816N 171234 J079901N 171235 K019922N 171236 J089918N 171237 K029907N 171238 K019906N

KRN KRP KPL KPL KPM KPM KPM KPM KPL KRP KPM KRN KRP KRP KRP KON KRP KRP KRP KRP KRN

ISSUED

Engine Model IO-470-V/VO

Eng. S/N C/S S/N 171239 K029904N 171240 K019901N 171242 K029910N 171243 L089905N 171247 K029909N 171249 L079906N

H/C KRP KRN KRP KRP KRP KRN

IO-520-A

112831 F059815N 112833 F159810N 112834 F159811N 112836 H039812N 112843 H079807N 112847 I079930N 112852 A229905N 112855 B179901N 112856 D089909N 112859 H289802N 112860 E189916N 112861 F109812N 112867 E069905N 112868 F239909N 112870 G149915N 112871 G299920N 112872 H209921N 112873 I079931N 112876 J079915N 112877 J069911N 112882 L079910N

KOL KOL KON KOL KOL KRN KPK KPL KPL KOL KPH KON KPL KRN KPM KRN KRN KRP KRP KRP KRP

IO-520-BB

813908 I169816N 580063 B019914N 580064 B159903N 580065 C089905N 813903 K129808N 813904 I169814N 813912 K169807N 813913 K169803N 813914 K189810N 813915 K179801N 813918 K169809N 813921 K139803N

KOM KOR KPM KPM KOP KOM KOP KOP KOR KOR KOP KPM

REVISED

PAGE NO REVISION TM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

17 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-BB

Eng. S/N C/S S/N 813926 A159917N 813927 A189904N 813928 A159920N 813929 A209907N 813934 B019910N 813938 A169910N 813940 B019911N 813942 B029902N 813943 C089901N 813944 B129907N 813945 C109915N 813946 C109907N 813954 C279901N 813955 C299901N 813956 B129910N 813959 D149902N 813961 D149913N 813963 D309904N 813964 D149912N 813965 D309902N 813966 D299913N 813968 E119911N 820261 K129806N

H/C KPM KPM KPM KOR KPL KOR KPL KPM KPM KPM KPM KPM KPM KPH KPM KPM KPM KPM KPM KPM KPH KPH KPM

810995 G209802N 810997 D059908N 816761 D059905N 816762 J089808N 816764 J119808N 816766 J099812N 816768 J289801N 816769 J289809N 816772 K309805N 816773 K309807N 816774 K259801N 816776 J299801N 816783 J309810N 816784 J299807N 816786 K259811N 816787 L029807N

KOP KPM KPM KOR KOM KOM KOP KOP KPM KPM KPM KOP KOP KOP KPM KPM

IO-520-C

ISSUED

Engine Model IO-520-C

Eng. S/N C/S S/N 816788 L019801N 816789 K259804N 816791 L029810N 816792 K259802N 816797 A129904N 816798 A129902N 816801 B099913N 816802 B099907N 816808 B109913N 816809 B109906N 816810 B119909N 816811 B109921N 816812 B119915N 816815 D019902N 816817 D069909N 816818 D069908N 816819 D059912N 816820 D019910N 816821 D069903N 816824 D079904N 816825 D059906N 816826 D079901N 816827 D079905N 816834 J099806N 816862 B099914N 816898 L019924N

IO-520-CB

H/C KPM KPH KPM KPH KPM KOM KPM KPM KOR KPM KPM KPM KPM KPM KPM KPH KPM KPM KPH KPM KPM KPH KPH KOM KPM KPM

299011 A1721173 KPM 299077 K169812N KOM 299078 K169805N KOM 299079 299086 299088 299090 299091 299092 299093 299094 299096 299097

REVISED

K169804N K189809N K129802N K179811N K179810N K199802N K189812N K199806N K169806N K189803N

KOP KOR KOP KOM KOR KOR KOR KOR KOM KOR

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

18 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-CB

Eng. S/N C/S S/N 299099 A159916N 299107 A169909N 299108 A209909N 299112 K189805N 299114 B049906N 299117 B129908N 299124 B129906N 299125 B019912N 299126 C109909N 299127 C269903N 299129 C269910N 299130 C269907N 299131 C279907N 299132 D079907N 299134 D079909N 299135 D079910N 299138 D149903N 299140 D149904N 299143 E119913N 299146 E119906N 299158 E109910N 299220 K139805N 299241 G069910N

H/C KPM KOR KOR KOR KPM KPM KPM KPL KPM KPH KPH KPH KPH KPM KPM KPM KPM KPM KPH KPH KPH KOP KPD

575935 D089901N 575939 I099914N 575942 I079924N 575943 J119907N 575946 K019902N 575947 K019905N 575948 K029914N 575950 L039908N 812958 D209812N 812968 F089807N 812969 F049811N 812973 F089804N 812975 F099812N 812976 F099809N 812977 F099807N 812979 F179806N

KPK KRP KRP KRP KRP KRP KRP KRN KOL KOL KOL KOL KOL KOL KOL KON

IO-520-D

ISSUED

Engine Model IO-520-D

Eng. S/N C/S S/N 812980 F179807N 812981 F179811N 812982 F099816N 812983 F189805N 812987 E059915N 812988 F099805N 812989 F099811N 812990 F099808N 812993 F169807N 812994 F099803N 812996 F189802N 812996 I079915N 812997 F169801N 816502 H039817N 816503 H039810N 816504 H039801N 816505 H039806N 816506 H039808N 816507 H049809N 816508 H039809N 816509 H039803N 816512 H099809N 816513 H039815N 816514 H119801N 816517 H099802N 816521 H049806N 816522 H049811N 816523 H049812N 816527 D109912N 816528 H279812N 816529 H319816N 816535 H279818N 816537 H109802N 816540 H319806N 816543 H279814N 816545 H129806N 816546 H289812N 816550 G149908N 816559 L039815N 816560 L039813N

REVISED

H/C KOL KON KON KON KPM KOL KOL KOL KOL KOL KON KRP KON KOL KOL KON KOL KOL KOL KOL KOL KON KOL KON KON KOL KOL KOL KPL KOM KOL KOM KOL KOL KOM KON KOL KPM KPK KPK

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

19 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-D

Eng. S/N C/S S/N 816565 L059806N 816569 L069807N 816572 L109803N 816579 B169914N 816580 B169906N 816582 B169916N 816585 C119903N 816589 C119910N 816590 C119916N 816591 D089905N 816592 C119915N 816593 C129908N 816595 C159923N 816598 C159901N 816599 C159904N 816600 C159902N 816603 C159922N 816607 D099910N 816608 D099904N 816609 D099909N 816610 D089914N 816611 D089916N 816612 D099908N 816613 D249913N 816615 D269905N 816617 D249907N 816619 E019916N 816621 E059902N 816622 E019918N 816623 E059906N 816624 E049904N 816625 E059904N 816626 E059901N 816630 E189921N 816632 E189902N 816636 D089915N 816638 F179808N 816644 F179817N 816651 D249906N 816652 E039912N 816657 F269906N

ISSUED

H/C KOL KOL KPK KPL KPL KPK KPL KPL KPK KPL KPK KPL KPL KPL KPL KPL KPL KPL KPL KPL KPK KPL KPL KPM KPL KPM KOL KPL KPL KPL KPL KPL KPL KPL KPL KPL KON KON KPM KPM KPL

Engine Model IO-520-D

Eng. S/N C/S S/N 816658 F269909N 816661 G269918N 816663 G289915N 816665 G279919N 816667 G299915N 816671 H249919N 816673 I089927N 816675 I039901N 816676 I039921N 816679 G159902N 816683 J049917N 816686 J049932N 816687 J069913N 816688 J089906N 816689 F239903N 816698 L029911N 816699 K109939N 816700 L079903N 816708 L069909N 816710 L069903N 816711 G269920N

H/C KPL KRN KRN KRN KRN KRN KRP KRN KRN KPL KRP KRP KRP KRP KRN KRN KRP KRN KRN KPH KRN

IO-520-E

215908 F269901N KPM 215912 D209808N KOL 215924 A259909N KPK 215926 C129917N KPL 215929 E199908N KPL 215931 I079902N KRP 215932 J049920N KRP 215933 J049937N KRP 215934 J059904N KRP 556632 J119905N KRP

IO-520-F

579251 F169810N 579256 L069801N 814775 E199901N 814815 D229816N 814816 D229805N 814817 D239804N 814818 D239808N 814831 F059812N

REVISED

KOL KOL KOL KOL KOL KOL KOL KOL

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

20 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-F

Eng. S/N C/S S/N 814832 F059816N 814833 F099817N 814847 F109805N 814848 F109806N 814853 F109807N 814855 F059801N 814856 F129802N 814862 F169804N 814867 F159808N 814869 H039805N 814872 H039816N 814874 H049805N 814878 H119804N 814883 H039813N 814886 H319807N 814893 H119805N 814894 H099811N 814896 H319812N 814898 H319814N 814900 H049801N 814920 H319809N 818810 F089803N 818815 I019803N 818838 D239820N 818840 I029801N 818914 F129809N 291253 E059920N 579248 I089906N 579250 F169813N 579252 F109817N 579257 L039818N 579258 B189904N 579259 C129914N 579260 G149906N 579261 G299917N 579262 I089925N 579263 J049936N 579264 J059908N 579265 K029905N 579266 L029918N

ISSUED

H/C KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KPM KRN KON KON KPK KPL KPL KPL KRN KRP KRP KRP KRN KRN

Engine Model IO-520-F

Eng. S/N C/S S/N 579268 N00AA196 579279 N00CA058 814808 E059919N 814814 D239809N 814827 F049807N 814830 F099814N 814837 F189801N 814838 F169818N 814840 F169812N 814843 F179803N 814845 F179818N 814846 E049907N 814850 F059810N 814851 E189926N 814852 F109814N 814854 F089809N 814857 F119805N 814859 F179816N 814861 F169805N 814865 E199911N 814880 E049911N 814897 F109810N 814907 H099821N 814908 D109903N 814921 E199910N 814952 L089817N 814953 I039905N 814965 A219909N 814967 A219904N 814968 A219915N 814969 A219912N 814974 A259911N 814976 A259914N 814977 B169902N 814978 B169915N 814979 B169917N 814980 B189905N 814981 B179908N 814984 B179911N 814985 B179905N

REVISED

H/C KRP KRP KPM KON KON KON KON KON KON KON KON KPL KON KPL KON KON KON KON KON KPL KPH KON KON KPL KPL KPH KRN KPK KPK KPK KPK KPK KPK KPL KPL KPL KPL KPK KPL KPL

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

21 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-F

Eng. S/N C/S S/N 814986 B179907N 814987 C119912N 814988 C119909N 814990 C119913N 814991 C119907N 814994 B189906N 814995 C129904N 814996 C119911N 814998 C119905N 814999 C129911N 815000 C129912N 818751 C139901N 818752 C159920N 818753 C159919N 818757 C139912N 818767 D098803N 818768 D109911N 818769 D109901N 818770 D089917N 818771 D109902N 818772 D099903N 818774 D239912N 818775 D249912N 818777 D239907N 818779 D269902N 818781 D269917N 818782 D249904N 818783 E059905N 818784 E039903N 818785 E039917N 818788 E049908N 818791 E059907N 818794 E189920N 818795 E189909N 818796 E189911N 818797 E189905N 818800 H279815N 818801 E199914N 818802 E199913N 818803 F169817N 818804 E059910N

ISSUED

H/C KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KPL KPK KPL KPL KPL KPL KPK KPL KPL KPM KPM KPM KPL KPM KPM KPM KPM KPL KPL KPL KPK KPM KPL KOM KPM KPL KON KPL

Engine Model IO-520-F

Eng. S/N C/S S/N 818807 D109905N 818809 D109910N 818816 D239905N 818823 F239922N 818824 F239915N 818829 F249915N 818831 F239908N 818835 E059903N 818847 G269913N 818848 G269925N 818849 G269921N 818850 G269927N 818853 G269910N 818855 G269923N 818856 G269904N 818857 G289910N 818858 G279923N 818859 G289916N 818860 G299927N 818862 G279914N 818864 G299921N 818865 G299904N 818866 G299919N 818867 G299901N 818868 G309912N 818869 G309906N 818870 G309914N 818878 H249911N 818880 I079904N 818881 I039914N 818882 I039912N 818885 H259911N 818887 I039913N 818890 J089909N 818892 I089926N 818894 H249906N 818901 J049915N 818906 J049933N 818907 J059927N 818908 J049923N 818909 J059902N

REVISED

H/C KPL KPK KPL KRN KRN KRN KRN KPM KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRP KRP KRN KRP KRP KRP KRP KRP

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

22 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-F

Eng. S/N C/S S/N 818910 J079907N 818915 J119904N 818916 J089904N 818929 K029918N 818933 L029915N 818935 L039904N 818936 L029904N 818939 L029917N 818943 L079915N 818948 L109906N 818949 L109921N 818979 N00CA107 818986 N00CA146 818995 N00CA354

H/C KRP KRP KRP KRP KRN KRN KRN KRN KRP KRP KRP KRP KRP KRP

IO-520-J

216537 I089905N

KRN

IO-520-K

224136 H099801N KOL 224140 B169913N KPK

IO-520-L

294901 D229820N 294902 D239805N 294903 D239806N 294905 F089806N 294906 F059813N 294907 F089812N 294908 F099802N 294909 F049812N 294910 F059808N 294911 F059807N 294912 F169806N 294913 E189917N 294914 F159804N 294915 F089801N 294916 F109809N 294917 E039905N 294919 F059814N 294920 H039814N 294925 H079809N 294930 E189925N 294938 E059913N

ISSUED

Engine Model IO-520-L

Eng. S/N C/S S/N 294941 H279817N 294943 E189919N 294947 E189915N 294958 A219905N 294959 A229911N 294960 A219914N 294962 A219913N 294963 A259913N 294965 A279901N 294970 C129903N 294971 C119918N 294973 C139907N 294974 C159903N 294977 D089911N 294979 D109906N 294980 D089907N 294982 D239908N 294983 D269908N 294985 E039901N 294988 E059917N 294989 E199904N 294990 E189807N 294991 E199906N 294992 E189908N 294993 F239923N 294996 D109907N 295001 L109801N 295003 G269903N 295005 G309905N 295006 G299929N 295007 G299914N 295008 G299930N 295012 G309910N 295013 H239905N 295014 H209909N 295018 I099913N 295019 I089923N 295020 J079905N 295021 J079902N 295025 I079909N 295027 I079922N

KOL KOL KOL KOL KOL KOL KOL KOL KOL KON KON KPL KOL KOL KON KPM KOL KOL KOL KPL KPL

REVISED

H/C KOM KPL KPL KPK KPK KPK KPK KPK KPK KPK KPK KPL KPL KPL KPL KPL KPM KPM KPL KPM KPL KPK KPL KPK KRN KPL KPK KRN KRN KRN KRN KRN KRN KRN KRN KRP KRP KRP KRP KRN KRN

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

23 of 60 MSB00-5

D

AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-520-L

Eng. S/N C/S S/N 295028 I079916N 295029 I089924N 295039 F119804N 295040 H099808N 295045 L029908N 295046 L029903N 295049 L039905N 295067 N00CA132 577231 F119808N 577234 F269913N 577236 I089903N 577237 K029903N

H/C KRN KRP KON KOL KRN KRP KRN KRP KON KPL KRN KRP

811623 J089806N 811624 J089802N 811625 J099809N 811630 K259814N 811632 A159907N 811634 B109920N 811635 B109912N 811642 B109909N 811644 D019912N 811645 D019906N 811646 D019903N 811650 D019907N 811652 D059910N

KOR KOR KOM KPH KPM KPM KPM KPM KPM KPM KPM KPM KPH

277688 K189801N 277721 I229809N 277725 K129809N 277726 K139801N 277727 K179802N 277728 K199803N 277730 K179807N 277733 A169906N 277738 B029903N 277739 B129915N 277747 E019902N 277748 C279902N 277752 D149908N

KOM KOM KOP KPM KOR KPM KOR KOR KPH KPM KPH KPM KPH

IO-520-M

IO-520-MB

ISSUED

Engine Model IO-520-MB

Eng. S/N C/S S/N H/C 277753 D149907N KPM 277781 K139802N KPM

IO-550-A

280488 I189814N 280490 I199805N 280491 I219815N 280493 J269804N 280495 I199802N 280497 J239802N 280498 J239810N 280499 J239803N 280500 J239811N 817001 J279805N 817002 K209806N 817005 J279806N 817006 A209902N

KOR KOR KOR KOM KOR KOR KOM KOR KOM KOM KOP KOR KPM

IO-550-B

296625 K229809N 297088 K229810N 297102 I169810N 297103 I189815N 297104 I199804N 297105 I229805N 297106 I219821N 297108 I219802N 297114 I189813N 297115 J249810N 297116 I209802N 297117 I189816N 297118 J259804N 297119 J259805N 297120 J269801N 297121 J269812N 297122 K209807N 297124 K219801N 297125 J279810N 297128 J259812N 297129 K219803N 297131 K229802N 297133 K239808N

KPH KPH KOR KOR KOR KOM KOP KOM KOR KOR KOR KOR KOM KOM KOM KOM KPH KOP KOM KOM KOP KOR KOR

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

24 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-550-B

Eng. S/N C/S S/N 297134 K209801N 297136 K209802N 297138 K199808N 297139 A199904N 297140 A199906N 297141 A189910N 297142 A209906N 297144 A209904N 297145 A209905N 297149 B059901N 297153 K209813N 297154 B039916N 297157 B059908N 297161 C249909N 297163 C299911N 297164 C249901N 297165 C259902N 297166 C259908N 297167 C299910N 297168 D299901N 297170 K239802N 297172 K199807N 297187 J239809N 682997 A169804N 684005 I169807N 684006 I219812N 684009 J249806N 684010 J279807N 684011 J279809N 684015 J259811N 684016 J269808N 684017 J269811N 684020 K239807N 684021 K239805N 684022 K239803N 684023 K209810N 684025 K199812N 684026 B039913N 684027 A199901N 684029 A199903N 684030 B039915N

ISSUED

H/C KOR KOP KPH KOM KOM KOM KOM KOR KOR KPM KOP KPM KPM KPM KPM KPM KPM KPM KPM KPK KPH KOP KOM KPM KOR KOR KOR KOM KOM KOM KOM KOM KOR KOR KOP KPH KOR KPM KOM KOM KPM

Engine Model IO-550-B

Eng. S/N C/S S/N 684031 B039912N 684032 B039907N 684033 B039910N 684034 B099901N 684035 B099905N 684036 B099903N 684037 B099902N 684038 C059907N 684039 C059903N 684040 C059905N 684041 C069901N 684042 C239916N 684043 C239917N 684044 C259903N 684045 C259904N 684046 C259909N 684048 C319910N 684050 C309901N 684051 C309903N 684052 D299906N 684053 D299905N 684058 E239901N 684110 I179802N 684113 K199811N 684114 B059920N 684115 C069911N 684119 A319916N 684121 C069905N 684745 J279808N

H/C KPH KPM KPM KPM KPM KPM KPM KOR KOR KOR KOR KPH KPM KPM KPM KPM KPM KPM KPM KPM KPM KRN KOR KOR KPM KOR KPM KPM KOM

684239 I219823N 684240 I219819N 684243 I229806N 684244 I219810N 684247 I229807N 684248 I219811N 684249 I219809N 684250 J249805N 684252 J249811N 684253 J269805N 684254 J249807N

KOP KOP KOM KOR KOR KOR KOR KOR KOR KOM KOR

IO-550-C

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

25 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-550-C

Eng. S/N C/S S/N 684255 J249809N 684256 J279803N 684257 J279802N 684258 J279801N 684259 J279804N 684261 K209815N 684262 K229804N 684263 K239809N 684264 K209805N 684266 K209811N 684267 K199809N 684268 K209808N 684269 K209812N 684270 A209901N 684271 A189913N 684273 A199905N 684274 B039914N 684276 B049910N 684277 B039906N 684278 B049907N 684279 B049908N 684280 B089901N 684281 B059918N 684282 B059922N 684283 B059917N 684284 C059910N 684285 C059904N 684287 C059906N 684288 C239913N 684290 C239915N 684291 C239914N 684292 C309904N 684293 C299906N 684294 C309905N 684295 C259910N 684296 D289903N 684297 D289901N 684298 D279904N 684300 D279902N 684301 D289904N 684303 D299903N

ISSUED

H/C KOR KOM KOM KOR KOM KOR KOR KOR KOP KOR KOR KOR KOR KOR KPM KOR KPM KPM KPM KPM KPM KPM KPM KPM KPM KOR KOR KOR KPH KPH KPM KPM KPM KPM KPM KPM KPH KPM KPM KPM KPH

Engine Model IO-550-C

Eng. S/N C/S S/N 684304 D299904N 684368 I169812N 684369 I179803N 684370 I199801N 684371 I179804N 684419 B089910N 684532 C069910N 684533 C069908N 684535 C259907N 684536 C259905N 684538 C319911N 815291 I209804N 815292 I219804N 815293 J259801N 815294 J259802N 815298 I219813N 815299 I219814N 815301 I219818N 815302 I219824N 815304 I199806N 815306 J239805N 815307 J239807N 815308 J239808N 815309 J239806N 815310 J239801N 815311 J269803N 815313 J279812N 815314 K229801N 815315 K209817N 815316 K199810N 815317 A189906N 815319 K209818N 815321 B099904N 815322 B059916N 815323 A199908N 815325 B089907N 815328 C069909N 815329 C069903N 815330 B059903N 815333 C249902N 815335 C259906N

REVISED

H/C KPM KOR KOR KOR KOR KPM KOR KOR KPM KPM KRP KOR KOM KOR KOR KOR KOP KOP KOP KOP KOR KOM KOR KOR KOR KOM KOR KOR KOR KPH KOM KOR KPM KPM KOM KPM KPM KPM KOM KPM KPM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

26 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-550-C

Eng. S/N C/S S/N 815339 B059910N 815340 C299908N 815342 C009904N 815344 B059913N 815346 D299902N 815347 C319902N 815378 F129905N 815383 I169809N

H/C KPM KPM KPH KPM KPK KPM KRP KOR

284283 D259804N 284284 D249814N 284286 D249815N 284287 D259801N 284289 D259803N 284290 D279801N 284293 H199918N 284294 G229808N 284295 G239812N 284299 D179916N 284313 A309910N 284314 A309903N 284315 A309902N 284316 B019904N 284317 B019905N 284318 A309906N 284319 A309904N 284321 D179909N 284322 D179903N 284323 D199904N 284324 D179915N 284325 D189904N 284327 H199908N 284330 G169910N 284331 G169911N 284333 G239809N 284335 J019903N 284336 J019922N 284337 H199911N 284339 H199920N 284340 J019913N 284341 J019918N

KOL KOL KOL KOL KOL KOL KRN KOL KOL KPL KPL KPL KPL KPL KPL KPL KPL KPK KPL KPL KPL KPK KRN KPM KPM KOL KRP KRP KRN KRN KRP KRP

IO-550-D

ISSUED

Engine Model IO-550-D

Eng. S/N C/S S/N 284342 J019911N 284349 J049904N 284350 G169908N 284351 J049912N 284352 J019905N 284355 K069906N 284357 A050008N 284359 A050011N 284360 A050006N 680020 A309901N

H/C KRP KRN KRN KRP KRN KRP KRN KRN KRN KPL

IO-550-E

283391 B019906N 283382 D249808N 283383 D249817N 283384 D249813N 283385 D249807N 283386 D249816N 283387 D259802N 283389 D279806N 283394 D179904N 283395 D179902N 283397 D249809N 283398 D199905N 283399 D189906N 283400 D199901N 283401 D179914N 283403 A050003N 283404 A080009N 283405 N00CA227 681045 A050002N 681048 A050005N

KPL KOL KOL KOL KOL KOL KOL KOL KPL KPL KOL KPL KPK KPK KPK KRN KRN KRP KRN KRN

IO-550-F

284851 284859 284861 284862 284863 284865 284869 284871 284872

KOL KOL KOL KOL KOL KOL KOL KOL KOL

REVISED

D249810N D279803N D249818N D279805N D279804N D279810N D279809N D259806N D279808N

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

27 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-550-F

Eng. S/N C/S S/N 284873 D279807N 284874 D279812N 284875 D279802N 284878 G239807N 284916 D249811N 284933 J019915N 284935 J019914N 284949 N00CA215 679523 D179908N 679531 J049914N 679532 J049908N 679533 A050007N 913750 D199910N

H/C KOL KOL KOL KOL KOL KRP KRP KRP KPL KRN KRP KRN KPL

679336 E079909N 289131 D259805N 289136 G229809N 289138 G229802N 289140 G229810N 289141 G229805N 289147 G239804N 679339 I169808N 679343 I229801N 679347 I209801N 679348 J259810N 679349 J259808N 679352 I209803N 679353 I229802N 679363 I189817N 679364 J259809N 679366 C319906N 679367 K219804N 679368 J269807N 679370 J269802N 679371 J239804N 679372 K209809N 679373 K229806N 679377 K229808N 679378 K209814N 679379 A189907N 679380 B039909N

KPK KOL KOL KOL KOL KOL KOL KOR KOM KOR KOR KOR KOR KOR KOR KOR KPM KOR KOM KOM KOR KOR KOR KOP KOP KOM KOM

IO-550-G

ISSUED

Engine Model IO-550-G

Eng. S/N C/S S/N 679381 K229805N 679382 K209816N 679383 A189911N 679384 B039911N 679385 B059914N 679386 B059902N 679387 B089902N 679388 B059921N 679389 B059911N 679390 B089909N 679391 B059905N 679392 B089904N 679393 I219805N 679394 C069906N 679395 C059902N 679396 C069907N 679397 C059913N 679398 B089906N 679399 C249906N 679400 C2999909 679401 C249903N 679402 C249904N 679403 C299907N 679404 C309906N 679405 C319908N 679437 C249910N 679438 C059914N 679439 C319901N 808508 J269809N 808509 C309902N

H/C KOR KOR KOM KPM KPM KPM KPM KPM KPM KPM KPM KOR KOM KPM KOR KPM KOR KPM KPM KPH KPM KPM KPM KPH KPM KPM KOR KPM KOM KPM

289130 D179901N 289131 D259805N 289136 G229809N 289138 G229802N 289140 G229810N 289141 G229805N 289147 G239804N 289148 D199908N 289149 D199909N

KPL KOL KOL KOL KOL KOL KOL KPL KPL

IO-550-L

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

28 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model IO-550-L

Eng. S/N C/S S/N 289152 J019902N 289153 J019907N 289154 J049910N 289155 J049911N 289157 H199907N 289160 A050001N 289161 N00BA593 289163 N00CA228 289169 N00CA586 678002 I119907N

H/C KRP KRP KRP KRP KRN KRN KRP KRP KRN KRN

683354 J269810N 683356 B089908N 683357 C059911N 683358 C059916N 683359 C269902N

KOR KPM KOR KOR KPM

807514 I239802N 807516 J019810N 807517 J019814N 807518 J019811N 807519 J019816N 807520 K059812N 807522 J019815N 807523 K079803N 807524 K059808N 807525 K069803N 807581 J029903N

KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC

IO-550-N

LTSIO-360-EB

LTSIO-360-KB

319386 K059815N 319388 J019817N 812054 I239804N 812056 J019812N 812057 J019808N 812059 I259809N 812062 K059814N 812063 K069811N 812064 K069805N 812065 K069808N 812066 K069810N 812067 K069802N

ISSUED

KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC

Engine Model Eng. S/N C/S S/N LTSIO-360-RB 321735 J019813N 321736 J019807N 321738 K059809N 321739 I309802N 321740 K059810N 321741 I259810N 321742 J019809N 321743 K069809N 321744 K069806N 321745 K079802N 321746 K069807N

H/C KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC

LTSIO-520-AE

246675 G159915N 246676 G159913N 246679 G159909N 246680 G159918N 246684 G159914N

KPL KPL KPL KPL KPL

TSIO-360-AB

237617 K109805N KPC 237618 K109815N KPC

TSIO-360-C

283560 J029805N KPC

TSIO-360-CB

236251 K109812N KPC 236252 K109801N KPC

TSIO-360-DB

817251 J029810N KPC

TSIO360-EB

809232 I259803N 809235 I249805N 809238 K069813N 809239 K109803N 809240 K109814N

KPC KPC KPC KPC KPC

TSIO-360-FB

299712 I299803N 299713 J019804N 299714 I259807N 299715 K049813N 299716 K069816N 299717 K109813N

KPC KPC KPC KPC KPC KPC

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

29 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model TSIO-360-FB

Eng. S/N C/S S/N H/C 299718 K109810N KPC 299720 K109808N KPC

TSIO-360-KB

TSIO-360-LB

320381 K069812N 320383 J019802N 811323 K099808N 811324 I259811N 811325 K049818N 811328 K059803N 811329 K099809N 811330 K109816N 811331 K099810N 811332 K109811N 811333 K109804N 811334 K109806N

KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC

247354 I249802N 247356 I259802N 247357 K099802N 247358 K099811N 247359 K099804N

KPC KPC KPC KPC KPC

TSIO-360-MB

279293 I249809N KPC 279294 K099807N KPC 279295 K069815N KPC

TSIO-360-RB

321483 I299802N 321484 I249808N 321485 I309805N 321486 K049815N 321487 K059802N 321488 I299806N 321489 K099803N 321490 K099805N 321491 K099806N 321492 K109809N

KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC

TSIO-360-SB

321791 K059804N KPC

TSIO-520-AE

246177 G169904N KPL 246178 F1999203 KPL 246179 G169903N KPL

ISSUED

Engine Model TSIO-520-AF

Eng. S/N C/S S/N H/C 245248 F169815N KON 245250 L109802N KPK

TSIO-520-B

176762 L029808N 176763 J099810N 176765 A139906N 176766 B119912N 176767 B119914N 176770 B109904N 176775 D069906N 176776 D059904N 176795 K309801N

KPM KOM KPM KPM KPM KPM KPM KPH KOM

TSIO-520-BB

287621 D299911N 287616 K169801N 287619 C089903N 287618 C089904N 287622 D149911N 287620 E119909N

KPH KPM KPM KPM KPM KPH

TSIO-520-C

178539 L079909N 178542 F179813N 178544 H079801N 178560 B169911N 178565 A039911N 178566 E039908N 178569 H129803N 178571 I039903N 178572 J079906N 178573 J049916N 178574 J059912N 178575 J059910N 178576 J089905N

KRP KON KOL KPL KPL KPM KOL KRN KRP KRP KRP KRP KRP

TSIO-520-CE

268583 C039923N 268585 C039920N 268586 C039919N 268590 L139901N 530169 C039922N 530172 L139902N 530173 L139914N

KPL KPL KPL KRP KPL KRP KRP

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

30 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model TSIO-520-D

Eng. S/N C/S S/N H/C 180110 J319803N KOP 180111 B109902N KPM

TSIO-520-E

TSIO-520-EB

183520 J109806N 812599 J089807N 812601 J089809N 812602 J109804N 812603 I109810N 812611 J319802N 812612 J299808N 812614 K309803N 812615 K259806N 812616 K259808N 812617 K309808N 812619 L029804N 812620 K249805N 812621 K259813N 812622 K259810N 812623 K259807N 812624 A139904N 812625 A139901N 812630 L029803N 812631 A139903N 812632 B099910N 812633 B119901N 812634 B109915N 812635 D019905N 812638 D019911N 812640 J289810N

KOM KOR KOM KOM KOM KOP KOP KPM KPH KPH KOM KPM KPH KPM KPM KPM KPM KPM KPM KPM KPM KPM KPH KPM KPM KOP

815023 F169808N 815032 K179806N 815035 C089906N 815038 C279911N 815040 C269906N 815042 D149915N 815043 E119918N 815057 K129801N

KON KOR KPM KPH KPM KPM KPH KOP

ISSUED

Engine Model TSIO-520-G

Eng. S/N C/S S/N H/C 216053 E039906N KPM

TSIO-520-H

217409 F109808N 217412 E189928N 217420 B169904N 217423 C119904N

KON KPL KPL KPK

TSIO-520-J

217424 D109908N 217426 E189918N 217428 F269905N 217429 F279902N 217430 F279907N 217432 G269926N 217433 I089902N 217438 L029906N 506894 F129806N 506895 K019921N 506896 H239901N 218992 B099917N

KPL KPL KPL KRN KRN KRN KRN KRN KON KRP KRN KPM

TSIO-520-JB

237193 A159911N KPM 237194 C279906N KPM

TSIO-520-L

241973 A129901N KPM 241974 A129903N KPM

TSIO-520-LB

815504 B049904N KPM

TSIO-520-M

291955 D169807N 291960 F089810N 291961 F089802N 291962 F059803N 291964 F109803N 291965 F109801N 291967 F159801N 291969 E199912N 291978 I079932N 291981 F119806N

REVISED

KOL KOL KOL KOL KON KOL KOL KPL KRP KON

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31 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model TSIO-520-M

Eng. S/N C/S S/N 291985 H279805N 291986 H279808N 532083 F049809N 532085 H279804N 532088 L109804N 532089 A219901N 532091 D089906N 532092 D249901N 532093 C119906N 532095 E049910N 532096 E049903N 532099 J049928N 532100 J059906N 532101 J069917N 532102 J079903N 532104 I039906N 532105 K019917N 532106 K029915N 532107 K039905N 532108 L029910N 532109 L029909N 532115 N00AA186 532118 N00CA065 532123 N00CA340 818001 L069802N 818007 A229901N 818008 A219917N 818010 A229906N 818011 L099809N 818015 B169908N 818016 B179906N 818017 B179916N 818018 B169905N 818020 C159921N 818021 C139908N 818022 D099905N 818023 D089913N 818024 D099906N 818026 D269906N 818027 C119902N

ISSUED

H/C KOM KOM KON KOM KPK KPK KPK KPM KPL KPM KPM KRP KRP KRP KRP KRN KRN KRP KRN KRN KRN KRP KRP KRP KPK KPK KPK KPK KPK KPL KPL KPL KPL KPL KPL KPL KPL KPL KPM KPL

Engine Model TSIO-520-M

Eng. S/N C/S S/N 818028 E019912N 818030 E189910N 818031 E189903N 818033 F229904N 818041 E069901N 818045 F279909N 818047 G239913N 818048 G299916N 818049 G269917N 818052 G299906N 818053 G289908N 818054 G299924N 818055 G309901N 818062 G299912N 818063 H259909N 818064 H249907N 818067 G299918N 818069 H259925N 818071 G299911N 818072 F179814N 818073 I039919N 818074 I039909N 818075 I099906N 818079 I089922N 818081 J079916N 818084 J089907N 818087 K019912N 818098 L109903N 818099 L029905N 818107 L089906N 818126 L099912N 818144 N00CA135

H/C KPL KPL KPL KRN KPM KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KON KRN KRN KRP KRP KRP KRP KRP KRP KRN KRP KRP KRP

TSIO-520-NB

813600 E269911N 813621 I189808N 813634 K179808N 813635 A159918N 813636 A159914N 813637 B129913N 813638 B159911N

KPL KOM KOR KPM KPM KPM KPM

REVISED

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32 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model TSIO-520-NB

Eng. S/N C/S S/N 813639 B159910N 813640 B159909N 813641 B159908N 813644 C109914N 813645 C279909N 813646 D079911N 813647 D079908N 813652 C109913N 813654 D299907N 813655 D309901N 813657 E119903N 813660 E119910N 813685 C109912N

H/C KPM KPM KPM KPM KPH KPM KPM KPM KPM KPH KPH KPH KPM

TSIO-520-P

278814 F059811N 278815 F089808N 278820 E059912N 278821 H129804N 278823 F129803N 278828 L069805N 278832 B169912N 278833 E039915N 278834 E069904N 278835 E189914N 278836 E199907N 278840 D089910N 278845 E039913N 278848 G269908N 278850 G269907N 278851 G269928N 278852 G299913N 278854 H209922N 278855 I039902N 278856 I089920N 278862 L079901N 513921 H259906N 513922 J049924N

KOL KOL KPM KOL KON KOL KPL KPL KPM KPL KPL KOL KPM KRN KRN KRN KRN KRN KRN KRP KRN KRN KRP

TSIO-520-R

293969 E069906N KPL 293978 F049808N KON

ISSUED

Engine Model TSIO-520-R

Eng. S/N C/S S/N 293979 F089805N 293985 F059805N 293986 F189806N 293988 F099810N 293992 F179804N 293993 F169816N 293994 F109802N 293997 H049808N 294007 H319813N 294008 E019910N 294014 H279816N 294050 L079803N 294051 B169909N 294052 B169907N 294054 B189903N 294055 C119901N 294059 B169903N 294063 E019919N 294066 E059918N 294068 E189922N 294069 E189904N 294070 E189924N 294072 D099902N 294073 D099911N 294074 F239911N 294076 H279807N 294079 F239910N 294080 F239918N 294081 F239924N 294085 F269902N 294092 G269919N 294096 G279913N 294098 G269906N 294100 G309916N 294101 G289911N 294102 G279924N 294104 G309908N 294105 C309909N 294106 H209907N 294107 H209919N

REVISED

H/C KON KOL KOL KON KON KON KOL KOL KOL KPM KOM KOL KPL KPL KPL KPL KPL KPL KPM KPL KPL KPL KPL KPL KRN KOM KRN KRN KRN KPM KRN KRN KRN KRN KRN KRN KRN KPL KRN KRP

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33 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Engine Model

TSIO-520-R

Eng. S/N C/S S/N 294108 H209927N 294111 J059901N 294112 I099908N 294113 I099912N 294114 I079908N 294115 I079925N 294116 I089910N 294118 I079923N 294119 J049919N 294121 J049922N 294122 J059921N 294123 J089927N 294124 J069918N 294126 J089913N 294128 J089916N 294130 H259905N 294134 L039901N 294138 L029914N 294140 L039902N 294142 L069904N 294144 L099918N 294154 N00CA001 294166 N00CA054 294171 N00CA059 522698 I039911N 522702 A259912N 522703 E039918N 522706 J069909N 522707 H209920N 522709 J089910N 522712 J049926N 522720 N00CA006

H/C KRN KRP KRN KRP KRN KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRN KRN KRN KRN KRN KRN KRP KRP KRP KRN KPK KPM KRP KRN KRP KRP KRP

239465 I089918N 239466 I039908N 239467 H039811N 239470 H269808N 239474 A259910N 239475 B189902N 239476 C129910N 239477 C129916N

KRP KRN KOL KOL KPK KPL KPL KPL

TSIO-520-T

ISSUED

Engine Model TSIO-520-T

Eng. S/N C/S S/N 239478 C139903N 239484 D089908N 239489 F269910N 239490 G299928N 239491 G239916N 239493 J059926N 239494 J089917N 239497 L029916N 239498 L109904N 515440 F099815N 515441 F159802N 515442 H109806N

H/C KPH KPL KPL KRN KRN KRP KRN KRN KRP KOL KOL KOL

TSIO-520-UB

527425 I189807N 527427 K169811N 527428 A169908N 527429 B019908N 527430 B049905N 527431 C089902N 527432 C279908N 527433 D149905N 527434 D299916N 527477 E109913N 809347 K169813N 809352 K179803N 809354 A169905N 809357 B159902N 809358 E019907N

KOM KOR KOR KOR KOR KOR KPH KPM KOR KPH KOR KOR KPM KPM KPH

TSIO-520-VB

816019 I189801N 816034 D299915N 816036 K149804N 816037 K189806N 816038 K199804N 816039 K149802N 816041 K189808N 816044 K189802N 816046 K189807N 816047 K179805N 816050 A169914N 816052 A169903N

KOM KOR KOP KOR KPM KOM KOR KOR KOR KOM KPM KOR

REVISED

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34 of 60 MSB00-5

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AFFECTED ENGINE MODELS BY ENGINE MODEL, ENGINE SERAIL NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE

Engine Model TSIO-520-VB

Eng. S/N C/S S/N 816053 A169902N 816054 A169912N 816055 A189901N 816056 A169913N 816057 B019915N 816058 B039902N 816061 A169907N 816062 A209908N 816063 B159901N 816064 B159912N 816065 B159904N 816067 B159905N 816068 B159906N 816069 B029904N 816070 C269905N 816072 C279904N 816073 C279910N 816075 C279905N 816079 C269909N 816080 D149910N 816081 D149906N 816086 D149914N 816087 D299910N 816088 E019904N 816089 E109909N 816090 E119905N 816092 E119904N 816093 E119902N

H/C KOR KOR KPM KPM KPM KPH KOR KOR KPM KPM KPM KPM KPM KPH KPH KPH KPH KPM KPM KPM KPM KPM KPH KPH KPH KPH KPH KPH

274437 K129805N 274438 K199805N 274439 K169815N 274443 C279912N 274450 E119901N

KOP KOR KOR KPM KPH

TSIO-520-WB

ISSUED

Engine Model TSIO-550-C

Eng. S/N C/S S/N 802589 J259803N 802590 K219805N 802591 I219803N 802592 C319904N 814506 I169811N 814507 J249802N 814509 J279811N 814512 B059907N 814514 A209903N

H/C KOM KOR KOM KPM KOR KOR KOM KPM KOR

TSIO-550-E

803059 A169803N 803067 C319905N 803070 I179801N 803071 B059915N 803072 B089903N 803073 B059906N 803074 B059912N 803075 B059904N 803077 I219801N 803078 A189908N 803079 J269806N 803080 K219802N 803081 A199907N 803082 A199902N 803086 B049911N 803087 C069902N 803088 B089905N 803089 C059912N 803090 C249907N 803091 C249911N 803093 C269901N 803094 C259901N 803095 C249905N 803097 C259911N

KPM KPM KOR KPM KPM KPM KPM KPM KOM KOM KOR KOP KOM KOM KPM KOR KPM KOR KPM KPM KPM KPM KPM KPH

TSIOL-550-A

809259 I219806N

KOM

REVISED

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35 of 60 MSB00-5

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SECTION 3 AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 643687 N00CA586 643687 N00CA589 643687 N00CA590 643687 N00CA591 646623 A050002N 646623 A050009N 646623 A050011N 646623 A309905N 646623 A309907N 646623 D179905N 646623 D179910N 646623 D179912N 646623 D189905N 646623 D199903N 646623 D199906N 646623 D239802N 646623 D249812N 646623 D279811N 646623 G169908N 646623 G169909N 646623 G169913N 646623 G229809N 646623 G239807N 646623 G239808N 646623 H199907N 646623 H199908N 646623 H199909N 646623 H199910N 646623 H199911N 646623 H199912N 646623 H199913N 646623 H199915N 646623 H199917N 646623 H199918N 646623 H199919N 646623 H199920N 646623 J019905N 646623 J019908N

ISSUED

Part # Serial # 646623 J019923N 646623 J019924N 646623 J049903N 646623 J049904N 646623 J049907N 646623 J049913N 646623 N00CA212 646623 N00CA218 646623 N00CA219 646623 N00CA225 646632 H199914N 649131 B179917N 649131 N00CA340 649131 N00CA342 649131 N00CA363 649133 D239803N 649133 D239815N 649133 G269911N 649133 K029912N 649133 L079904N 649134 A219916N 649134 A229902N 649134 A229903N 649134 A229913N 649134 A259908N 649134 A259916N 649134 A279902N 649134 A279903N 649134 B119903N 649134 B179902N 649134 B179903N 649134 B179904N 649134 B179909N 649134 B179910N 649134 B179913N 649134 B179913N 649134 B179914N 649134 B179918N

H/C KRN KRN KRN KRN KRN KRN KRN KPL KPL KPK KPK KPK KPK KPK KPL KOL KOL KOL KRN KRN KRN KOL KOL KOL KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRP

H/C KRP KRN KRN KRN KRP KRP KRP KRP KRP KRP KRN KPK KRP KRP KRP KOL KOL KRN KRP KRN KPK KPK KPK KPK KPK KPK KPK KPK KPL KPL KOL KPL KPL KPL KPL KOL KPK KPL

Part # Serial # 649134 B189901N 649134 C119914N 649134 C119917N 649134 C129902N 649134 C129905N 649134 C129906N 649134 C129907N 649134 C129909N 649134 C129913N 649134 C129915N 649134 C139904N 649134 C139905N 649134 C139906N 649134 C139909N 649134 C139910N 649134 C139911N 649134 C149913N 649134 D089903N 649134 D099901N 649134 D109904N 649134 D109909N 649134 D209807N 649134 D209809N 649134 D209810N 649134 D209811N 649134 D229801N 649134 D229802N 649134 D229803N 649134 D229806N 649134 D229808N 649134 D229809N 649134 D229810N 649134 D229811N 649134 D229812N 649134 D229813N 649134 D229814N 649134 D229815N 649134 D229817N 649134 D229822N

REVISED

H/C KPL KPK KPK KPL KPL KPL KPL KPL KPK KPL KPL KPK KPL KPL KPL KPL KPL KPL KPL KPL KPL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 649134 D229819N 649134 D229821N 649134 D239801N 649134 D239807N 649134 D239811N 649134 D239812N 649134 D239813N 649134 D239814N 649134 D239816N 649134 D239817N 649134 D239818N 649134 D239819N 649134 D239821N 649134 D239822N 649134 D239823N 649134 D239824N 649134 D239901N 649134 D239902N 649134 D239903N 649134 D239904N 649134 D239906N 649134 D239909N 649134 D239910N 649134 D239911N 649134 D249801N 649134 D249802N 649134 D249803N 649134 D249804N 649134 D249805N 649134 D249806N 649134 D249902N 649134 D249903N 649134 D249905N 649134 D249908N 649134 D249910N 649134 D249911N 649134 D249914N 649134 D249915N

ISSUED

Part # Serial # 649134 D249916N 649134 D249917N 649134 D249918N 649134 D269901N 649134 D269903N 649134 D269904N 649134 D269907N 649134 D269909N 649134 D269910N 649134 D269911N 649134 D269912N 649134 D269913N 649134 D269914N 649134 D269915N 649134 D269916N 649134 D269918N 649134 E039907N 649134 E039909N 649134 E039911N 649134 E049901N 649134 E049902N 649134 E049906N 649134 E059908N 649134 E059914N 649134 E059916N 649134 E069902N 649134 E189913N 649134 E189923N 649134 E189927N 649134 E199902N 649134 E199903N 649134 E199905N 649134 F059802N 649134 F089811N 649134 F109804N 649134 F109811N 649134 F109818N 649134 F119801N

H/C KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KOL KPL KPL KPL KPM KPL KPM KPL KPL KOL KOL KOL KOL KOL KOL KPM KPL KPM KPM KPM KPM KPM KPL

H/C KPM KPM KPM KPM KPM KPM KPM KPM KPL KPM KPM KPM KPM KPM KPM KPM KPM KPL KPL KPM KPM KPL KPL KPL KPM KPM KPL KPL KPL KPL KPL KPL KOL KOL KON KON KON KON

Part # Serial # 649134 F119802N 649134 F119803N 649134 F119807N 649134 F119809N 649134 F119810N 649134 F119811N 649134 F119812N 649134 F129801N 649134 F129804N 649134 F129805N 649134 F129807N 649134 F129808N 649134 F129810N 649134 F129811N 649134 F129812N 649134 F159803N 649134 F159805N 649134 F159807N 649134 F159809N 649134 F159812N 649134 F169802N 649134 F169803N 649134 F169814N 649134 F179801N 649134 F179802N 649134 F179809N 649134 F179812N 649134 F179815N 649134 F189803N 649134 F199801N 649134 F229919N 649134 F239807N 649134 F269911N 649134 F269912N 649134 F269915N 649134 F269916N 649134 G099930N

REVISED

H/C KON KON KON KON KON KON KON KON KOL KON KOL KOL KOL KON KOL KOL KOL KON KON KOL KON KOL KON KOL KON KOL KON KON KON KON KRN KOL KPL KPL KPM KPL KRN

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 649134 G149910N 649134 G149909N 649134 G149911N 649134 G149912N 649134 G149913N 649134 G149916N 649134 G159901N 649134 G159905N 649134 G159906N 649134 G269902N 649134 G269905N 649134 G269924N 649134 G279902N 649134 G279903N 649134 G279904N 649134 G279906N 649134 G279907N 649134 G279908N 649134 G279910N 649134 G279911N 649134 G279915N 649134 G279916N 649134 G279917N 649134 G279918N 649134 G279922N 649134 G289901N 649134 G289902N 649134 G289905N 649134 G289906N 649134 G289907N 649134 G289909N 649134 G289912N 649134 G289917N 649134 G289918N 649134 G289919N 649134 G289920N 649134 G289921N

ISSUED

Part # 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134

H/C KPM KPM KPM KPM KPM KPM KPM KPM KPM KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN

Serial # G289922N G289923N G289924N G289925N G289926N G289927N G289928N G289929N G289930N G299902N G299903N G299905N G299907N G299908N G299909N G299922N G299923N G299925N G299926N G309903N G309904N G309907N G309909N G309913N G309915N G309917N G309918N G309919N H049804N H049810N H049814N H049815N H049816N H059804N H059809N H069812N H098808N

H/C KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KOL KOL KOL KOL KOL KOL KOL KOL KOL

Part # Serial # 649134 H099818N 649134 H099819N 649134 H109803N 649134 H109804N 649134 H119809N 649134 H119811N 649134 H209906N 649134 H209908N 649134 H209910N 649134 H209917N 649134 H209918N 649134 H209923N 649134 H209924N 649134 H209925N 649134 H209926N 649134 H239902N 649134 H239903N 649134 H239904N 649134 H239906N 649134 H239907N 649134 H239909N 649134 H239910N 649134 H239911N 649134 H239912N 649134 H239913N 649134 H239914N 649134 H239915N 649134 H239916N 649134 H239917N 649134 H249901N 649134 H249902N 649134 H249903N 649134 H249904N 649134 H249908N 649134 H249909N 649134 H249910N 649134 H249913N

REVISED

H/C KON KOL KON KON KOL KOL KRN KRP KRP KRP KRN KRN KRN KRN KRN KRN KRN KRN KRP KRN KRN KRN KRN KRN KRN KRN KRN KRP KRN KRN KRN KRN KRN KRN KRN KRN KRN

PAGE NO REVISION TM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 649134 H249914N 649134 H249915N 649134 H249916N 649134 H249917N 649134 H249918N 649134 H249920N 649134 H249921N 649134 H249922N 649134 H249923N 649134 H259901N 649134 H259902N 649134 H259903N 649134 H259904N 649134 H259907N 649134 H259908N 649134 H259910N 649134 H259912N 649134 H259913N 649134 H259914N 649134 H259915N 649134 H259916N 649134 H259917N 649134 H259918N 649134 H259919N 649134 H259920N 649134 H259921N 649134 H259923N 649134 H259924N 649134 H259926N 649134 H289800N 649134 H289802N 649134 H319808N 649134 H319810N 649134 H319815N 649134 I019801N 649134 I019802N 649134 I019805N 649134 I029801N

ISSUED

Part # Serial # 649134 I029804N 649134 I029805N 649134 I039904N 649134 I039907N 649134 I039910N 649134 I039916N 649134 I039917N 649134 I039918N 649134 I039920N 649134 I079903N 649134 I079905N 649134 I079907N 649134 I079912N 649134 I079913N 649134 I079914N 649134 I079917N 649134 I079919N 649134 I079920N 649134 I079921N 649134 I079926N 649134 I079928N 649134 I079929N 649134 I089901N 649134 I089904N 649134 I089907N 649134 I089908N 649134 I089909N 649134 I089911N 649134 I089912N 649134 I089913N 649134 I089914N 649134 I089915N 649134 I089916N 649134 I089917N 649134 I089919N 649134 I089921N 649134 I089928N 649134 I089929N

H/C KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KOL KOL KOL KOL KOL KOL KOL KOL KOL

H/C KOL KOL KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRP KRP KRP KRP KRP KRP KRP KRP KRN KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP

Part # Serial # 649134 I099903N 649134 I099904N 649134 I099910N 649134 I099915N 649134 I099916N 649134 J059903N 649134 J059905N 649134 J059907N 649134 J059909N 649134 J059911N 649134 J059914N 649134 J059915N 649134 J059919N 649134 J059920N 649134 J059922N 649134 J059923N 649134 J059924N 649134 J069901N 649134 J069902N 649134 J069914N 649134 J069916N 649134 J079904N 649134 J079909N 649134 J079912N 649134 J079913N 649134 J079914N 649134 J079917N 649134 J089902N 649134 J089914N 649134 J089919N 649134 J089920N 649134 J089923N 649134 J089926N 649134 J119901N 649134 K019908N 649134 K019910N 649134 K019915N

REVISED

H/C KRP KRP KRP KRN KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRN KRP KRP KRP KRP KRP KRN KRP KRP

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 649134 K019920N 649134 K019923N 649134 K029901N 649134 K029902N 649134 K029906N 649134 K039905N 649134 L029904N 649134 L029912N 649134 L029913N 649134 L039816N 649134 L039817N 649134 L039903N 649134 L039907N 649134 L039909N 649134 L049803N 649134 L059809N 649134 L069806N 649134 L069808N 649134 L079802N 649134 L079902N 649134 L079908N 649134 L079911N 649134 L089901N 649134 L089903N 649134 L099909N 649134 L099911N 649134 L099913N 649134 L099917N 649134 N00AA189 649134 N00AA190 649134 N00AA192 649134 N00AA193 649134 N00AA195 649134 N00CA093 649134 N00CA144 649134 N00CA324 649134 N00CA344

ISSUED

Part # Serial # 649134 N00CA345 649134 N00CA352 649134 N00CA353 649134 N00CA354 649134 N00CA355 649134 N00CA358 649134 N00CA377 649134 N00CA381 649135 F109813N 649135 G309902N 649135 G309911N 649135 H029908N 649135 H039802N 649135 K019901N 649135 K019906N 649135 L089902N 649138 A289905N 649138 A289913N 649138 B189910N 649138 B199905N 649138 C149901N 649138 C149903N 649138 C149906N 649138 C169902N 649138 D156818N 649138 D169818N 649138 D209804N 649138 E199924N 649138 F039818N 649138 F239805N 649138 H149804N 649138 J119910N 649138 J119912N 649138 J129901N 649138 J129903N 649138 J149904N 649138 N00CA173

H/C KRN KRP KRP KRP KRN KRN KRN KRN KRN KPK KPK KRN KRN KRN KPK KOL KOL KOL KOL KRN KRP KRN KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP KRP

H/C KRP KRP KRP KRP KRP KRP KRP KRP KON KRN KRN KRP KOL KRN KRN KRP KPK KPL KPL KPL KPK KPK KPK KPL KOL KOL KOL KPL KOL KOL KON KRP KRN KRN KRP KRP KRN

Part # Serial # 649138 N00CA174 649138 N00CA203 649141 A299905N 649141 A299907N 649141 A299909N 649141 B189907N 649141 B189908N 649141 B199901N 649141 B199909N 649141 C159907N 649141 C159909N 649141 C179902N 649141 C179906N 649141 D179810N 649141 D189908N 649141 D209801N 649141 E199918N 649141 E199920N 649141 E199922N 649141 F029806N 649141 F049805N 649141 F209801N 649141 F209802N 649141 F209803N 649141 F209808N 649141 G319920N 649141 H139809N 649141 H139810N 649141 H139815N 649141 H259927N 649141 H259934N 649141 H269901N 649141 H269909N 649141 H269911N 649141 I029809N 649141 I039808N 649141 I039809N

REVISED

H/C KRP KRP KPK KPK KPK KPL KPL KPL KPL KPL KPK KPK KPL KOL KOL KOL KPL KPL KPL KOL KON KON KON KON KOL KRN KON KON KON KRN KRN KRN KRN KOL KOL KOL KOL

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 649141 I039811N 649141 I039812N 649141 I099923N 649141 I099925N 649141 I109907N 649141 J119919N 649141 J129908N 649141 J129916N 649141 J139902N 649141 J139909N 649141 J139920N 649141 J139922N 649141 K049904N 649141 K049912N 649141 K049915N 649141 L029815N 649141 L029816N 649141 L039807N 649141 L109812N 649141 N00CA199 649141 N209807N 649141 N249802N 649144 G159917N 649148 L139904N 649148 L139906N 649148 L139910N 649148 L139911N 649148 L139912N 649148 N00BA523 649895 A139902N 649895 A139905N 649895 A159902N 649895 A159903N 649895 A159904N 649895 A159905N 649895 A249808N 649895 B099906N 649895 B099909N 649895 B099912N

ISSUED

Part # Serial # 649895 B099918N 649895 B109901N 649895 B109903N 649895 B109917N 649895 B109918N 649895 B109922N 649895 B119904N 649895 B119905N 649895 B119906N 649895 B119907N 649895 B119908N 649895 B119910N 649895 B119916N 649895 B119917N 649895 D019901N 649895 D019908N 649895 D019909N 649895 D059902N 649895 D059903N 649895 D059907N 649895 D059909N 649895 D059911N 649895 D069901N 649895 D069902N 649895 D069904N 649895 D079903N 649895 F189908N 649895 I109811N 649895 I119811N 649895 I119812N 649895 J089810N 649895 J099801N 649895 J099804N 649895 J099808N 649895 J099811N 649895 J099815N 649895 J099816N 649895 J119801N 649895 J119804N

H/C KOL KOL KRN KRP KRP KRP KRN KRP KRN KRP KRP KRP KRP KRP KRP KPK KPK KPK KPK KRN KOL KOL KPM KRP KRP KRP KRP KRP KRP KPM KPM KOM KPM KOM KPM KPM KPM KPM KPM

H/C KPM KPM KPM KPM KPM KPM KPM KPM KPM KPM KPM KPM KPH KPM KPM KPM KPM KPM KPH KPM KPM KPH KPH KPM KPM KPM KRP KOM KOM KOM KOM KOM KOM KOM KOM KOM KOR KOM KOM

Part # Serial # 649895 J289802N 649895 J289803N 649895 J289806N 649895 J289808N 649895 J299809N 649895 J299813N 649895 J309803N 649895 J309807N 649895 J309808N 649895 J309809N 649895 J319801N 649895 J319804N 649895 J319805N 649895 K249801N 649895 K259803N 649895 K259805N 649895 K309802N 649895 L019803N 649895 L019805N 649895 L019806N 649895 L019808N 649895 L019809N 649895 L029801N 649895 L029802N 649895 L029806N 649895 L029809N 649896 A159901N 649896 B099908N 649896 B099911N 649896 B109905N 649896 B109908N 649896 B109910N 649896 B109914N 649896 B109916N 649896 D019904N 649896 D059901N 649896 D079902N 649896 G209816N 649896 J109802N

REVISED

H/C KOP KOP KOP KOP KOP KOP KOP KOP KOP KOP KOP KOP KOM KPM KPM KPM KPM KPM KPM KPM KPH KPM KPM KOM KPM KPM KOM KPM KPM KPM KPM KPM KPM KPH KPM KPM KPM KOR KOM

PAGE NO REVISION TM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 649896 J119803N 649896 J289804N 649896 J289805N 649896 K029801N 649896 K029803N 649896 K309804N 649896 K309809N 649896 L019802N 649898 A139915N 649898 A159912N 649898 A159913N 649898 A159915N 649898 A159919N 649898 A169901N 649898 A169904N 649898 A169911N 649898 A169915N 649898 A189903N 649898 A209910N 649898 A209912N 649898 A209913N 649898 A209914N 649898 B019907N 649898 B019909N 649898 B019913N 649898 B029901N 649898 B039901N 649898 B039903N 649898 B039904N 649898 B049901N 649898 B049903N 649898 B109907N 649898 B129901N 649898 B129902N 649898 B129903N 649898 B129904N 649898 B129905N 649898 B129909N 649898 B129911N

ISSUED

Part # Serial # 649898 B129912N 649898 B129914N 649898 B129916N 649898 C099901N 649898 C099902N 649898 C099903N 649898 C099904N 649898 C099905N 649898 C099906N 649898 C109901N 649898 C109903N 649898 C109904N 649898 C109905N 649898 C109906N 649898 C109908N 649898 C109910N 649898 C109911N 649898 C109916N 649898 C109917N 649898 C269908N 649898 C299902N 649898 C299903N 649898 C299904N 649898 C299905N 649898 D149909N 649898 D299908N 649898 D299909N 649898 D299912N 649898 D299914N 649898 D309905N 649898 E019903N 649898 E019905N 649898 E109908N 649898 E119907N 649898 E119908N 649898 E119912N 649898 E119915N 649898 I139813N 649898 I169813N

H/C KOM KOP KOP KOP KOP KOM KOM KPM KPM KPM KPH KPM KPM KOR KPM KOR KPM KPM KOR KOP KOR KOR KPH KPH KOR KPH KPH KPH KPH KPM KPM KPH KPM KPM KPM KPM KPM KPM KPM

H/C KPM KPM KPM KPM KPM KPH KPM KPM KPM KPM KPM KPM KPM KPM KPM KPM KPM KPH KPM KPH KPH KPH KPH KPH KPM KPM KPM KPH KPH KPM KPH KPH KPH KPH KPH KPH KPH KOM KOM

Part # Serial # 649898 I169815N 649898 K129803N 649898 K129807N 649898 K129810N 649898 K129811N 649898 K139804N 649898 K149801N 649898 K149803N 649898 K149805N 649898 K149806N 649898 K169802N 649898 K169808N 649898 K169810N 649898 K169814N 649898 K179804N 649898 K179809N 649898 K189804N 649898 K189811N 649898 K199801N 649898 L189808N 649900 B059909N 649900 C059915N 649900 C069904N 649900 C269904N 649900 C299909N 649900 C319903N 649900 C319907N 649900 C319909N 649900 D279901N 649900 D279905N 649900 D279906N 649900 I219816N 649900 I219820N 649900 J039809N 649900 J249808N 649900 K209803N 649900 K229803N 649900 K229807N 652004 N00CA556

REVISED

H/C KOM KOP KOP KOP KOP KOP KOM KOR KOM KOP KPM KOR KOR KOM KOM KOR KOM KOR KOR KOM KPM KOR KPH KPM KPH KPM KPM KPM KPK KPK KPK KOR KOP KOR KOR KOP KOR KPM KPH

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AFFECTED SERVICE SPARE CRANKSHAFTS (continued) BY CRANKSHAFTPART NUMBER, CRANKSHAFT SERIAL NUMBER AND HEAT CODE Part # Serial # 652004 N00CA560 652004 N00CA561 652004 N00CA565 652004 N00CA566 652004 N00CA567 652004 N00CA569 652004 N00CA574 652006 E079822N 652009 B199913N 652009 E079801N 652009 F259801N 652009 F259804N 652009 F289906N 652009 H259811N 652009 J159908N 652009 L169909N 652009 N00CA557 652009 N00CA559 652009 N00CA571 652009 N00CA576 652010 A030009N 652010 B199915N 652010 B209904N 652010 E069801N 652010 E069806N 652010 E069807N 652010 E069809N 652010 E079805N 652010 F259806N 652010 F289905N 652010 F289910N 652010 F289913N 652010 F289917N 652010 H029902N 652010 H029904N 652010 H249807N 652010 H249815N 652010 H249817N

ISSUED

Part # Serial # 652010 H249818N 652010 H259801N 652010 H259818N 652010 K049918N 652010 K049919N 652010 K059903N 652010 K059911N 652010 L089803N 652010 L089813N 652010 N00CA562 652010 N00CA570 652011 A030002N 652011 A030004N 652011 B189914N 652011 B209906N 652011 C189907N 652011 C189908N 652011 E069803N 652011 E069907N 652011 E079804N 652011 E079806N 652011 E079811N 652011 E079824N 652011 F289904N 652011 F289907N 652011 J189905N 652011 L089808N 652011 L089814N 652011 L239903N 652011 L239905N 652011 N00CA575 652039 A299908N 652039 F049803N 652039 F049804N 652039 I039804N 653129 I249803N 653129 I249804N 653129 I249810N

H/C KPH KPH KPH KPH KPH KPH KPH KOM KPH KOM KOM KOM KPH KOM KPH KPH KPH KPH KPH KPH KPH KPH KPH KOM KOM KOM KOM KOM KOM KPH KPH KPH KPH KPH KPH KON KON KOM

H/C KOM KOM KOM KPH KPH KPH KPH KPH KPH KPH KPH KPH KPH KPL KPH KPM KOM KOM KPH KOM KOM KOM KOM KPH KPH KPH KPH KPH KPH KPH KPH KPK KON KOL KOL KPC KPC KPC

Part # Serial # 653129 I259801N 653129 I309803N 653129 I309804N 653129 J019801N 653129 J019803N 653129 K069814N 653136 I239803N 653136 I239805N 653136 I239806N 653136 I239807N 653136 I239808N 653136 I239809N 653136 I239810N 653136 I239811N 653136 K059811N 653136 K079804N 653136 K079810N 653137 J029802N 653137 J029803N 653137 J029804N 653138 J259705N 653139 J029807N 653139 J059802N 653139 J059803N 653139 J059807N 653139 J059809N 653139 J059810N 653139 J059811N 653139 J059812N 653139 N00AA049 654432 A189909N 654432 A189912N 654432 C059909N 654432 I219808N 654432 I219817N 654432 I229804N 654432 K209804N 655382 I119907N

REVISED

H/C KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KPC KOR KPC KPC KPC KPC KPC KPC KPC KPC KPC KPM KPM KOR KOR KOR KOM KOP KRN

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SECTION 4 AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # A030002N A030004N A030009N A050002N A050009N A050011N A139902N A139905N A139915N A159901N A159902N A159903N A159904N A159905N A159912N A159913N A159915N A159919N A169901N A169904N A169911N A169915N A189903N A189909N A189912N A209910N A209912N A209913N A209914N A219916N A229902N A229903N A229913N A249808N A259908N A259916N A279902N A279903N A289905N A289913N A299905N A299907N

SERIAL # A299908N A299909N A309905N A309907N B019907N B019909N B019913N B029901N B039901N B039903N B039904N B049901N B049903N B059909N B099906N B099908N B099909N B099911N B099912N B099918N B109901N B109903N B109905N B109907N B109908N B109910N B109914N B109916N B109917N B109918N B109922N B119903N B119904N B119905N B119906N B119907N B119908N B119910N B119916N B119917N B129901N B129902N

PART # H/C 652011 KPH 652011 KPH 652010 KPH 646623 KRN 646623 KRN 646623 KRN 649895 KPM 649895 KPM 649898 KPM 649896 KOM 649895 KOM 649895 KPM 649895 KOM 649895 KPM 649898 KPM 649898 KPH 649898 KPM 649898 KPM 649898 KOR 649898 KPM 649898 KOR 649898 KPM 649898 KPM 654432 KPM 654432 KPM 649898 KOR 649898 KOP 649898 KOR 649898 KOR 649134 KPK 649134 KPK 649134 KPK 649134 KPK 649895 KPM 649134 KPK 649134 KPK 649134 KPK 649134 KPK 649138 KPK 649138 KPL 649141 KPK 649141 KPK

ISSUED

PART # H/C 652039 KPK 649141 KPK 646623 KPL 646623 KPL 649898 KPH 649898 KPH 649898 KOR 649898 KPH 649898 KPH 649898 KPH 649898 KPH 649898 KPM 649898 KPM 649900 KPM 649895 KPM 649896 KPM 649895 KPM 649896 KPM 649895 KPM 649895 KPM 649895 KPM 649895 KPM 649896 KPM 649898 KPH 649896 KPM 649896 KPM 649896 KPM 649896 KPH 649895 KPM 649895 KPM 649895 KPM 649134 KPL 649895 KPM 649895 KPM 649895 KPM 649895 KPM 649895 KPM 649895 KPM 649895 KPH 649895 KPM 649898 KPM 649898 KPM

SERIAL # B129903N B129904N B129905N B129909N B129911N B129912N B129914N B129916N B179902N B179903N B179904N B179909N B179910N B179913N B179913N B179914N B179917N B179918N B189901N B189907N B189908N B189910N B189914N B199901N B199905N B199909N B199913N B199915N B209904N B209906N C059909N C059915N C069904N C099901N C099902N C099903N C099904N C099905N C099906N C109901N C109903N C109904N

REVISED

PART # H/C 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649134 KPL 649134 KOL 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649134 KOL 649134 KPK 649131 KPK 649134 KPL 649134 KPL 649141 KPL 649141 KPL 649138 KPL 652011 KPL 649141 KPL 649138 KPL 649141 KPL 652009 KPH 652010 KPH 652010 KPH 652011 KPH 654432 KOR 649900 KOR 649900 KPH 649898 KPM 649898 KPM 649898 KPH 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # C109905N C109906N C109908N C109910N C109911N C109916N C109917N C119914N C119917N C129902N C129905N C129906N C129907N C129909N C129913N C129915N C139904N C139905N C139906N C139909N C139910N C139911N C149901N C149903N C149906N C149913N C159907N C159909N C169902N C179902N C179906N C189907N C189908N C269904N C269908N C299902N C299903N C299904N C299905N C299909N C319903N

SERIAL # C319907N C319909N D019901N D019904N D019908N D019909N D059901N D059902N D059903N D059907N D059909N D059911N D069901N D069902N D069904N D079902N D079903N D089903N D099901N D109904N D109909N D149909N D156818N D169818N D179810N D179905N D179910N D179912N D189905N D189908N D199903N D199906N D209801N D209804N D209807N D209809N D209810N D209811N D229801N D229802N D229803N

PART # H/C 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPM 649898 KPH 649898 KPM 649134 KPK 649134 KPK 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649134 KPK 649134 KPL 649134 KPL 649134 KPK 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649138 KPK 649138 KPK 649138 KPK 649134 KPL 649141 KPL 649141 KPK 649138 KPL 649141 KPK 649141 KPL 652011 KPM 652011 KOM 649900 KPM 649898 KPH 649898 KPH 649898 KPH 649898 KPH 649898 KPH 649900 KPH 649900 KPM

ISSUED

PART # H/C 649900 KPM 649900 KPM 649895 KPM 649896 KPM 649895 KPM 649895 KPM 649896 KPM 649895 KPM 649895 KPH 649895 KPM 649895 KPM 649895 KPH 649895 KPH 649895 KPM 649895 KPM 649896 KPM 649895 KPM 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649898 KPM 649138 KOL 649138 KOL 649141 KOL 646623 KPK 646623 KPK 646623 KPK 646623 KPK 649141 KOL 646623 KPK 646623 KPL 649141 KOL 649138 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL

SERIAL # D229806N D229808N D229809N D229810N D229811N D229812N D229813N D229814N D229815N D229817N D229819N D229821N D229822N D239801N D239802N D239803N D239807N D239811N D239812N D239813N D239814N D239815N D239816N D239817N D239818N D239819N D239821N D239822N D239823N D239824N D239901N D239902N D239903N D239904N D239906N D239909N D239910N D239911N D249801N D249802N D249803N

REVISED

PART # H/C 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 646623 KOL 649133 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649133 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KPL 649134 KPL 649134 KPL 649134 KPM 649134 KPL 649134 KPM 649134 KPL 649134 KPL 649134 KOL 649134 KOL 649134 KOL

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # D249804N D249805N D249806N D249812N D249902N D249903N D249905N D249908N D249910N D249911N D249914N D249915N D249916N D249917N D249918N D269901N D269903N D269904N D269907N D269909N D269910N D269911N D269912N D269913N D269914N D269915N D269916N D269918N D279811N D279901N D279905N D279906N D299908N D299909N D299912N D299914N D309905N E019903N E019905N E039907N E039909N

SERIAL # E039911N E049901N E049902N E049906N E059908N E059914N E059916N E069801N E069803N E069806N E069807N E069809N E069902N E069907N E079801N E079804N E079805N E079806N E079811N E079822N E079824N E109908N E119907N E119908N E119912N E119915N E189913N E189923N E189927N E199902N E199903N E199905N E199918N E199920N E199922N E199924N F029806N F039818N F049803N F049804N F049805N

PART # H/C 649134 KOL 649134 KOL 649134 KOL 646623 KOL 649134 KPM 649134 KPL 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPL 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPL 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 646623 KOL 649900 KPK 649900 KPK 649900 KPK 649898 KPM 649898 KPM 649898 KPH 649898 KPH 649898 KPM 649898 KPH 649898 KPH 649134 KPM 649134 KPL

ISSUED

PART # H/C 649134 KPL 649134 KPM 649134 KPM 649134 KPL 649134 KPL 649134 KPL 649134 KPM 652010 KOM 652011 KOM 652010 KOM 652010 KOM 652010 KOM 649134 KPM 652011 KPH 652009 KOM 652011 KOM 652010 KOM 652011 KOM 652011 KOM 652006 KOM 652011 KOM 649898 KPH 649898 KPH 649898 KPH 649898 KPH 649898 KPH 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649134 KPL 649141 KPL 649141 KPL 649141 KPL 649138 KPL 649141 KOL 649138 KOL 652039 KON 652039 KOL 649141 KON

SERIAL # F059802N F089811N F109804N F109811N F109813N F109818N F119801N F119802N F119803N F119807N F119809N F119810N F119811N F119812N F129801N F129804N F129805N F129807N F129808N F129810N F129811N F129812N F159803N F159805N F159807N F159809N F159812N F169802N F169803N F169814N F179801N F179802N F179809N F179812N F179815N F189803N F189908N F199801N F209801N F209802N F209803N

REVISED

PART # H/C 649134 KOL 649134 KOL 649134 KON 649134 KON 649135 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KON 649134 KOL 649134 KON 649134 KOL 649134 KOL 649134 KOL 649134 KON 649134 KOL 649134 KOL 649134 KOL 649134 KON 649134 KON 649134 KOL 649134 KON 649134 KOL 649134 KON 649134 KOL 649134 KON 649134 KOL 649134 KON 649134 KON 649134 KON 649895 KRP 649134 KON 649141 KON 649141 KON 649141 KON

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE

SERIAL # F209808N F229919N F239805N F239807N F259801N F259804N F259806N F269911N F269912N F269915N F269916N F289904N F289905N F289906N F289907N F289910N F289913N F289917N G099930N G149909N G149910N G149911N G149912N G149913N G149916N G159901N G159905N G159906N G159917N G169908N G169909N G169913N G209816N G229809N G239807N G239808N G269902N G269905N G269911N G269924N

SERIAL # G279902N G279903N G279904N G279906N G279907N G279908N G279910N G279911N G279915N G279916N G279917N G279918N G279922N G289901N G289902N G289905N G289906N G289907N G289909N G289912N G289917N G289918N G289919N G289920N G289921N G289922N G289923N G289924N G289925N G289926N G289927N G289928N G289929N G289930N G299902N G299903N G299905N G299907N G299908N G299909N

PART # H/C 649141 KOL 649134 KRN 649138 KOL 649134 KOL 652009 KOM 652009 KOM 652010 KOM 649134 KPL 649134 KPL 649134 KPM 649134 KPL 652011 KPH 652010 KPH 652009 KPH 652011 KPH 652010 KPH 652010 KPH 652010 KPH 649134 KRN 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649134 KPM 649144 KPM 646623 KRN 646623 KRN 646623 KRN 649896 KOR 646623 KOL 646623 KOL 646623 KOL 649134 KRN 649134 KRN 649133 KRN 649134 KRN

ISSUED

PART # 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134 649134

H/C KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN KRN

SERIAL # G299922N G299923N G299925N G299926N G309902N G309903N G309904N G309907N G309909N G309911N G309913N G309915N G309917N G309918N G309919N G319920N H029902N H029904N H029908N H039802N H049804N H049810N H049814N H049815N H049816N H059804N H059809N H069812N H098808N H099818N H099819N H109803N H109804N H119809N H119811N H139809N H139810N H139815N H149804N H199907N

REVISED

PART # H/C 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649135 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649135 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649141 KRN 652010 KPH 652010 KPH 649135 KRP 649135 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KON 649134 KOL 649134 KON 649134 KON 649134 KOL 649134 KOL 649141 KON 649141 KON 649141 KON 649138 KON 646623 KRN

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # H199908N H199909N H199910N H199911N H199912N H199913N H199914N H199915N H199917N H199918N H199919N H199920N H209906N H209908N H209910N H209917N H209918N H209923N H209924N H209925N H209926N H239902N H239903N H239904N H239906N H239907N H239909N H239910N H239911N H239912N H239913N H239914N H239915N H239916N H239917N H249807N H249815N H249817N H249818N H249901N H249902N

SERIAL # H249903N H249904N H249908N H249909N H249910N H249913N H249914N H249915N H249916N H249917N H249918N H249920N H249921N H249922N H249923N H259801N H259811N H259818N H259901N H259902N H259903N H259904N H259907N H259908N H259910N H259912N H259913N H259914N H259915N H259916N H259917N H259918N H259919N H259920N H259921N H259923N H259924N H259926N H259927N H259934N H269901N

PART # H/C 646623 KRN 646623 KRN 646623 KRN 646623 KRN 646623 KRN 646623 KRN 646632 KRN 646623 KRN 646623 KRN 646623 KRN 646623 KRN 646623 KRN 649134 KRN 649134 KRP 649134 KRP 649134 KRP 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRP 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRP 649134 KRN 652010 KON 652010 KON 652010 KOM 652010 KOM 649134 KRN 649134 KRN

ISSUED

PART # H/C 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 652010 KOM 652009 KOM 652010 KOM 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649141 KRN 649141 KRN 649141 KRN

SERIAL # H269909N H269911N H289800N H289802N H319808N H319810N H319815N I019801N I019802N I019805N I029801N I029804N I029805N I029809N I039804N I039808N I039809N I039811N I039812N I039904N I039907N I039910N I039916N I039917N I039918N I039920N I079903N I079905N I079907N I079912N I079913N I079914N I079917N I079919N I079920N I079921N I079926N I079928N I079929N I089901N I089904N

REVISED

PART # H/C 649141 KRN 649141 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649141 KOL 652039 KOL 649141 KOL 649141 KOL 649141 KOL 649141 KOL 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRN 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRN 649134 KRP 649134 KRP

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # I089907N I089908N I089909N I089911N I089912N I089913N I089914N I089915N I089916N I089917N I089919N I089921N I089928N I089929N I099903N I099904N I099910N I099915N I099916N I099923N I099925N I109811N I109907N I119811N I119812N I119907N I139813N I169813N I169815N I219808N I219816N I219817N I219820N I229804N I239803N I239805N I239806N I239807N I239808N I239809N I239810N

SERIAL # PART # H/C I239811N 653136 KPC I249803N 653129 KPC I249804N 653129 KPC I249810N 653129 KPC I259801N 653129 KPC I309803N 653129 KPC I309804N 653129 KPC J019801N 653129 KPC J019803N 653129 KPC J019905N 646623 KRN J019908N 646623 KRP J019923N 646623 KRP J019924N 646623 KRN J029802N 653137 KPC J029803N 653137 KPC J029804N 653137 KPC J029807N 653139 KPC J039809N 649900 KOR J049903N 646623 KRN J049904N 646623 KRN J049907N 646623 KRP J049913N 646623 KRP J059802N 653139 KPC J059803N 653139 KPC J059807N 653139 KPC J059809N 653139 KPC J059810N 653139 KPC J059811N 653139 KPC J059812N 653139 KPC J059903N 649134 KRP J059905N 649134 KRP J059907N 649134 KRP J059909N 649134 KRP J059911N 649134 KRP J059914N 649134 KRP J059915N 649134 KRP J059919N 649134 KRP J059920N 649134 KRP J059922N 649134 KRP J059923N 649134 KRP J059924N 649134 KRP

PART # H/C 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRN 649134 KRP 649141 KRN 649141 KRP 649895 KOM 649141 KRP 649895 KOM 649895 KOM 655382 KRN 649898 KOM 649898 KOM 649898 KOM 654432 KOR 649900 KOR 654432 KOR 649900 KOP 654432 KOM 653136 KPC 653136 KPC 653136 KPC 653136 KPC 653136 KPC 653136 KPC 653136 KPC

ISSUED

SERIAL # PART # H/C J069901N 649134 KRP J069902N 649134 KRP J069914N 649134 KRP J069916N 649134 KRP J079904N 649134 KRP J079909N 649134 KRP J079912N 649134 KRP J079913N 649134 KRP J079914N 649134 KRP J079917N 649134 KRP J089810N 649895 KOM J089902N 649134 KRP J089914N 649134 KRN J089919N 649134 KRP J089920N 649134 KRP J089923N 649134 KRP J089926N 649134 KRP J099801N 649895 KOM J099804N 649895 KOM J099808N 649895 KOM J099811N 649895 KOM J099815N 649895 KOM J099816N 649895 KOR J109802N 649896 KOM J119801N 649895 KOM J119803N 649896 KOM J119804N 649895 KOM J119901N 649134 KRP J119910N 649138 KRP J119912N 649138 KRN J119919N 649141 KRP J129901N 649138 KRN J129903N 649138 KRP J129908N 649141 KRN J129916N 649141 KRP J139902N 649141 KRN J139909N 649141 KRP J139920N 649141 KRP J139922N 649141 KRP J149904N 649138 KRP J159908N 652009 KPH

REVISED

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # J189905N J249808N J259705N J289802N J289803N J289804N J289805N J289806N J289808N J299809N J299813N J309803N J309807N J309808N J309809N J319801N J319804N J319805N K019901N K019906N K019908N K019910N K019915N K019920N K019923N K029801N K029803N K029901N K029902N K029906N K029912N K039905N K049904N K049912N K049915N K049918N K049919N K059811N K059903N K059911N K069814N

SERIAL # K079804N K079810N K129803N K129807N K129810N K129811N K139804N K149801N K149803N K149805N K149806N K169802N K169808N K169810N K169814N K179804N K179809N K189804N K189811N K199801N K209803N K209804N K229803N K229807N K249801N K259803N K259805N K309802N K309804N K309809N L019802N L019803N L019805N L019806N L019808N L019809N L029801N L029802N L029806N L029809N L029815N

PART # H/C 652011 KPH 649900 KOR 653138 KOR 649895 KOP 649895 KOP 649896 KOP 649896 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOP 649895 KOM 649135 KRN 649135 KRN 649134 KRN 649134 KRP 649134 KRP 649134 KRN 649134 KRP 649896 KOP 649896 KOP 649134 KRP 649134 KRP 649134 KRN 649133 KRP 649134 KRN 649141 KRP 649141 KRP 649141 KRP 652010 KPH 652010 KPH 653136 KPC 652010 KPH 652010 KPH 653129 KPC

ISSUED

PART # H/C 653136 KPC 653136 KPC 649898 KOP 649898 KOP 649898 KOP 649898 KOP 649898 KOP 649898 KOM 649898 KOR 649898 KOM 649898 KOP 649898 KPM 649898 KOR 649898 KOR 649898 KOM 649898 KOM 649898 KOR 649898 KOM 649898 KOR 649898 KOR 649900 KOP 654432 KOP 649900 KOR 649900 KPM 649895 KPM 649895 KPM 649895 KPM 649895 KPM 649896 KOM 649896 KOM 649896 KPM 649895 KPM 649895 KPM 649895 KPM 649895 KPH 649895 KPM 649895 KPM 649895 KOM 649895 KPM 649895 KPM 649141 KPK

SERIAL # L029816N L029904N L029912N L029913N L039807N L039816N L039817N L039903N L039907N L039909N L049803N L059809N L069806N L069808N L079802N L079902N L079904N L079908N L079911N L089803N L089808N L089813N L089814N L089901N L089902N L089903N L099909N L099911N L099913N L099917N L109812N L139904N L139906N L139910N L139911N L139912N L169909N L189808N L239903N L239905N N00AA049

REVISED

PART # H/C 649141 KPK 649134 KRN 649134 KRN 649134 KRN 649141 KPK 649134 KPK 649134 KPK 649134 KRN 649134 KRN 649134 KRN 649134 KPK 649134 KOL 649134 KOL 649134 KOL 649134 KOL 649134 KRN 649133 KRN 649134 KRP 649134 KRN 652010 KPH 652011 KPH 652010 KPH 652011 KPH 649134 KRP 649135 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649141 KPK 649148 KRP 649148 KRP 649148 KRP 649148 KRP 649148 KRP 652009 KPH 649898 KOM 652011 KPH 652011 KPH 653139 KPC

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AFFECTED SERVICE SPARE CRANKSHAFTS BY CRANKSHAFT SERIAL NUMBER, CRANKSHAFT PART NUMBER AND HEAT CODE SERIAL # N00AA189 N00AA190 N00AA192 N00AA193 N00AA195 N00BA523 N00CA093 N00CA144 N00CA173 N00CA174 N00CA199 N00CA203 N00CA212 N00CA218 N00CA219 N00CA225 N00CA324 N00CA340 N00CA342 N00CA344 N00CA345 N00CA352 N00CA353 N00CA354 N00CA355 N00CA358 N00CA363 N00CA377 N00CA381 N00CA556 N00CA557 N00CA559 N00CA560 N00CA561 N00CA562 N00CA565 N00CA566 N00CA567 N00CA569

SERIAL # N00CA570 N00CA571 N00CA574 N00CA575 N00CA576 N00CA586 N00CA589 N00CA590 N00CA591 N209807N N249802N N00CA574 N00CA575 N00CA576 N00CA586 N00CA589 N00CA590 N00CA591 N209807N N249802N

PART # H/C 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649148 KRP 649134 KRP 649134 KRP 649138 KRN 649138 KRP 649141 KRN 649138 KRP 646623 KRP 646623 KRP 646623 KRP 646623 KRP 649134 KRP 649131 KRP 649131 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649134 KRP 649131 KRP 649134 KRP 649134 KRP 652004 KPH 652009 KPH 652009 KPH 652004 KPH 652004 KPH 652010 KPH 652004 KPH 652004 KPH 652004 KPH 652004 KPH

ISSUED

PART # H/C 652010 KPH 652009 KPH 652004 KPH 652011 KPH 652009 KPH 643687 KRN 643687 KRN 643687 KRN 643687 KRN 649141 KOL 649141 KOL 652004 KPH 652011 KPH 652009 KPH 643687 KRN 643687 KRN 643687 KRN 643687 KRN 649141 KOL 649141 KOL

REVISED

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SECTION 5

A.

GENERAL INFORMATION:

Teledyne Continental Motors will provide the following specialized tools and equipment required to perform the procedure detailed in this service bulletin: MSB 00-5 Tool Kit Contents 1 each-Crankshaft Boring Tool & Adapter 1 each Instructional Video 1 each-Positive Stop Depth Rod 1 each .025 Feeler Gage 1 each-End Mill 2 each-Coring Bit (Rotobroach) 1 each-De-burring Tool (1 spare blade) 20 each-Core Sample Bags and Labels. One crankshaft (2) core samples per bag.

1. 2. 3. 4. 5. 6. 7. 8.

1. Zinc Chromate Primer- non aerosol 2. Acid brushes or cotton swabs 3. LPS-1 Spray Lubricant- non-silicon/nonTeflon based. 4. Dye Check Kit 5. Dial Type Torque Wrench; 0-200 inch lbs. 6. Spark plug gaskets. 7. Propeller hub O-ring. WARNING Do not use silicon or Teflon based coolants or lubricants during any part of this procedure. Silicon and/or Teflon based products will affect the reliability of the dye check procedure.

PRE-CORING PROCEDURE:

Verify that engine model and serial number, or replacement crankshaft serial number, is listed as affected by this service bulletin. Service spare crankshafts affected by this service bulletin which have not been installed in an engine must be inspected prior to being installed. ISSUED

1. Remove engine cowling to gain access to the upper spark plugs and propeller mounting hardware. Remove upper spark plug ignition leads and spark plugs. 2. Remove propeller spinner, spinner bulkhead and propeller. If the aircraft is equipped with propeller de-ice or anti-ice, follow the aircraft manufacturer’s instructions for removal of this equipment, if required for propeller removal. 3. Using a clean shop towel, clean the propeller flange.

The following supplies must be obtained locally.

B.

Affected engines installed in aircraft must be inspected within the next 10 hours of operation. For engines installed in aircraft proceed as follows. In accordance with the aircraft manufacturer’s maintenance manual:

4. Record engine model and serial number, crankshaft serial number and total engine time on shop repair work order and on the labels provided by TCM. C.

MOUNTING TOOLING:

Before installing the crankshaft boring tool and crankshaft flange adapter, insure that the adapter face and counter bore are clean and free of any debris. Insure that the mounting studs are secure in the propeller flange adapter mounting plate. 1. Plug the crankshaft opening with a clean shop towel to prevent any debris from entering the crankshaft oil transfer area. 2. Using a piece of plastic, fabricate a protective cover for the engine and nacelle area. In the approximate center of the piece of plastic, cut a slit 6 inches long. Slip the crankshaft propeller flange through the slit, drape the upper part of the plastic over the top of the engine and drape

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plate does not contact any portion of the engine surrounding the propeller flange or the aircraft cowling.

the lower part in such a manner that the plastic protects the lower portion of the engine and the nacelle area.

7. Position the boring tool propeller flange adapter plate mounting studs to align with selected propeller flange holes and slide the adapter studs through the propeller flange holes. Secure the coring tool flange to the propeller flange with the two nuts provided with the tooling. Tighten nuts to 150 inch lbs. FIGURE 1 PROTECTIVE PLASTIC COVER 3. Place a drip pan under the plastic to catch cooling/lubricating fluid and metal shavings.

8. The red mark made on the propeller flange must be visible through the boring tool adapter plate hole. If the red mark is not visible, remove the boring tool from the propeller flange and repeat the above steps 5,6 and 7.

4. On the propeller flange, identify, and using a red magic marker, mark the location from which the core samples will be taken. See Figure 2. 5. Locate the two crankshaft flange holes that will be used to mount the adapter and boring tool. See Figure 2.

MARK CORE SAMPLE LOCATION WITH RED MARKER

ADAPTER STUD MOUNT HOLE

FIGURE 3 VERIFICATION OF CORING SAMPLE LOCATION & TOOL ALIGNMENT D.

REMOVAL OF NITRIDE LAYER:

Removal of the nitride layer from the forward face of the crankshaft flange will require spot facing an area .025 inches deep for each core sample. To remove the nitride layer proceed as follows:

ADAPTER STUD MOUNT HOLE

FIGURE 2 FLANGE CORE SAMPLE AREA MARKED 6. Rotate the crankshaft so that the crankshaft flange holes to be used to mount the adapter plate and boring tool (identified in step 4) are positioned so that, when installed, the adapter ISSUED

1. With the boring tool and adapter plate correctly positioned and mounted, install the end mill provided with the tool kit into the boring chuck. Insure that the flats machined on the shank of the end mill align with the allen set screw in the chuck. Tighten the set

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screws with the allen wrench provided in the tool kit. See FIGURES 4 and 5.

5. To set the correct depth of the spot face, position a .025 feeler gage so that it is captured between the mounting adapter surface and the end on the positive stop rod as the rod is moved forward. Lock the positive stop rod in place using the thumb screw or set screw on top of the rod adapter. See Figure 6. .025 FEELER GAGE

FIGURE 4 END MILL FOR SPOT FACING PROPELLER FLANGE FRONT FACE

THUMB SCREW OR SET SCREW

POSITIVE STOP ROD

FIGURE 6 POSITIVE STOP ROD SET-UP FOR .025 SPOT FACE 6. Back the end mill away from the front surface of the propeller flange and remove the feeler gage. CAUTION Eye protection must be worn during the machining processes. Steel shavings will be made during this procedure. FIGURE 5 INSTALLING END MILL 2. Install a dial type inch pound torque wrench into the square drive on the side of the boring tool. Ensure that the range of motion is sufficient to allow the end mill to contact the work. 3. Install the positive stop rod provided into the holder mounted on the top of the boring tool motor. 4. Advance the end mill toward the front face of the crankshaft flange until the end mill contacts the flange. ISSUED

7. Turn the boring tool on using the switch provided on the tool. 8. Slowly advance the end mill toward the front face of the crankshaft flange by applying pressure to the handle of the dial type torque wrench. 9. Spray generous amounts of coolant/lubrication (LPS-1) onto the work and end mill during the spot facing operation. 10. Maintain a constant pressure on the torque wrench during the spot facing operation, but do not exceed 110 inch lbs. See Figure 7.

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1. Mount the coring rotobroach into the boring tool chuck. Ensure that the rotobroach is positioned so that a portion of the set screw flat protrudes from the end of the chuck. Secure the rotobroach by tightening the allen set screw in the chuck. See FIGURE 5 and 8.

FIGURE 7 USING TORQUE WRENCH TO MAINTAIN CONSISTENT FEED RATE 11. Spot face the front face of the propeller flange until the positive stop rod contacts the adapter plate surface. Additionally, as the nitrided surface is penetrated an audible sound change will occur and the feed rate of the end mill will increase as the end mill cuts into the non-nitrided steel. 12. Back the end mill away from the propeller flange front face and turn OFF the boring tool. 13. Loosen the thumb screw or set screw securing the positive stop rod in place and sliding the rod aft remove it from the holder. 14. Remove the end mill from the boring tool chuck. Clean the machining debris from the boring tool and adapter flange. E. PROPELLER FLANGE SAMPLE PROCEDURE:

CORING

With the boring tool and adapter plate mounted to the propeller flange, proceed as follows:

ISSUED

FIGURE 8 ROTOBROACH CORING BIT 2. Ensure that the torque wrench has sufficient travel for the rotobroach to drill through the propeller flange. 3. Turn the boring tool on and advance the rotobroach toward the propeller flange by applying pressure to the handle of the torque wrench. Spray generous amounts of coolant/lubricant (LPS-1) onto the propeller flange and rotobroach as it contacts and bores into the propeller flange. 4. Apply consistent pressure of 100 to 110 inch lbs. to the torque wrench to control boring tool feed rate pressure during the initial stages of the coring operation. Apply generous amounts of coolant/lubricant (LPS-1) to the work surface and rotobroach throughout the machining operation. Occasionally back the rotobroach away form the work surface to clear the cutting flutes of machining debris. See Figure 9.

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5. As the rotobroach contacts the nitrided back wall of the propeller flange, the feed rate will decrease. It may be necessary to increase the feed rate pressure to 140 to 180 inch lbs. Do not apply more than 200 inch lbs. of force to the rotobroach. If the rotobroach stops cutting, install new rotobroach and continue coring operation.

10. Supporting the boring tool and propeller flange adapter plate loosen and remove the two nuts on the aft side of the propeller flange that secured the boring tool and adapter plate to the propeller flange. 11. Remove the boring tool and adapter plate from the propeller flange.

NOTE: Rotobroach will require replacement after coring 2 to 3 crankshafts. Tool life is dependent on maintaining the proper feed rate pressure and providing a continuous and generous flow of lubricant/coolant (LPS-1) during the coring operation.

FIGURE 10 PROPELLER FLANGE CORE SAMPLES (One crankshaft set (2) per sample bag) 12. Clean the machining debris from the boring tool adapter plate and from the propeller flange. FIGURE 9 ROTOBROACH TAKING CORE SAMPLE

13. Position the boring tool and adapter plate 180 degrees from its previous position to machine the second core sample.

6. Once the rotobroach has cut through the back wall of the propeller flange, release the pressure on the torque wrench and pull the rotobroach out of the machined hole in the propeller flange and clear of the boring tool adapter plate.

14. Mount and seat the boring tool and adapter plate onto the propeller flange and secure in place by installing the two nuts onto the studs protruding from the back side of the propeller flange.

7. Loosen the allen set screw and remove the rotobroach and propeller flange core sample from the boring tool chuck.

15. Ensure that the red mark identifying the desired machining area of the propeller flange is visible through the adapter plate boring hole. See FIGURE 3.

8. Remove the core sample from the rotobroach and place it in the self sealing plastic bag provided. See Figure 10.

16. To obtain the second propeller flange core sample repeat PART D steps 1 through 14 and PART E steps 1 through 12.

9. Fill out the label on the front of the selfsealing plastic bag in its entirety.

ISSUED

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F. CLEANING AND CHAMFERING CORE SAMPLE HOLES: After removing the boring tool and adapter plate from the propeller flange, clean and chamfer the core sample hole as follows: 1. Ensure that the front and aft face of the propeller flange is clean and free of any machining debris.

FIGURE 12 CORE SAMPLE HOLE AFTER CHAMFERING 4. Using 180 crocus cloth or emery paper polish the core sample hole I.D. 5. Clean the core sample holes and propeller flange using a lint free shop towel dampened with Acetone.

FIGURE 11 CHAMFERING CORE SAMPLE HOLE NOTE: The chamfering tool has a spring loaded cutting blade. To chamfer the aft side of the core sample hole, apply enough pressure to the chamfering tool to cause the blade to retract sufficiently to allow the tool to pass through the core sample hole.

6. Measure edge distance of core sample hole to propeller flange O.D. Minimum edge distance is .080 inches. If edge distance is less than .080 inches, contact TCM at 1-334438-3411 for removal and replacement of crankshaft.

2. Using the chamfering tool provided in the tool kit, chamfer the core sample hole I.D. on the front and aft faces of the propeller flange. See Figure 11. 3. Apply a light even pressure to the tool during the chamfering process.

MINIMUM EDGE DISTANCE .080 INCHES

FIGURE 13 CORE SAMPLE HOLE MINIMUM EDGE DISTANCE 7. Visually inspect core sample holes for sharp edges and burrs. Remove any sharp edges or burrs prior to proceeding. See Figure 12.

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G. DYE CHECK HOLES:

OF

CORE

to cure completely prior to installation of the propeller. See Figure 14.

SAMPLE

In accordance with ASTM E 1417 perform a complete Dye Check Inspection of the core sample holes and the adjacent front and aft flange surfaces ¼ inches around the holes. 1. Brush red visible dye check penetrant in the core sample holes and the surrounding area on the front and aft flange faces. 2. Brush red visible dye check penetrant in the core sample holes and the surrounding area on the front and aft flange faces. FIGURE 14 CORE SAMPLE HOLE AFTER APPLICATION OF ZINC CHROMATE PRIMER

3. Allow penetrant to dwell for a minimum of 20 minutes. 4. Clean off residual penetrant with a clean lint free shop towel dampened with penetrant remover. 5. Apply removable dye check developer by spraying a light, uniform coating to cover the core sample hole I.D. and the surrounding area. 6. Allow developer to dwell for 15 minutes. 7. Visually inspect affected area surrounding the core sample holes on the front and aft face of the propeller flange for crack indications. If no crack indications are noted, proceed to Part H. 8. If crack indications are noted, contact Teledyne Continental Motors Service Representative at 1-888-200-7565. H. PAINTING CORE SAMPLE HOLES: 1. Clean all dye check residue from the core sample holes and surrounding area with penetrant remover or acetone. 2. Using an acid brush or cotton swab, apply zinc chromate primer to core sample holes and chamfered areas on the front and aft faces of propeller flange. Allow the primer ISSUED

I.

MAILING SAMPLE:

Ensure that the label on the plastic bag containing the core samples is completed in its entirety. Place plastic core sample bag in an overnight envelope and mail to: Teledyne Continental Motors 2039 Broad Street Mobile, Alabama 36615 ATTN: MSB 00-5 J. RETURNING AIRCRAFT AND ENGINE TO SERVICE: In accordance with the aircraft manufacturer’s maintenance manual and Teledyne Continental Motors engine maintenance manual or overhaul manual perform the following: 1. Remove protective plastic covering from around the crankshaft propeller flange and engine. 2. Remove the shop towel or other protective device that was used to protect the interior of

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the crankshaft during the sample coring process. 3. Insure that propeller flange is clean and free of any debris that would interfere with correct seating and installation of the aircraft propeller. 4. In accordance with the aircraft manufacturer’s maintenance manual install propeller, propeller spinner bulkhead and spinner. Torque attaching hardware to values specified in the aircraft manufacturer’s maintenance manual. 5. Install upper sparkplugs using new gaskets and torque to 300 to 360 inch lbs. 6. Install ignition leads and torque “B” nuts to 110-120 inch lbs. 7. Install engine cowling. 8. Perform a complete engine ground run up in accordance with the aircraft manufacturer’s maintenance manual.

K. WARRANTY The labor and material required to comply with this service bulletin will be covered by Teledyne Continental Motors New, Rebuilt or Gold Medallion Warranty policy as applicable to the affected engine. Labor hours approved to comply with this service bulletin will not exceed 3 ½ manhours per affected engine. Reimbursement for compliance with the inspection specified in this service bulletin will be processed using the “Crankshaft Material Inspection Reimbursement Form” on the last page of the service bulletin. To ensure prompt processing of you reimbursement, complete the form in its entirety and attach a copy of the repair work order and customer invoice. Mail reimbursement form to: Teledyne Continental Motors 2039 Broad Street

Teledyne Continental Motors will notify the FBO via Internet e-mail, FAX or telephone upon completing the testing on the core samples. Evaluation of core samples should be completed in 24 to 48 hours after the samples are received by Teledyne Continental Motors.

Mobile, Alabama 36615

Engines with crankshaft core samples meeting the acceptance criteria may be returned to service. Teledyne Continental Motors will provide a logbook attachment indicating the core samples from the specified engine are acceptable and that the engine may be returned to service.

1. Removing and reinstalling engine. Non- turbocharged : 29 manhours Tubrocharged: 36 manhours

Make an engine logbook entry compliance with TCM MSB 00-5.

stating

Make an aircraft logbook entry referring to removal and installation of the propeller, propeller spinner and spinner bulkhead to facilitate compliance with TCM MSB 00-5.

ATTN: WARRANTY ADMINISTRATION If crankshaft replacement is required, the following labor allowances will apply:

If field replacement of the crankshaft is authorized by Teledyne Continental Motors, the following labor allowances will apply: 1. Engine disassembly to facilitate crankshaft replacement only and reassembly after replacement crankshaft installation: Non-turbocharged: 35 manhours Turbocharged: 37 manhours NOTE: Claims submitted that include labor and material charges not related to crankshaft replacement will be denied and returned to the submitter. Do not separate pistons from

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cylinders, Remove cylinder sufficiently to remove the piston pin only. If a varnish layer has formed on the piston pin between the piston pin bosses and the connecting rod bushing, lightly spray the effected area with carburetor cleaner to soften the varnish and aid in piston pin removal. Do not use tools that may damage the aluminum end plugs of the piston pin. Engine test run after crankshaft replacement: 1. In an engine test cell: 2. In the aircraft:

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

CRANKSHAFT MATERIAL INSPECTION REIMBURSEMENT FORM For Compliance of MSB 00-5 Attach a copy of the shop work order and invoice to this form.

DATE:_______________

Complete the following information: ENGINE MODEL: ______________________________________________________________ ENGINE SERIAL NUMBER:_____________________________________________________ ENGINE TOTAL TIME: _________________________________________________________ CRANKSHAFT SERAIL NUMBER: _______________________________________________ AIRCRAFT MODEL: __________________ AIRCRAFT REG. NUMBER: ________________ OWNER NAME: _______________________________________________________________ ADDRESS: ____________________________________________________________________ CITY: __________________________ STATE: ________________ ZIP: _________________ COUNTRY: __________________________ PHONE: ________________________________ FAX: ________________________________ E-MAIL ADDRESS: ____________________________________________________________ AMOUNT of Reimbursement Requested___________________. MAKE REIMBURSEMENT CHECK PAYABLE TO: OWNER: _____ or FBO: _______ FBO NAME: ___________________________________________________________________ ADDRESS: ____________________________________________________________________ CITY: __________________________ STATE: ________________ ZIP: _________________ COUNTRY: ___________________________ PHONE: ______________________________ FAX: __________________________________ E-MAIL ADDRESS: ____________________________________________________________ MAIL COMPLETED FORM TO: TELEDYNE CONTINENTAL MOTORS P.O. BOX 90 MOBILE, AL 36601 ATTN: WARRANTY ADMINISTRATION

TCM USE ONLY DATE:_____________________________________ APPROVED SIGNATURE:____________________ AMOUNT:__________________________________ ACCOUNTING VERIFICATION: ______________ CHECK NUMBER: __________________________

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

MANDATORY SERVICE BULLETIN The Subject Matter of This Service Bulletin Is Incorporated In Whole Or In Part in an FAA Airworthiness Directive

CATEGORY 1

MSB 00-6A Technical Portions FAA Approved Supersedes MSB00-6

SUBJECT: SLICK SERVICE BULLETIN SB 1-00A PURPOSE:

COMPLIANCE: MODELS AFFECTED:

To advise owners, operators and FBO’s of mandatory replacement of certain Slick Model 6314, 6324 and 6364 Magnetos As specified in the “COMPLIANCE” section of Slick SB 1-00A All O-300, IO-360 series, TSIO-360 Series, and LTSIO-520-AE engines

Unison Industries has issued Slick Service Bulletin SB 1-00A mandating immediate replacement of certain Slick Part Number 6314 (TCM P/N 653271), Slick P/N 6324 (TCM P/N 653292) Magnetos and Slick P/N 6364 (TCM P/N 649696) Affected magnetos were manufactured during November and December of 1999 and may be identified by their serial number. Refer to the Models affected section of the attached Slick Service Bulletin SB 1-00A for serial number effectivity. Refer to Slick Service Bulletin SB 1-00A for warranty terms and limitations. TCM New or Rebuilt engines shipped from the factory with an affected magneto installed, replacement magnetos must be ordered from TCM. Submit warranty claims for replacement of affected magnetos through a TCM Distributor. Engines with affected magnetos installed, as a service spare part, replacement magnetos must be ordered from a Unison Distributor. Submit warranty claims for replacement of affected magnetos through a Unison Distributor.

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SB1-00A

SLICK Service Bulletin

TO: Aircraft manufacturers, distributors, dealers, engine overhaul facilities, owners and operators of Slick magnetos. SUBJECT: Mandatory replacement of magnetos on certain 6-cylinder Teledyne Continental Motors engines. BACKGROUND INFORMATION: There has been an incident in which the impulse coupling stop pin migrated out of the magneto frame of a Slick 6314 magneto. The stop pin entered the gear train of the engine, resulting in damage to the gear train and engine accessories. Although an investigation is underway to determine the reason for the loose stop pin, data indicates that the condition is limited to a specific range of magneto model and serial numbers produced during November and December 1999. COMPLIANCE: Effective immediately, and prior to further flight, operators of TCM O-300, IO-360, LTSIO-520-AE, and TSIO-360 engines are required to determine if their engines are equipped with Slick 6314, 6324, or 6364 magnetos from the affected serial number range. If it is determined that the engine is equipped with magnetos from the affected serial number range, then the aircraft is prohibited from further flight until the magnetos have been replaced with units that have serial numbers outside of the affected range. PROOF OF COMPLIANCE: Appropriate logbook entries. PARTS REQUIRED PER BULLETIN: Replace magnetos as required. TOOLS REQUIRED PER BULLETIN: Standard shop tools. Slick Master Service Manual F1100. WEIGHT CHANGE: None. MAGNETO MODELS AFFECTED: Model 6314, 6324, and 6364 magnetos manufactured during November and December 1999 within the following serial number range: 99110001 thru 99129999 ENGINE MODELS AFFECTED: Teledyne Continental Motors: O-300 - All Models IO-360 - All Models LTSIO-520-AE - All Models TSIO-360 - All Models

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SLICK Service Bulletin SB1-00A DETAILED INSTRUCTIONS: A. Locate magneto serial number on magneto dataplate. If magneto serial number is determined to be within the range specified in this bulletin, remove the magneto from engine in accordance with the latest revision of the engine manufacturer’s manuals. B. Inspect the magneto to confirm that the stop pin is present in the magneto frame. View the drive end of the magneto where the impulse coupling is attached and position the magneto as detailed in Figure 1. The magneto stop pin should be located at approxi mately the 8 o’clock position. Only one stop pin is installed in the magneto and the hole in the magneto frame located at the 4 o’clock position should be open.

STOP PIN

Figure 1 C. If the stop pin is present in the magneto frame, replace the magneto with a new or serviceable unit. If the magneto stop pin is not present in the magneto frame, proceed as detailed in step D or E. D. O-300, IO-360, and TSIO-360 engines: NOTE: Conduct the following inspection in accordance with the latest revision of the engine manufacturer’s overhaul manuals and inspection procedures. 1. Remove both magnetos, alternator or generator and starter adapter from the acces sory case. 2. Visually inspect the entire engine gear train for damaged or broken gears and gear teeth. 3. Inspect the visible portions of the engine crankcase and accessory case for damage due to the stop pin becoming lodged between the gear train, crankcase or accessory case.

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SLICK Service Bulletin SB1-00A 4. Inspect oil pump drive gear teeth and inner cam gear teeth for damage. 5. Recover the stop pin from the engine 6. Replace any engine drive train component that has incurred damage. If a gear is found to be damaged and replaced, the mating gears must be removed and magnafluxed in accordance with the applicable engine overhaul manual. 7. If the accessory case is damaged, repair or replace the accessory case. If the engine crankcase is damaged a complete engine disassembly will be required to repair or replace the crankcase. E. LTSIO-520-AE engines: NOTE: Conduct the following inspection in accordance with the latest revision of the engine manufacturer’s overhaul manuals and inspection procedures. 1. Remove both magnetos, starter adapter, fuel pump, vacuum pumps and accessory drive pads. 2. Visually inspect the entire engine gear train for damaged or broken gears and gear teeth. 3. Inspect the visible portions of the engine crankcase and accessory case for damage due to the stop pin becoming lodged between the gear train, crankcase or accessory case. 4. Inspect oil pump drive gear teeth and inner cam gear teeth for damage. 5. Recover the stop pin from the engine 6. Replace any engine drive train component that has incurred damage. If a gear is found to be damaged and replaced, the mating gears must be removed and magnafluxed in accordance with the applicable engine overhaul manual. 7. If the accessory case is damaged, repair or replace the accessory case. If the engine crankcase is damaged a complete engine disassembly will be required to repair or replace the crankcase. WARRANTY: A. Magneto replacement only: 1. For new or overhauled TCM engine within warranty, submit a warranty claim with a TCM distributor. 2. For magnetos purchased through aftermarket distribution sources or supplied on field overhauled engines, submit a warranty claim through an authorized Unison distributor of Slick magnetos.

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SLICK Service Bulletin SB1-00A B. Engine inspection and repair only: 1. For new or factory overhauled TCM engines within warranty, submit a warranty claim with a TCM distributor. 2. For TCM engines that are out of warranty or have been field overhauled, submit a warranty claim through an authorized Unison distributor of Slick magnetos. LABOR ALLOWANCE: A. For new or overhauled TCM factory engines within warranty, standard warranty labor rates will be honored. Warranty claims for labor must be filed with a TCM distributor. B. For magnetos purchased through aftermarket distribution sources or supplied on nonfactory overhauled engines, Unison will allow for the following: 1. Removal/replacement of each magneto on a non-turbocharged engine- 1.5 hours posted shop rate. 2. Removal/replacement of each magneto on a turbocharged engine- 2 hours posted shop rate. 3. Warranty claims for labor must be filed with a Unison distributor of Slick magnetos.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 1

MANDATORY SERVICE BULLETIN

MSB07-4

The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Issued Airworthiness Directive

Technical Portions FAA Approved

SUBJECT:

KELLY AEROSPACE POWER SYSTEM’S TURBOCHARGER REPLACEMENT

PURPOSE:

To ensure compliance with Kelly Aerospace Power System’s Service Bulletin No. 027.

COMPLIANCE

Compliance is Mandatory. Issuance of a Federal Aviation Administration (FAA) Airworthiness Directive (AD) is expected on this subject.

MODELS AFFECTED:

TSIO- 520-BE; TSIO-550-A,B,C,E and G

Teledyne Continental Motors (TCM) currently utilizes engine turbochargers purchased from Kelly Aerospace Power Systems. Kelly Aerospace Power Systems has issued Service Bulletin 027 covering certain TCM P/N 646677 (Kelly P/N 466304-0003) turbochargers manufactured in 2007. This bulletin is mandatory and must be complied with. An Airworthiness Directive is expected to be issued on the subject. Compliance is required as follows: 1. Any affected engine model with a serial number listed in Table 1 must be inspected prior to further flight in accordance with the attached Kelly Aerospace Power Systems Service Bulletin 027. 2. Any of the above listed engine models which has had a turbocharger replaced in the field between March 1, 2007 and the effective date of this bulletin must have the turbocharger inspected prior to further flight in accordance with the attached Kelly Aerospace Power Systems Service Bulletin 027.

TABLE 1 Serial Number 802854 802855 802856 802859 802860 802861 802862 802863 802864 802865 802866

Serial Number 802867 802868 802876 802877 802878 802881 802882 814585 915033 915039 915040

Model TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C

Model TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550C TSIO550G TSIO550G TSIO550G

Serial Number 915041 915042 915043 915044 915046 915048 915050 915061 915062

Model TSIO550G TSIO550G TSIO550G TSIO550G TSIO550G TSIO550G TSIO550G TSIO550G TSIO550G

WARRANTY Warranty coverage will be applied under the TCM Warranty Policy applicable to the engine or part. ISSUED

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Service Bulletin Compliance is Considered Mandatory

The technical content of this letter is FAA Approved

Bulletin No. 027

DRAFT

Issue Date: July 24, 2007

TURBOCHARGER INSPECTION AND REPLACEMENT

INTRODUCTION:

It has come to the attention of Kelly Aerospace Power Systems of a disabled turbocharger where the turbine and compressor wheel shaft bearing journals were pushed inward and damaged on a part number 466304-0003 turbocharger. Examination of the damage revealed that a conical vibration along the turbine wheel and shaft assembly was the principal source of the damage. Investigation of the cause has determined that the turbine wheel shaft assembly for this particular turbocharger may have been improperly balanced. Continued operation with a turbine wheel shaft imbalance may result in the separation of the turbine wheel head from the shaft rendering the turbocharger inoperative and may result in the partial or total loss of engine power. This Service Bulletin is being issued to mandate the replacement of affected turbochargers P/N 466304-0003 (TCM P/N 646677) manufactured in March 2007, as listed by serial number in the table below. COMPLIANCE: Prior to next flight. If the turbocharger replacement can not be accomplished on site, a ferry permit is required to deliver the aircraft to a suitable facility for repair. (To determine if the turbocharger is suitable to apply for a ferry permit, see visual inspection below.) EFFECTIVITY: Any aircraft utilizing a Teledyne Continental Motors engine with a Kelly Aerospace Power Systems turbocharger P/N 466304-0003 (TCM P/N 646677) with the serial numbers listed below. Suspect Serial Numbers

New

KBL00782

KBL00796

KCL00625

KCL00679

KCL00692

KCL00705

KCL00718

KBL00783

KBL00797

KCL00626

KCL00680

KCL00693

KCL00706

KCL00719

KBL00784

KCL00581

KCL00627

KCL00681

KCL00694

KCL00707

KCL00720

KBL00785

KCL00582

KCL00629

KCL00682

KCL00695

KCL00708

KCL00721

KBL00786

KCL00583

KCL00631

KCL00683

KCL00696

KCL00709

KCL00722

KBL00787

KCL00584

KCL00632

KCL00684

KCL00697

KCL00710

KCL00724

KBL00788

KCL00585

KCL00633

KCL00685

KCL00698

KCL00711

KCL00725

KBL00789

KCL00587

KCL00636

KCL00686

KCL00699

KCL00712

KCL00726

KBL00790

KCL00588

KCL00637

KCL00687

KCL00700

KCL00713

KCL00727

KBL00792

KCL00589

KCL00638

KCL00688

KCL00701

KCL00714

KCL00728

KBL00793

KCL00590

KCL00639

KCL00689

KCL00702

KCL00715

KCL00730

KBL00794

KCL00621

KCL00677

KCL00690

KCL00703

KCL00716

KCL00731

KBL00795

KCL00623

KCL00678

KCL00691

KCL00704

KCL00717

Kelly Aerospace Power Systems Service Bulletin 027

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PROCEDURE: CAUTION:: This procedure must be performed by competent and qualified personnel familiar with engine and airframe maintenance activities that are specific to turbocharged aircraft. CAUTION:: Do not depend on this Service Bulletin for gaining access to the aircraft or engine. This will require that you use the applicable manufacturers maintenance manuals or service instructions. In addition, any preflight or inflight operational checks require use of the appropriate AFM or POH. This procedure has two steps. First, the visual inspection, the purpose is to determine if the turbocharger may be used and is suitable for the relocation of the aircraft. Second, the basic instructions to remove, replace, and check the turbocharger. See caution above. See Table on page 1 for serial numbers affected. Typical Turbocharger Installation

P/N 466304-0003 TCM P/N 646677

Compressor Inlet Duct Data Tag in this Area VISUAL INSPECTION:

Exhaust Outlet Duct

Figure 1 - Turbocharger Installation

1. Access the aircraft turbochargers in accordance with the instructions in the aircraft maintenance manual. 2. Remove the compressor inlet ducts to expose the compressor wheels. Refer to Figure 1. 3. Visually inspect each turbocharger through the compressor inlet for any signs of contact. Look for witness marks from the impeller wheel, giving careful attention to the outer edges of the wheel blades and the inner wall of the compressor housing. Contact marks on the housing from the wheel will appear as a burnishing on the inner wall. Grooves or gouges of any sort are cause for turbocharger replacement. Utilize supplemental lighting if needed to facilitate visual inspection. Refer to Figure 2, page 3. 4. If any anomalies are noted during the visual inspection, replace the turbocharger. If nothing appears in the visual inspection, the turbocharger is suitable for further use. This will allow the aircraft to be relocated to a qualified facility for turbocharger replacement.

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Kelly Aerospace Power Systems Service Bulletin 027

New

Figure 2 - Turbocharger Inspection Points TURBOCHARGER REPLACEMENT: 1. The affected turbocharger P/N 466304-0003 (TCM P/N 646677) must be removed and replaced per the table shown on page 1. Each aircraft has two turbochargers. Check the data tag on each to identify whether the serial number of the turbocharger is one that is affected. When identification is made, remove the turbocharger from the aircraft. Removal must be in accordance with the aircraft and/or engine manufacturers maintenance manuals or service instructions. Contact the aircraft manufacturer to determine the disposition of the suspect turbocharger and information regarding the return of the turbocharger(s). All warranty applications must be made through the aircraft manufacturer. Refer to Fig 1 as required. 2. Upon replacement of the turbocharger, it is recommended that the inlet and outlet oil lines be flushed and the oil and oil filter be changed in accordance with the aircraft and/or engine manufacturers maintenance manual or service instructions. 3. Utilizing the applicable aircraft and/or engine manufacturers maintenance manuals or service instructions, re-install the turbocharger assembly and connect the oil lines. Connect the turbocharger compressor inlet duct and coupling, torque the clamps to manufacturer specifications. Connect the exhaust outlet duct carefully, position and torque the “V” band clamp to manufacturer specifications. It is critical that a new gasket be installed at the oil drain adapter and the installed and torqued down properly. An oil leak in this area may result in engine oil starvation and subsequent engine failure. RETURN TO SERVICE:

NOTE:: Check for the latest publication issued by the applicable aircraft manufacturer regarding exact aircraft model, serial number and warranty procedures.

1. When the turbocharger has been replaced, the aircraft may now be prepared for return to service. 2.

Refer to Kelly Aerospace Power Systems Service Bulletin 23 and perform the recommended turbocharger operational tests. This consists of turbocharger pre-lubrication, ground running tests, and and operational flight test. Make sure no air, exhaust, or oil leaks are present. Service Bulletin may be viewed or downloaded online via www.kellyaerospace.com.

4.

Utilizing the applicable aircraft and engine manufacturers maintenance manuals, install any portion of the aircraft removed to gain access.

5.

Upon successful completion of this service bulletin per the applicable compliance time listed on page 1, make an appropriate log book entry.

New

Kelly Aerospace Power Systems Service Bulletin 027

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PARTS REQUIRED: One (1) or two (2) each, turbocharger, part number 466304-0003* (TCM P/N 646677) as required. Up to (4) each, turbocharger oil inlet or drain adapter gasket, part number as per the engine or aircraft manufacturers parts list. Parts must be obtained from the engine or airframe manufacturer. * The approved turbocharger replacement part may be P/N 466304-0003 (new) or P/N 466304-9003 (rebuilt). WARRANTY STATEMENT: The sole warranty applicable to this service publication is related to the terms and conditions in the aircraft or engine manufacturers Limited Warranty Policy. This publication does not imply or state any responsibility for the workmanship of any person or entity performing work or maintenance on the turbocharger, engine, or aircraft. All claims for warranty must be forwarded to the the airframe and/or engine manufacturer per the requirements contained in their Limited Warranty policies as applicable. CONTACT INFORMATION: If you have any questions concerning the instructions in this service bulletin, please contact Kelly Aerospace Power Systems Technical Support at 888-461-6077. Questions concerning aircraft service or operation must be forwarded to the applicable manufacturer of that product.

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Kelly Aerospace Power Systems Service Bulletin 027

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 1

MANDATORY SERVICE BULLETIN

MSB08-2

The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Issued Airworthiness Directive

Technical Portions FAA Approved

SUBJECT:

AD 2008-06-51 PRECISION AIRMOTIVE LLC® FUEL INJECTION SERVO

PURPOSE:

To notify owners of the issuance of FAA Emergency Airworthiness Directive 2008-06-51 and Precision Airmotive LLC Mandatory Service Bulletin PRS-107 Revision 1.

COMPLIANCE: Initial inspection required prior to the next flight. Recurring inspection is required at each engine oil change or every 50 flight hours, whichever occurs first, until a permanent repair is implemented. MODELS AFFECTED:

TSIO-360-RB, LTSIO-360-RB; See Chart 1.

The Federal Aviation Administration has issued Emergency Airworthiness Directive 2008-06-51, effective 03/12/2008, concerning Precision Airmotive LLC Mandatory Service Bulletin PRS-107 Revision 1, dated 3/6/2008, for inspection of certain RSA-5 and RSA-10 Fuel Injection Servos. New, Rebuilt, Overhauled or Repaired Servos shipped after August 22, 2006 must be inspected in accordance with the Emergency Airworthiness Directive 2008-06-51 prior to the next flight and at the recurring inspection intervals noted in the Emergency Airworthiness Directive 2008-06-51. NOTE: Emergency Airworthiness Directive 2008-06-51 must be complied with prior to the next flight and at the recurring inspection intervals contained therein.

WARNING Failure to comply with Emergency Airworthiness Directive 2008-06-51 and the attached Mandatory Service Bulletin may result in loss of engine power, engine damage, airframe damage, personal injury or death. ENGINE MODEL SERIAL NUMBER EFFECTIVITY TSIO-360-RB NEW 322782 AND LATER TSIO-360-RB REBUILT 819277 AND LATER LTSIO-360-RB NEW 322535 AND LATER LTSIO-360-RB REBUILT 819528 AND LATER ALL AFFECTED ENGINE MODELS ON WHICH THE FUEL INJECTION SERVO WAS OVERHAULED, REPAIRED, OR REPLACED AFTER AUGUST 22, 2006.

CHART 1 ISSUED

REVISED

PAGE NO REVISION TM

MO 03

DAY 14

YEAR 2008

MO

DAY

YEAR

T e le d y n e C o n t in e n t a l M o t o r s, In c . P.O. BOX 90 MOBILE, AL 36601 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

1 of 1 MSB08-2

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 1

MANDATORY SERVICE BULLETIN

MSB08-5

The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Issued Airworthiness Directive

Technical Portions FAA Approved

SUBJECT:

Kelly Aerospace® Service Bulletin 030

PURPOSE:

To provide notification to affected owners of mandatory turbocharger system inspection.

COMPLIANCE

Within the 10 hours of operation following 2-15-2008, or at the next regularly scheduled maintenance event, whichever occurs first.

MODELS AFFECTED: Aerospace

GTSIO-520-L,M,N; TSIO520-AF,P; TSIOL-550-A,C or any Teledyne Continental Engine utilizing the turbochargers listed below and in Kelly Service Bulletin 030

GENERAL Kelly Aerospace Power Systems has issued Service Bulletin 030 dated February 15, 2008, concerning certain specific serial numbered turbochargers as installed on the engines listed above. Kelly Aerospace Power Systems Service Bulletin 030 MUST be performed on these engines as instructed in their attached Service Bulletin. For additional information concerning Kelly Aerospace Power Systems 030, contact Kelly Customer Service at (888) 461-6077 Engine Model

TCM Part Number

Kelly Part Number

GTSIO-520-L,N

641672-3

465930-0003

TSIOL-520-A,C

652964

466412-0004 (Ram only)

TSIO-520-AF, P

Not TCM furnished

465680-0004

GTSIO-520-M

641672-2

465930-0002

WARRANTY

All warranty consideration in conjunction with this bulletin will be provided by Kelly Aerospace Power Systems.

ISSUED

REVISED

PAGE NO REVISION TM

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DAY

YEAR

05

28

2008

MO

DAY

YEAR

© 2007 TELEDYNE TECHNOLOGIES, INC.

T e le d y n e C o n t in e n t a l M o t o r s, In c . P.O. BOX 90 MOBILE, AL 36601 251-438-3411

1 of 1 MSB08-5

Original

Service Bulletin Compliance is Considered Mandatory

The technical content of this letter is FAA Approved

Bulletin No. 030

Issue Date: February 15, 2008

TURBOCHARGER EXHAUST FLANGE INSPECTION AND/OR TURBINE HOUSING REPLACEMENT (TCM) INTRODUCTION: It has come to the attention of Kelly Aerospace Power Systems (KAPS) that a possible interference condition may exist between the turbocharger turbine exhaust outlet flange area and the mating flange of the airframe exhaust tube. The piloted type exhaust tube flange may contact the filet radius of the turbine housing relief cut not allowing the two flange faces to meet properly. (see Figure 3 on page 4) Turbine housings manufactured between August 25, 2006 and January 25, 2008 are suspect. If this condition exists, exhaust pipe security may be compromised. While the exhaust outlet side of the turbocharger turbine has relatively low pressures, the potential of an exhaust leak, a loosening of the “V” band clamp, and a rise of temperature within the engine cowling exist. Left uncorrected, failure of the “V” band clamp may occur with possible loss of the tail pipe connection with resultant uncontained hot exhaust gas within the engine cowl. This Service Bulletin is being issued to mandate the inspection and/or replacement of affected turbocharger turbine housing(s) P/N 441977-0023 or 441977-0025 as found on KAPS turbochargers per the serial numbers found in the table below. COMPLIANCE: Within the next ten (10) hours time in service or at the next regularly scheduled maintenance event or annual inspection which ever occurs first. EFFECTIVITY: Any Cessna P210 Pressurized Centurion utilizing a Teledyne Continental Motors (TCM) TSIO-520-AF or TSIO-520-P engine with a Cessna P/N C295001-0202 (465680-0004) turbocharger. Any Cessna 404 Titan utilizing a TCM GTSIO-520-M engine with a TCM P/N 641672-2 (465930-0002) turbocharger. Any Cessna 414 utilizing a TCM TSIOL-550-A, C engine with a TCM P/N 652964 (466412-0003) turbocharger. Any Cessna 421 Golden Eagle utilizing a TCM GTSIO-520-L,N engine with a TCM P/N 641672-3 (465930-0003) turbocharger. Any RAM Modification using a 466412-0004 turbocharger.

Rev. New

Kelly Aerospace Power Systems Service Bulletin 030

Page 1 of 5

Suspect Serial Numbers For: Turbocharger P/N 465930-0003 (TCM 641672-3) with GTSIO-520-L,N engine, P/N 466412-003 (TCM 652964) with TSIOL-550-A, C engine, and P/N 466412-0004 (used in RAM modifications only). (Utilizing P/N 441977-0023 turbine housings.) JHL00386

JHL00387

JHL00388

JHL00389

JHL00390

JHL00391

JHL00392

JHL00393

JHL00394

JHL00395

JHL00396

JHL00397

JHL00398

JHL00399

JHL00400

JIL00284

JIL00285

JIL00286

JIL00287

JIL00288

JIL00289

JIL00290

JIL00291

JIL00292

JIL00293

JIL00905

JIL00906

JIL00907

JIL00908

JIL00909

JIL00910

JIL00911

JIL00912

JIL00913

JKL00023

JKL00024

JKL00025

JLL00176

JLL00177

JLL00490

JLL00491

JLL00492

JLL00493

JLL00494

KAL00167

KAL00168

KAL00252

KAL00253

KAL00254

KAL00255

KAL00256

KAL00452

KAL00453

KAL00454

KAL00455

KAL00456

KBL00271

KBL00272

KBL00273

KBL00274

KBL00275

KBL00276

KBL00277

KCL00846

KCL00847

KCL00848

KCL00849

KCL00850

KCL00851

KCL00852

KCL00853

KEL00044

KEL00045

KFL00129

KFL00151

KGL00225

KGL00226

KGL00227

KHL00321

KHL00322

KHL00323

KHL00324

KHL00325

KHL00326

KHL00327

KHL00328

KHL00329

KHL00330

KHL00331

KHL00452

KHL00453

KIL00157

KIL00158

KIL00159

KIL00160

KIL00161

KIL00162

KIL00163

KIL00164

KIL00165

KIL00758

KIL00759

KIL00760

KIL00763

KIL01235

KIL01236

KIL01237

KIL01238

KIL01239

KIL01240

KIL01444

KIL01445

KIL01446

KIL01447

KIL01448

KIL01449

KJL00027

Suspect Serial Numbers For: Turbocharger P/N 465680-0004 (Cessna C295001-0202) with a TSIO-520-AF or TSIO-520-P engine and P/N 465930-0002 (TCM 641672-2) with a GTSIO-520-M engine. (Utilizing P/N 441977-0025 turbine housings.) JJL00128

JJL00129

JJL00130

JJL00661

JJL00662

JKL00026

JLL00173

JLL00175

KDL00037

KDL00942

KDL00943

KDL00944

KDL00945

KGL00132

KGL00183

KIL00590

KIL00632

KIL00633

KIL00634

Page 2 of 5

Kelly Aerospace Power Systems Service Bulletin 030

Rev. New

PROCEDURE:

CAUTION:: This procedure must be performed by competent and qualified personnel familiar with engine and airframe maintenance activities that are specific to turbocharged aircraft.

CAUTION:: Do not depend on this Service Bulletin for gaining access to the aircraft or engine. This will require that you use the applicable manufacturers maintenance manuals or service instructions. In addition, any preflight or in flight operational checks require use of the appropriate AFM or POH. INSPECTION:

NOTE:: If the turbocharger installed on the engine(s) can be positively identified as not being affected by this service bulletin using the aircraft log books or other certified aircraft paperwork, no further action is necessary. If it cannot be established positively, then inspection of the data tag will be required.

1.

Access the aircraft turbocharger by removing the cowling as required in accordance with the instructions contained in the Cessna Aircraft maintenance manual. Refer to appropriate aircraft in Figure 1.

2.

Identify the affected turbocharger by checking data tag for part number and serial number and comparing to the suspect serial number table on page 2. If the turbocharger is affected continue with these instructions, if not, proceed to the “Return to Service” section step 3 and 4.

3.

Carefully remove the “V” band clamp from around the turbocharger turbine housing at the turbocharger exhaust outlet taking care not to move the exhaust tube and tail pipe assembly. Figure 2 shows a “V” band clamp improperly installed, notice gap and clamp riding up on flange.

4.

Inspect the turbocharger turbine housing at the flange area captured by the “V” band clamp. Use a feeler gauge at the split line between the turbine housing flange and the exhaust tube flange all around the circumference. The maximum gap should not exceed .005 inch at any point. If you suspect or know that the exhaust tube and tail pipe assembly was moved at any point prior to checking for the gap, apply pressure towards the turbine housing flange before taking a measurement. Refer to Figure 3 on page 4.

5.

If a gap exceeding tolerance is found, the turbocharger and tail pipe assembly should be removed. To accomplish this, follow the instructions contained in the Cessna Aircraft or STC holder’s maintenance manual or as applicable the appropriate TCM service information. Inspect and clean flange areas using methods recommended by Cessna or TCM. Do not attempt repair of the turbine housing. Connect the cleaned exhaust tube to the turbocharger and re-inspect per step 4 above. If the gap still exceeds tolerance, the turbocharger turbine housing (P/N 441977-23 or 441977-25) must be replaced. Proceed to step 6. If gap tolerance is not exceeded, metal stamp a 1/8” upper case “I” in the area shown in Fig 4 (per step 7) to indicate the instruction was performed then proceed to step 10.

RAM modifications not shown

Figure 1 - Turbocharger Installation Rev. New

Kelly Aerospace Power Systems Service Bulletin 030

Page 3 of 5

Typical Turbocharger Exhaust Tube Installation Shown

Figure 2 - “V” band Clamp Showing Gap

Figure 3 - Gap Inspection Area

Figure 4 - Turbine Housing Trouble Area 6. The turbocharger must be sent to a properly certificated part 145 repair station (or foreign equivalent) experienced in turbocharger repair. 7. Once the turbocharger has been repaired, visually inspect for condition and orientation of the turbine housing then, using a 1/8” metal stamp of an upper case “I”, stamp the turbine housing in the area shown in Figure 4. Care must be taken not to extend stamp within 1/8” of the mating edge as it may bulge and distort the mating surface. When stamped, proceed with the installation. 8. Utilizing the applicable aircraft, STC holder and/or engine manufacturers maintenance manuals or service instructions, re-install the turbocharger assembly.

Page 4 of 5

Kelly Aerospace Power Systems Service Bulletin 030

Rev. New

NOTE:: If the existing “V” band clamp is to be used, it should be inspected for damage on the inside of the “V” prior to re-use. If the inside radius of the “V” is flattened or cut it should not be used. Obtain the clamp part number from the appropriate aircraft or engine parts catalog. 9. When connecting the exhaust tube and tail pipe assembly to the repaired turbocharger, it is advisable to re-check the flange fit per step 4 prior to installing the clamp. Carefully, position and install the “V” band clamp to manufacturer specifications and proceed to “Return to Service” below. 10. If gap tolerance was not exceeded and the metal stamp “I” has been applied per step 5, carefully, position and install the “V” band clamp to manufacturer specifications and proceed to “Return to Service” below. RETURN TO SERVICE: 1. When the turbocharger has been replaced, the aircraft may now be prepared for return to service. 2.

Refer to Kelly Aerospace Power Systems Service Bulletin 23 and perform the recommended turbocharger operational tests. This consists of turbocharger pre-lubrication, ground running tests, and and operational flight test. Make sure no air, exhaust, or oil leaks are present. Service Bulletin may be viewed or downloaded online via www.kellyaerospace.com.

3.

Utilizing the applicable Cessna Aircraft or STC holder’s maintenance instructions and/or manuals, install the engine cowls removed to gain access.

4.

Upon successful completion of this service bulletin per the applicable compliance time listed on page 1, make an appropriate log book entry that includes the affected turbocharger model and serial number, along with an appropriate statement of the inspection and/or repair.

MATERIAL REQUIRED: One (1) or two (2) each, turbocharger turbine housing, P/N 441977-23 or 441977-25 as required. All KAPS parts must be obtained through an AVIALL, Inc.. supplier. AVIALL is the sole distributor for KAPS turbocharger parts NOTE: Other incidental parts may be required during the removal and installation of the turbocharger. These parts must be obtained per the aircraft or engine manufacturers parts list from the applicable manufacturer. DISPOSITION OF STOCK: Any turbocharger which appears on the Suspect Serial Number Table(s) on page 2 which remains in stock may be returned for repair or replacement. WARRANTY STATEMENT: Kelly Aerospace Power Systems will supply warranty consideration for each affected KAPS Turbine Housing (up to two per aircraft). Additionally, up to one (1) hour labor per engine or two (2) hours labor per aircraft (at 75.00 USD) will be allowed for the inspection and repair required in this service bulletin. Warranty must be filed through AVIALL Inc. with the affected turbine housing returned. All normal KAPS warranty procedures apply. No other warranty consideration related to this service publication applies. This publication does not imply or state any responsibility for the workmanship of any person or entity performing work or maintenance on the turbocharger, engine, or aircraft. CONTACT INFORMATION: If you have any questions concerning the instructions in this service bulletin, please contact Kelly Aerospace Power Systems Technical Support at (888) 461-6077.

Questions concerning aircraft service or operation must be forwarded to the applicable manufacturer of that product.

Rev. New

Kelly Aerospace Power Systems Service Bulletin 030

Page 5 of 5

TELEDYNE CONTINENTAL @ AIRCRAFT ENGINE

Category 1

MANDATORY SERVICE BULLETIN

MSBO9-IB

lA The Subject Matter Of This Sewice Bulletin Is Incorporated Supersedes Technical Portions FAA In Whole Or In Part In An FAA Issued Airworthiness Approved Directive MSB09-19

SUBJECT:

CYLINDER REPLACEMENT

BACKGROUND: As of the date of this Bulletin, Teledyne Continental Motors (TCM) has identified the cause of cracks in 35 cylinders manufactured from November 1, 2007 to January 30,2009. TCM has determined that the EQ3 cylinder head casting tool used in the manufacturing process created an area of reduced thickness that may result in a crack after prolonged operation. This crack manifests itself in the area between the upper sparkplug bore and the fuel injectorlprimer nozzle bore. The cracked cylinders returned to date have occurred on engines from high use fleet operations with occurrence times ranging from approximately 430 to 1,300 total hours. Replacement cylinders conforming to proven production history will be provided. While there have been no accidents or incidents related to this cylinder head crack, TCM has elected to replace all cylinder assemblies with the EQ3 head casting. TCM will provide warranty assistance for this purpose through December 3 1,2009.

REVISION A:

TCM has identified a group of approximately 300 cylinders produced in August and September 2006 that were made from the EQ3 tooling. TCM issued Revision A to MSB09-1 to incorporate this information in three key changes to the MSB. They are: 1. Update the Engine Models Affected list to include a more complete model list. 2. Adds Table 1A to list additional engine serial numbers that may be affected by this bulletin.

1

3. Adds Table 2A to list additional cylinder serial numbers that may be affected by this bulletin.

REVISION 8:

To clarify required permits to move aircraft with cracked cylinder(s). Clarify part and serial numbers in Tables 1A, 2.4.

PURPOSE:

This Mandatory Service Bulletin (MSB) is issued to require inspection to identify the EQ3 cylinders and to require the further inspection and replacement of those cylinders in order to ensure a timely and orderly retirement of the EQ3 cylinders. This MSB has been divided into two sections to aid all parties in complying with its requirements.

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

Section 1provides the details on cylmder inspection and replacement: Step 1:Provides instructions to determine if your cylinders have been manufactured with the EQ3 head. Step 2: Provides cylinder inspection and replacement instructions based on the total hours in service. Section 2 contains tables listing engines and cylinders that may have EQ3 heads installed. These engines and cylinders were shipped from November 1,2007 through January 30,2009. In addition, a group of approximately 300 cylinders produced in August and September of 2006 were made from the EQ3 tooling. Suspect engines and cylinders containing that group are provided in Tables 1A and 2A.

COMPLIANCE: Identify all potentially affected cylinders, listed in Tables 1, lA, 2, and 2A, within the next twenty (20) flight hours but in no case later than April 30, 2009. If any cylinder has the EQ3 head, notify TCM to schedule a replacement. All EQ3 cylinders must be replaced no later than December 3 1.2009. For cylinders with 400 hours or more total time in operation, Step 2 (Cylinder Inspection Instructions) must also be completed within twenty (20) hours of operation or by April 30,2009, whichever is earlier, and every fifty (50) hours of operation thereafter until cylinder replacement. Tables 1, lA, 2, and 2A are believed to contain the cylinders produced by the EQ3 tooling. However, to assure that all EQ3 cylinders have been found, any engine or cylinder that has been purchased from TCM since August, 2006, for an engine model listed in MODELS AFFECTED, should be inspected even if not listed in Tables 1, 1A, 2, or 2A. The inspection should take place no later than the next maintenance event such as an oil change, annual or 100 hour inspection, but in time for replacement for all EQ3 cylinders no later than December 31,2009.

IF A CRACK IS PRESENT, THE CYLINDER MUST BE REPLACED IMMEDIATELY. TO SUPPORT REPLACEMENT AT AN AUTHORIZED MAINTENANCE FACILITY, AN FAA SPECIAL FLIGHT PERMIT FOR A REPOSITIONING FLIGHT MUST BE REQUESTED FROM THE LOCAL FAA. THIS FLIGHT MAY BE AUTHORIZED ONLY IF NO FUEL OR COMBUSTION STAINING IS FOUND AT THE SUBJECT INSPECTION LOCATION. IF STAINING IS FOUND, DO NOT OPERATE THE ENGINE AND CONTACT TCM FOR ASSISTANCE PRIOR TO FURTHER FLIGHT.

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

MODELS AFFECTED: 0470-G, K, L, R, S, M, U; 10470-C, D, E, F, H, L, M, N, S, U, V, VO; TSI0470-B, C, D; 10520-A, B, BA, BB, C, CB, D, E, F, J, K, L, M, MB; TSI0520-AF, B, BB, C, CE, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, UB, VB, WB; 10550-A, B, C, D, E, F, L; IOF550-B, C, D, E, F, L..

SECTION 1 GENERAL

The EQ3 head casting cylinder assemblies are identified by a four (4) fin relief at the bottom lower left hand portion of the cylinder head (as installed on the engine) and a depression cast EQ3 in the cylinder head rocker boss (overhead) area as shown in Figures 1 and 2. These cylinders are to be replaced in accordance with the guidelines set forth in this bulletin and based upon applicable engine model and aircraft manufachlrer procedures. All EQ3 cylinders must be replaced no later than December 3 1,2009. STEP 1 - E 0 3 CYLINDER HEAD IDENTIFICATION AND REGISTRATION

For all engines and cylinders identified in Tables 1, lA, 2, and 2A of this MSB: confirm affectivity in accordance with the following instnictions. Inspect all potentially affected cylinders, within the next twenty (20) flight hours, but no later than April 30, 2009. Verify affectivity of all engine models and cylinders in accordance with Tables I , IA, 2, and 2A and the MODELS AFFECTED section. The engine serial number is located on the engine data plate and the cylinder serial number is located on the crankcase side of the top portion of the cylinder head as installed on the engine (Reference Figure 3). For affected cylinders with 400 hours or more total time in operation, STEP 2 is also required.

Note:

A. For engine models identified in MODELS AFFECTED, use the engine log book to determine if a cylinder replacement has occurred with a cylinder produced between November 1, 2007 and January 30, 2009. If cylinder replacement(s) are verified to have occurred, proceed to "Cylinders Installed on an Engine" below. If no such cylinder replacements have occurred, no further action is required. Make an engine logbook entry recording the results of this inspection and compliance with this MSB. B. For those engines and cylinders listed in Tables 1, IA, 2, and 2A, or cylinders requiring further inspection in accordance with m . A above, proceed as follows.

C. For any of the engines listed in MODELS AFFECTED that may have been shipped or had a cylinder replaced since August, 2006, proceed as follows. CYLINDERS INSTALLED ON AN ENGINE: NOTE: All cylinders must be checked for affectivity. Depending on manufacturing [late andlor maintenance practices, an engine may have any number between zero and six of the affected cylinders. ISSUED

MO 02

REVISED

DAY

1

12

1

YEAR

MO

2009

07

YEAR

DAY

1

14

1

. Teledyne

C o n t ~ n e n t aM l o t o r s , Inc. P.0 BOX90 MOBILE, AL 36601 251.438-3411

2009

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

PAGE NO REVISION

3ofq9 MSBO9-1

B

I. Open or remove the engine cowling in accordance with the airframe manufacturer's instructions to the point necessary to allow visual access to the cylinders on both sides of the engine (Figure 4). 2. Access the area of the cylinder head casting as shown in Figure 5. This area is visible as you look down at the cylinders in their mounted condition from above the engine compartment.

a. Look for a 6 digit part number casting mark such as "649166" or similar. In addition to the casting mark number, there may be a letter indicator such as AE, AD or similar. (Reference Figure 5) b. If a number casting mark is present, it indicates the cylinder head assembly is not covered by this MSB and no further action is required. . Make an engine logbook entry recording the results of this inspection and compliance with this MSB. c. If a number casting mark ispresent, then the cylinder may be covered by this MSB. Verify the EQ3 cylinder SIN as shown in Figure 3 is present and listed in Table 2. If so, proceed to completion and registration and STEP2. CYLINDERS NOT INSTALLED ON AN ENGINE:

1. Cylinders with a depression cast EQ3 in the cylinder head rocker boss area as shown in Figure 2 are covered by this MSB and must be exchanged. 2. Contact TCM in accordance with the completion and registration section below.

"CAUTION": DO NOT1

ON ANY ENGINE.

COMPLETION AND REGISTRATION

1. Upon completion of the required inspection, if no EQ3 cylinders are identified, reinstall or replace all items that have been removed to perform this inspection in accordance with the applicable manufacturer's instructions. Tighten all loosened or removed hardware in accordance with the applicable manufacturer's instructions. Make an appropriate logbook entry stating findings and compliance with this MSB. 2. If EQ3 cylinders are identified:

a. Complete the Customer Information form located at the end of this bulletin. b. Proceed to STEP. STEP 2 - CYLINDER INSPECTION AND REPLACEMENT INSTRUCTIONS

A. For affected cylinders less than 400 hours total time in operation: 1. No detailed inspection is required beyond those provided in the applicable TCM

maintenance and overhaul manuals andlor the applicable airframe manufacturer's maintenance manual. Reinstall or replace all items that have been removed to perform this inspection in accordance with the applicable manufacturer's instructions. Torque all loosened or removed hardware in accordance with the applicable manufacturer's instructions. Make an appropriate logbook entry stating findings and compliance with the MSB. Contact TCM to schedule a replacement cylinder. All EQ3 cylinders must be replaced no later than December 3 1,2009.

MO 02

IDAY I 1

12

1

yEAR

2009

IMO IDAY IYEAR 1

07

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Teledyne ~ o n t i n z t a M l o t o r s , Inc. P.O. BOX 90 MOBILE, AL 36601 251-438-3411

2009

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

d0f1g MSBOS-I

B

B. For affected cylinders with 400 hours or more total time of operation The following inspection must also be accomplished. Additional inspections are required at each fifty (50) hour interval until the cylinder is replaced.

IF A CRACK IS P R E S ~ N I , IHE CYLINDER MUST BE REPLACED IMMEDIATELY. TO SUPPORT REPLACEMENT AT AN AUTHORIZED MAINTENANCE FACILITY, AN FAA SPECIAL FLIGHT PERMIT FOR A REPOSITIONING FLIGHT MUST BE REQUESTED FROM THE LOCAL FAA. THIS FLIGHT MAY BE AUTHORIZED ONLY IF NO FUEL OR COMBUSTION STAINING IS FOUND AT THE SUBJECT INSPECTION LOCATION. IF STAINING IS FOUND, DO NOT OPERATE THE ENGINE AND CONTACT TCM FOR ASSISTANCE PRIOR TO FURTHER FLIGHT Remove the engine cowling and cooling baffles in accordance with the airframe manufacturer's instructions to the point necessary to allow visual access to each affected cylinder's upper spark plug area. 2. Remove the ignition lead from the top spark plug. Remove the top spark plug, NOTE: Visual evidence of a crack in the inspection area between upper spark plug bore and fuel injection nozzle/primer port as indicated in Figure 6 does not require further verification with a dye penetrant inspection. 3

Install a protective cap in the top spark plug bore to prevent contamination from entering the cylinder bore area.

4. Using a flashlight and a lox power magnifying glass, perform a detailed visual inspection of the area between the fuel injector nozzle boss and the upper spark plug. (Reference Figures 6 and 7)

5. If crack indications are found, proceed to step 12(a) below. 6. If no crack indications are noted during the visual inspection or if the mechanic has any questions coucerniug the presence of cracks in the affected area, proceed to step 7 below. N0TE:Dye-penetrant inspection must be performed by a properly qualified mechanic in accordance with the manufacturer's instructions. Use "Magnaflnx@ Portable Spotcheck Kit" or equivalent. These kits can be purchased through most aviation industry distributors. 7. Using Dye-penetrant "CleanerRemover", thoroughly clean the area between the upper spark plug bore and fuel injection nozzlelprimer port as shown in Figure 7. 8. Spray the "PenetrantDye" onto the cleanldry area indicated in Figure 7. Allow the "PenetrantDye" enough time to set in accordance with the manufacturer's instructions.

9. Remove and clean the area in which the "PenetrantIDye" was applied in accordance with the manufacturer's instructions.

I PAGE NO IREVISION I

10. Spray the "Developer" onto the cleanldry area indicated in Figure 7. Allow the "Developer" enough time to dwell in accordance with the manufacturer's instructions for the determination of the existence of a crack. a. If a crack is present, its appearance and location will be similar to that shown in Figure 8. b. Refer to Step 12, below, for required actions in either a "No Crack Present" or a "Crack Present" case. 11. Repeat steps 2 through 7 on all remaining identified EQ3 head casting cylinder assemblies. 12. Complete the following based on the results of the inspection. a. Preceding Inspection Reveals No Cracks i. If required, clean the area thoroughly to remove the Developer. Remove the protective cap from the spark plug bore. Prepare the previously removed spark plugs for re-installation in accordance with the spark plug manufacturer's maintenance instructions. Reinstall each spark plug in its previous location. Torque the spark plug to 300 - 360 inllbs. ii. Install the ignition lead and torque 518" B-nut to 90 - 95 inllbs and 314" B-nut to 100 - 120 inllbs. iii. Reinstall all items that have been removed to perform this inspection. Tighten all loosened or removed hardware in accordance with the applicable manufacturer's instructions. b. Preceding Inspection Reveals Cracks i. If a crack is verified and fuel or combustion staining was noted in the inspection area, contact TCM before further flight. ii. Contact TCM via one of the means listed below and on the Customer Information Form to schedule replacement of the affected cylinder(s). iii. If a crack is verified see the following warning for contact instruction.

IF A CRACK IS PKESEN.I.,-THE CYLINDER MUST BE REPLACED IMMEDIATELY. TO SUPPORT REPLACEMENT AT AN AUTHORIZED MAINTENANCE FACILITY, AN FAA SPECIAL FLIGHT PERMIT FOR A REPOSITIONING FLIGHT MUST BE REOUESTED FROM THE LOCAL FAA. THIS FLIGHT MAY BE AUTHORIZED ONLY IF NO FUEL OR COMBUSTION STAINING IS FOUND AT THE SUBJECT INSPECTION LOCATION. IF STAINING IS FOUND, DO NOT OPERATE THE ENGINE AND CONTACT TCM FOR ASSISTANCE PRIOR TO FURTHER FLIGHT NOTE: Replacement cylinders will be readily identified by both the "NT" indented casting mark located in the cylinder head rocker a r m boss region and by the absence of a four (4) fin relief. These replacement cylinders can also be identified by having a serial number sequence of AC09BA001 and higher.

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

FIGURE 1 Cylinder Head Casting Four (4) Fin relief Location SECTION 2 TABLE 1 Possible EQ3 Cylinder Equipped Factory Engines Engine Model 0470K (Rebuilt) 0470L (Rebuilt) 0470R (New) 0470R (Rebuilt) 0470s (New) 0470s (Rebuilt) 0470U (New) 0470U (Rebuilt) I0470C (Rebuilt) I0470F (Rebuilt) I0470L (New) I0470L (Rebuilt) I0470N (New) I0470N (Rebuilt) 10470s (Rebuilt) I0470V p e w ) I0470V (Rebuilt) I0520BA (Rebuilt) 10520BB (New) 10520BB (Rebuilt)

I0520C (Rebuilt) 10520CB (New) 10520CB (Rebuilt) 10520D (New) I0520D (Rebuilt)

Engine Serial Number 049560 - 049562 832925 - 832936 466902 - 466915 834219 - 834266 464643 - 464645 819195 - 819207 470902 - 470907 834458 - 834498 295611 - 295615 833666 - 833678 468685 - 468689 298347 - 298372 458199,458200 096841 - 096844 109430 - 109432 455812 171360 - 171362 822977 - 823000,836650 580226 - 580232 830218 - 830250, 836900 - 836910 831016 - 831048 576414 - 576424 831830 - 831869 581599 - 581613 832577 - 832634

O 2009 TELEDYNE CONTINENTAL MOTORS. INC.

Engine Model 10520E (Rebuilt) 10520F (New) 10520F (Rebuilt) 105205 (Rebuilt) 10520K (Rebuilt) 10520L (New) 10520L (Rebuilt)

Engine Serial Number 215988 215993 579399 - 579413 835185 - 835267 216546 - 216548 224180 577309 - 577319 295480 - 295500 835900 - 835926 826223,826225,826230,826231, 826234 - 826237 829201 - 829212 817109 688601 - 688639 690427-690448,690451 690478 - 690481 690495 - 690553 690570 690624 - 690635 834721 834732 - 834790 688375 - 688400 690151,690152 690190 690198 690217 690224 690231 690252 - 690284 690318 - 690358 692439 817108 833538 833565 833570 833584 833590 - 833600 833604 - 833606 833609 - 83361 I 833614,833615 680099 680109 680113-680119 833226 833250,833253 833255 - 833287 833290 - 833297 833300 - 833315 833319,833320 681149,681150 679602 - 679615 82421 1 - 824246 678010 - 678012 289227 - 289241 525105 245264 176861 287688 501657 - 501659

-

10520M (Rebuilt) 10520MB (Rebuilt) 10550A (Rebuilt) 10550B (New)

10550B (Rebuilt) 10550C (New)

-

10550C (Rebuilt)

-

-

10550D (New) I0550D (Rebuilt)

10550E (New) 10550F (New) I0550F (Rebuilt) I0550L (New) 10550L (Rebuilt) TS10520AF (New) TSI0520AF (Rebuilt) TSI0520B (Rebuilt) TS10520BB (Rebuilt) TS10520C (New) ISSUED MO 02

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Engine Model TS10520C (Rebuilt) TS10520CE (New) TS10520E (Rebuilt) TS10520EB (New) TS10520EB (Rebuilt) TS10520H (New) TS10520H (Rebuilt) TS10520J (Rebuilt) TS10520JB (Nerv) TS10520K (Rebuilt) TS10520LB (Rebuilt) TS10520M (New)

TS10520M (Rebuilt) TS10520N (Rebuilt) TS10520NB (Rebuilt) TS10520P (New) TS10520P (Rebuilt) TS10520R (New)

-

TS10520R (Rebuilt)

TS10520T (New) TS10520T (Rebuilt) TSI0520UB (New) TS10520UB

TS10520VB (New) TS10520VB (Rebuilt)

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TS10520WB (New)

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Engine Serial Number 178652 - 178659 530186 - 530191 826357 - 826359 510851,510852 815210 -815216 506915,506917 217497 - 837151 825255,825256 533002,533003 224611 815518 - 815522 532378 532381 - 532404 532406 - 53241 1 532413 - 532416 532418 532423 - 532427 532429 830756 - 830781 228649 822443 - 822458 513959 513960 278946 - 278955 522840 - 522856 522858 522860 522862,522864,522865,522867 522869 - 522871 289626 - 289630 289632,289633, 289635 - 289638 289640 - 289643 289645 - 289649 289651,289653,289654 515445,515446 829573 - 829587 829589 527615 - 527620 809479 809481 - 809484 809487 529134 - 529142 832103 832105 836163 836165,836167,836170,836171,836173, 836175,836176,836178 836180 - 836183 836185,836186 518961 518964

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Table 1A Revision A Possible EQ3 Cylinder Equipped Factory Engines Engine Model O470K (Rebuilt) O470L (Rebuilt) 0470R (Rebuilt) 0470s (Rebuilt) O470U (New) 0470U (Rebuilt) 10470F (Rebuilt) 10470L (New) 10470L (Rebuilt) 10470N (Rebuilt) 10470s (Rebuilt) 10470U (Rebuilt) 10470V (Rebuilt) 10520A (Rebuilt) I0520BA (Rebuilt) 10520BB (New) 10520BB (Rebuilt) 10520C (Rebuilt) 10520CB (Rebuilt) 10520D (New) 10520D (Rebuilt) 10520E (New) 10520F (Rebuilt) 10520K (Rebuilt) 10520L (New) 10520L (Rebuilt) 10520M (Rebuilt) 10520MB (Rebuilt) 10550A (New) 10550B (New)

-

-

-

10550B (Rebuilt) 10550C (New)

10550C (Rebuilt) 10550D (Rebuilt) 10550F (Rebuilt) 10550F (New) TS10520B (Rebuilt) TS10520C (Rebuilt) TSI0520CE (New) TS10520E (Rebuilt) TS10520G (Rebuilt) TS10520M (New) ISSUED

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DAY

1

Engine Serial Number 049554 832916 - 832918 834174,834175,834181,834184 819179 470892,470893 834414,834415,834421,834426 833658 - 833660 468679 298324,298326 - 298334 096832,096833 109426 118471 118473 171355 832167,832168 822948,822949,822952 580221 830172 - 830177 830976 - 830986,830995 831779 - 831782,831786 581596 832533 - 832538 556649 830610 - 830614,830620,830647 224177 577299 - 577301 295431 - 295439,295441,295443 826203 - 826206 829177 829181 682060 688644 - 688648 688494 - 688497 688500 - 688505,688513 690409 834670 834673,834675 688264,688265, 688269 - 688272 688290 690165 - 690170 690173 833467 - 833473 833184 824167,824171 679592 176860 178643 178645 530183 826348 216062 532331

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Engine Model TS10520M (Rebuilt) TS10520P (Rebuilt) TS10520R (New) TS10520R (Rebuilt) TS10520T (Rebuilt) TS10520UB (Rebuilt) TS10520VB (Rebuilt)

Engine Serial Number 830731,830732,830734 278942 522813,522814 289602 829555 809471,809473 832026 832028 - 832031 832041 518957-518958 822622 - 822624

TS10520WB (New) TS10520WB (Rebuilt)

TABLE 2 Possible EQ3 Cylinders Cylinder Part 655467AI,A3,A5,A6, A7, A8 EQ7020,EQ7093 655468 A l , A3, A5,A6, A7, AX, A9 EQ7027, EQ7094 655469AI,A6, A7, AX, A9 EQ6989, EQ7048

Cylinder Serial

Engine Models 0470-G,K,L,R,S,M 10470C

04704 10470-D,E,F,H,L,M,N,S,U,V,VO TS10470-B, C, D 10520-A,B,BA,BB,C,CB,D,E,F,J,K,L,M,MB

Serial number range applies to all cylinder part numbers;

10550-A,B,C, IOF550-B, TSI0520-AF,CE,UB AC07K.4001 through

Cylinder Serial Number Explanation ID

YEAR

MONTH

SERIAL

ID = AC is the component identification code for cylinder. Year = 07 represents 2007 Month = K is the month code for November ( A = January, etc) Serial = Begin with AOOleach month, After A999, will go to B001, etc. ISSUED DAY

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Table 2A Revision A, B Possible EQ3 Cylinders Cylinder Part 655467AI,A3,A5,A6, A7, A8 EQ7020, EQ7093 655468 A l , A3, A5,A6, A7, AS, A9 EQ7027, EQ7094 655469AI,A6, A7, A8,A9 EQ6989, EQ7048 655470Al ,A3, A4 EQ7053 655471AI,A3, A4 EQ7089 655472AI,A3, A4 EQ7088 655484AI,A4, A5 EQ7350 655485AI,A3, A4 EQ7309

Engine Models 0470-G,K,L,R,S,M 10470C

Cylinder Serial

Serial number ranges apply to all cylinder part numbers;

0470-U 10470-D,E,F,H,L,M,N,S,U,V,VO TS10470-B, C, D

10520-A,B,BA,BB,C,CB,D,E,F,J,K,L,M,MB 10550-A,B,C, IOF550-B, TS10520-AF,CE,UB AC06DB782 through AC06DB80 1 TSI0520-B,BB,C,D,DB,E,EB,G,H,J,JB,K,KB, AC06GC044 through TS10520-L,LB,M,N,NB,P,R,T,VB,WB AC06HC702 10550-D,E,F,L IOF550-D,E,F,L, AC061.45 1 1,627,679, 714 10550-B,C

Cylinder Serial Number Explanation ID

YEAR

MONTH

SERIAL

AC

06

G

C044

ID = AC is the component identification code for cylinder. Year = 06 represents 2006 Month = K is the month code for November ( A = January, etc) Serial = Begin with AOOleach month, After A999, will go to B001, etc.

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FIGURE 2 Location of EQ3 Marking in the Cylinder Head Rocker Box

Overhead Area

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FIGURE 3 Cylinder Serial Number and Engine Data Plate Locations

FIGURE 4 Example of Top Down View with Cowling Removed Typical Engine Installation

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

FIGURE 5 Rocker Arm Boss (overhead view of cylinder in mounted condition)

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FIGURE 6 Qpical Visual Crack Indications

O 2009 TELEDYNE CONTINENTAL MOTORS, INC.

FIGURE 7 Inspection Area Between Upper Spark Plug Bore and Fuel Injection NozzleIPrimer Port

FIGURE 8 Cylinder Head Crack Indication with Dye Penetrant

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Narraniy 1. Initial Inspection: a. Up to two hours labor at the posted shop rate will be paid to cover the initial inspection aerformed at 400 hours enrrine total time. b. ?he inspection must be performed by a TCM FBO Services member. c. The Compliance Sheet attached to this bulletin or the on-line Compliance Form must be filled out in fuli and returned to TCM to validate this warranty adjustment. 2. Cylinder Replacement: a. Cylinder replacement will be performed at designated TCM Cylinder Replacement Program Centers. b. TCM will pay for parts and labor associated with the cylinder replacements performed at the designated TCM Cylinder Replacement Program Centers provided that the work is completed on or before December 3 1,2009. 3. For aircraft that cannot be flown to a TCM Cylinder Program Replacement Center, contact TCM Technical Customer Service at 888-826-5465 (25 1-436-8299) or [email protected] for assistance.

NOTE: IN ACCORDANCE WITH THE TERMS OF THE APPLICABLE TCM WARRANTY POLICY, FAILURE TO COMPLY WITH THIS MSB ON OR BEFORE DECEMBER 31,2009, VOIDS ANY AND ALL WARRANTIES COVERING PRODUCTS THAT ARE THE SUBJECT OF THIS MSB.

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MSB09-1- Customer Information Form

Serial Number

Yes / No Yes / No Yes / No Yes / No

#3 #4

#5 #6

Yes / No Yes / No Yes / No Yes / No

This form can be submitted electronically through the TCM website, by facsimile or by phone. 1. 2. 3. 4.

Web site entry can be accomplished at: www.tcmlink.com/cylinder The form can be e-mailed to [email protected] The form can be faxed to (251) 432-7352. You can call in your information to (888)-200-7565 or (251)-436-8665

The form mav be mailed to: PO Box 1436. Mobile. AL 36633-1436 ISSUED

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TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

MANDATORY SERVICE BULLETIN The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

CATEGORY 1

MSB644

SUPERSERDES SERVICE BULLETIN 637

FAA APPROVED SUBJECT:

REPLACEMENT OF MAGNETO COILS AND ROTATING MAGNETS

REASON FOR BULLETIN:

To reduce the compliance time originally specified in Bendix Corporation Service Bulletin 560A, therefore, retiring from service certain older coils and rotating magnets. This bulletin also requires the replacement of various coils that were previously acceptable under the instructions listed in its original 1972 issuance.

EQUIPMENT AFFECTED:

I.

All S-20, S-200, S-600 series magnetos with: A. Bendix (not TCM) red or black data plates having serial number: 1. With letter prefix A and numerical serial number 16057 or lower (example: A16057); or 2. Without letter prefix, below 2000000. (example: 925638) B. Bendix (not TCM) blue data plate (Marked "REMANUFACTURED") and serial number lower than 901001. II. All S-1200 series magnetos with: A. Bendix (not TCM) red data plates having serial number: 1. With letter prefix A and numerical serial number 132843 or lower (example: A132843); or 2. Without letter prefix, below 2000000. (example: 925638). B. Bendix (not TCM) blue data plate (Marked "REMANUFACTURED") and serial number lower than 901001. NOTE . . . Data plate colors (Black, Red, and Blue) refer to original factorysupplied data plates. To determine applicability if the original data plate color is uncertain, (i.e. if the color has been removed, or if a Bendix or TCM service spare yellow data plate has been installed, or if the data plate is marked with the name of a field overhaul shop), the most stringent of the serial number ranges listed above must be applied. NOTE . . . The newest magneto affected by this Service Bulletin was built December 31, 1978. Magnetos built by Bendix in Jacksonville, FL, and magnetos built by TCM in Atlanta, GA (as indicated on the magneto data plate) ARE NOT AFFECTED.

COMPLIANCE:

MO 04

ISSUED DAY YEAR 04

94

For all affected equipment not marked as detailed under "identification" below, compliance with this bulletin is required at next 100 hour inspection, annual inspection, or progressive maintenance inspection, whichever comes first.

MO

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1 of 3

NOTE . . . Previous compliance with Service Bulletin 560 or 560A does not guarantee compliance with this service bulletin. Some of the coils which were permissible under Service Bulletin 560 or 560A are to be replaced under this Service Bulletin. Compliance with Service Bulletin 637, however, is the same as compliance with this Service Bulletin. DETAILED INSTRUCTIONS: To prevent failure of the affected magnetos due to malfunction or failure of the coil or rotating magnet, accomplish the following: A. COILS: (S-20, S-200, S-1200 Series Magnetos only) Disassemble magneto as specified in the current applicable service manual to allow access to the coil. All Bendix coils which cannot be identified as detailed under the heading "Replacement Coils" in Table 1 must be replaced. B. ROTATING MAGNETS: (S-20, S-200, S-600 Series Magnetos only) Disassemble magneto as specified in the current applicable service manual to allow full visual inspection of the largest diameter of the rotating magnet surface. Rotating magnets which display the characteristics shown in Figure 1 (i.e. flat magnet sides or brass lamination inserts) must be replaced. While current rotating magnets differ in shaft length, thread pitch, and keyway location, they all incorporate round rotating magnet casting and laminations of a dull iron color. Refer to the current applicable service manual parts list to determine part number of replacement rotating magnet.

TABLE 1 – COIL REPLACEMENT DATA MAGNETO SERIES

COILS TO BE REPLACED PART NUMBER

S-20#

S-20,# S-200

S-1200

NOTES:

MO 04

10-51303 10-76384

7KΩ to 9KΩ

10-160886

12KΩ to 16KΩ

10-163172 10-163209

7KΩ to 9KΩ

10-160887

12KΩ to 16KΩ

10-349271

17KΩ to 23Ω

COLOR

PART NUMBER

SECONDARY RESISTANCE VALUES

COLOR

Opaque Amber to Dark Purple

Marked:

10-357164(A) or 10-357165(A)-20 Order: 10-357165-20S

12KΩ to 16KΩ

Bright Red to Dark Red

Opaque Amber to Dark Purple

Marked:

10-357164(A)

12KΩ to 16KΩ

Bright Red to Dark Red

20KΩ to 26KΩ

Blue to Olive Green to Black

Opaque Amber

Order: 10-357165-1 Marked: 10-391088 Order: 10-391088-1

#

Refer to current applicable magneto service manual parts list for specific application of coil part number to magneto part number.

•

Positive identification of current coils is best made by reading the part number directly off the coil. Secondary resistance values and color are give to aid identification.



Letter “A” sometimes follows number marked on part.

ISSUED DAY YEAR 04

SECONDARY RESISTANCE VALUES

REPLACEMENT COILS *

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IDENTIFICATION: Upon compliance with Detailed Instructions, identify each magneto as follows: A. S-20, S-200, and S-600 series magnetos - Metal stamp .010 deep maximum the letter "C" 3/16 inches high, midway and centered between the timing plug boss and the curved surface at the rear of distributor housing. B. S-1200 series magnetos - Metal stamp .010 deep maximum the letter "C" 3/16 inches high, centered between the timing plug boss and data plate, adjacent to the magneto housing rib. C. Make an engine logbook entry indicating magneto part number, serial number, date of compliance and method of compliance.

Figure 1. Rotating Magnet Types to be replaced

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TELEDYNE CONTINENTAL ® IGNITION SYSTEMS

MANDATORY SERVICE BULLETIN The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

CATEGORY 1

MSB645

SUPSEDES SERVICE BULLETIN 599D FAA APPROVED SUBJECT:

INSPECTION OF RIVETED IMPULSE COUPLINGS AND STOP PINS

REASON FOR BULLETIN:

To decrease operational wear rate of impulse coupling and to prevent engine stoppage.

EQUIPMENT AFFECTED:

All TCM & Bendix S-20, S-1200, D-2000 and D-3000 series magnetos with riveted impulse couplings as installed on TCM, Lycoming, Franklin and other manufacturer's engines.

COMPLIANCE:

NOTE . . . Affected magnetos with data plates identified with the letter "A" in the lower right quarter have the new snap ring cam assembly installed and do not require recurring 100 hour inspections per this bulletin. Service history of magnetos equipped with snap-ring impulse couplings indicates that they must be inspected for wear at 500 hour intervals as specified in the latest revision of the applicable Service Support Manual, PERIODIC MAINTENANCE Section, Paragraph 6.2.2. A. On aircraft with affected equipment with less than 100 operating hours since the last impulse coupling wear inspection, perform this inspection at or before the accumulation of 100 hours and each 100 hours thereafter. On aircraft with affected equipment that have accumulated more than 100 hours since the last impulse coupling wear inspection, perform this inspection within the next 10 hours and each 100 hours thereafter. B. Impulse coupling cam assemblies not meeting the criteria of this bulletin must be replaced with new snap ring cam assemblies. C. As an alternative to recurring 100 hour inspections of RIVETED Impulse couplings, operators may at any time either install improved snap-ring impulse coupling cam assemblies (see Detailed Instructions, Paragraph 2) or retrofit to Shower-of-Sparks Ignition where possible. Magnetos retrofitted with snap-ring impulse coupling cam assemblies may be identified as shown in Figure 6. Magnetos retrofitted to Shower-ofSparks may be identified by part number.

GENERAL INFORMATION A.

Impulse couplings and stop pins are subject to wear during use. Wear may be accelerated by malfunctioning engine counterweights or improper lubrication. Engine failures have occurred on engines operating with impulse couplings worn beyond maximum allowable limits. Inspection in accordance with this bulletin is required of all TCM/Bendix magnetos with RIVETED impulse couplings.

MO 04

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MO

REVISED DAY YEAR

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1 of 6

B.

TCM has redesigned the cam assemblies to include snap ring fastening technology which strengthens the cam axle and reduces wear. WARNING . . . The impulse coupling will function adequately during engine start even though the coupling is worn. Starting performance is not an indicator of coupling wear condition. Such wear can only be determined by performing the inspection as described in this service bulletin. If wear is excessive, impulse coupling failure may occur and cause engine failure. WARNING . . . Any cam assembly that is found to have been repaired or modified must be replaced.

DETAILED INSTRUCTIONS 1

Impulse Coupling Inspection

1.1

Remove magneto from engine.

1.2

Inspect the heel of the flyweight. See Figure 2. A polished area extending from the heel toward the toe of the flyweight is an indicator of severe wear and the cam assembly must be replaced.

1.3

Using an inspection light and 4X or greater inspection lens, inspect the stop pins in the magneto flange or housing. A shiny spot on the stop pin at the point of flyweight contact is acceptable. A wear notch at this point is unacceptable. A damaged or worn stop pin requires replacement of the magneto, stop pin housing or flange depending on magneto type and extent of damage. (Refer to the latest revision of the applicable TCM Ignition Systems Service Support Manual.)

1.4

Inspect for flyweight and axle wear on each flyweight as follows:

1.4.1

Rotate the impulse coupling so the flyweight axles are positioned at the stop pins as shown in Figure 2. Lock rotor in place using rotor holding tool. Use of 11-8465 rotor holding tool or equivalent is necessary. CAUTION . . . Rotor is to be locked on drive end only. Do not use distributor gear lock devices. Use of such devices may result in gear tooth damage. See figure 1.

1.4.2

For Type S-25 and S-1225 magnetos (with impulse coupling recessed into the magneto flange) push on flyweight trigger ramp (see Figure 4A) using bent wire as shown in Figure 3A. Ensure that flyweight tail rests against body trip-dog. Proceed to step 1.4.4.

1.4.3

For all other affected magneto models, form wire into hook as shown in Figure 3B. Reach between the cam and the flyweight with wire hook as near as possible to the stop pin. Pull outward on the flyweight as shown in Figure 4B. Ensure that flyweight tail rests against body trip-dog.

1.4.4

Insert feeler gage between the stop pin and flyweight to determine clearance ("X" of Figure 4) while the flyweight is forced outward. Maintain constant outward force on the flyweight while measuring clearance to ensure accuracy.

1.4.5

Remove the wire to relax the flyweight. Add .014 in. Feeler gauge to your determined "X" value. Attempt to pass "X plus .014" feeler gauges between flyweight and stop pin. See Figure 5. If gauges pass, remove and discard worn cam assembly. Replace the entire impulse coupling assembly or cam assembly with new snap ring impulse coupling or snap ring cam assembly as specified in paragraph 2. If gauges do not pass, coupling may be returned to service or replaced with new snap ring impulse coupling or snap ring cam assembly as specified in Paragraph 2.

MO 04

ISSUED DAY YEAR 04

94

MO

REVISED DAY YEAR

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MOBILE ALABAMA 36601 334-438-3411

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2 of 6

FIGURE 1. INSPECTION SET-UP

FIGURE 3. WIRE HOOK CONFIGURATIONS ALL DIMENSIONS ARE APPROXIMATE

FIGURE 2. FLYWEIGHT TERMINOLOGY AND POSITIONING

FIGURE 4. “X” VALUE MEASUREMENT

FIGURE 5. FLYWEIGHT TO AXLE WEAR CHECK

MO 04

ISSUED DAY YEAR 04

94

MO

REVISED DAY YEAR

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MOBILE ALABAMA 36601 334-438-3411

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3 of 6

NOTE . . . Main spring must always be replaced when coupling is disassembled. 1.5

Make an engine logbook entry indicating compliance with the inspection portion of Service Bulletin. If coupling is returned to service, record "X" values for each flyweight in logbook entry.

2

Replacement of Riveted Cam Assembly with Snap-Ring Cam Assembly.

2.1

If not already accomplished, remove magneto from engine.

2.2

Remove impulse coupling from magneto following disassembly instructions specified in the applicable magneto manual included in TCM Ignition Systems Master Service Manual, Form X40000. If not already accomplished, inspect stop pins as described in paragraph 1.3 of this bulletin.

2.3

Using Table 1 select the correct new impulse coupling part number for the part number magneto being worked on.

2.3.1

At customer's option, a new cam assembly may be selected from Table 1 and field assembled into a serviceable used body. For body inspection criteria and impulse coupling assembly instructions, refer to General Overhaul and Assembly sections of the applicable TCM Ignition Systems Service Support Manual. NOTE . . . Impulse coupling main spring must be replaced with a new part any time coupling body and cam assembly are separated. All impulse couplings use spring 10-51324 except those marked with a triangle in table 1.

2.4

Assemble impulse coupling and related drive parts onto magneto, following assembly instructions in the applicable magneto service manual.

2.5

Mark magneto data plate with letter "A" in lower right quarter to indicate snap ring cam assembly has been installed.

2.6

Install magneto onto engine and adjust timing as per engine manufacturer's latest published instructions.

2.7

Make an engine logbook entry indicating compliance with the replacement portion of this Service Bulletin. Include magneto part number and serial number in logbook entry.

TABLE 2 SNAP RING IMPULSE COUPLING TEST LIMITS MAGNETO TYPE

FULL ENGAGEMENT SPEED (RPM)

FULL DISENGAGEMENT SPEED (RPM)

D6LN-3000 D6LN-2000

0-75 Minimum

450 Maximum

All Others

0-125 Minimum

450 Maximum

FIGURE 6. SNAP-RING CAM ASSEMBLY IDENTIFICATION

MO 04

ISSUED DAY YEAR 04

94

MO

REVISED DAY YEAR

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4 of 6

2.8

When testing snap ring impulse coupling operation, couplings shall perform within limits as shown in Table 2. Remove and replace any coupling which does not meet this test. TABLE 1: IMPULSE COUPLING APPLICATIONS

MAGNETO P/N

MAGNETO TYPE

10-51360-26 10-51360-28 10-51360-37 10-51360-41 10-51360-45 10-51360-46 10-51360-47 10-51360-54 10-51360-55 10-51365-32 10-51365-34 10-51365-35 10-51365-39 10-51365-40 10-51365-43 10-51365-47 10-51365-48 10-51365-54 10-51365-57 10-52350-19 10-52350-20 1079020-6 10-79020-10 10-79020-11 10-79020-16 10-79020-17 10-79020-18 10-79020-19 10-79020-118 10-79020-119 10-500556-101 10-500556-901 10-349350-4 10-349350-5 10-349350-6 10-349350-7 10-349365-1 10-349365-3 10-349365-5 10-349365-6 10-349365-9 10-349365-10 10-349370-4

S4LN-21 S4RN-21 S4LN-21 S4RN-21 S4LN-21 S4RN-21 S4LN-21 S4LN-21 S4LN-21 S6LN-21 S6RN-21 S6RN-21 S6LN-21 S6RN-21 S6LN-21 S6LN-21 S6RN-21 S6RN-21 S6LN-21 S6RN-23 S6LN-23 S6LN-25 S6RN-25 S6LN-25 S6LN-25 S6LN-25 S6LN-25 S6RN-25 S6LN-25P S6RN-25P S6RSC-25P S6RSC-25P S6RN-1225 S6RN-1225 S6LN-1225 S6LN-1225 S4LN-1227 S4LN-1227 S4RN-1227 S4RN-1227 S4LN-1227 S4RN-1227 S6LN-1227

MO 04

ISSUED DAY YEAR 04

94

MO

RIVETED IMPULSE COUPLING P/N

10-59474 10-59473 10-59474 10-160862 10-59474 10-59473 10-59474 10-357265 10-357265 10-70370 10-89137 10-157164 10-59479 10-59478 10-70370 10-70370 10-59476 10-59478 10-70370 10-59476 10-70370 10-102053 10-160892 10-102053 10-102053 10-102053 10-102053 10-160892 10-102053 10-160892 10-160892 10-160892 10-349367 10-349367 10-349368 10-349368 10-349363 10-349359 10-349358 10-349358 10-391429 10-391427 10-349371 REVISED DAY YEAR

SNAP RING IMPULSE COUPLING P/N

10-400313 10-400302 10-400313 10-400301 10-400313 10-400302 10-400313 10-400321 10-400321 10-400315 10-400305 10-400306 10-400314 10-400304 10-400315 10-400315 10-400303 10-400304 10-400315 10-400303 10-400315 10-400316 10-400307 10-400316 10-400316 10-400316 10-400316 10-400307 10-400316 10-400307 10-400307 10-400307 10-400309 10-400309 10-400319 10-400319 10-400318 10-400317 10-400308 10-400308 10-400327 10-400312 10-400320

LAG ANGLE

25 25 25 25 25 25 25 15 15 45 35 45 45 35 45 45 35 35 45 35 45 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 35 25 25 25 15 15 35

BODY P/N

10-52903 10-51333 10-52903 10-51395 10-52903 10-51333 10-52903 10-52903 10-52903 10-70371 10-76232 10-51333 10-52903 10-51395 10-70371 10-70371 10-51333 10-51395 10-70371 10-51333 10-70371 10-70371 10-76232 10-70371 10-70371 10-70371 10-70371 10-76232 10-70371 10-76232 10-76232 10-76232 10-76232 10-76232 10-70371 10-70371 10-52903 10-52903 10-51333 10-51333 10-52903 10-51333 10-70371

OLD RIVETED CAM ASSY P/N

NEW SNAP RING CAM ASSY P/N

10-59437 10-59436 10-59437 10-59436 10-59437 10-59436 10-59437 10-85231 10-85231 10-59472 10-59439 10-102079 10-59472 10-59439 10-59472 10-59472 10-59439 10-59439 10-59472 10-59439 10-59472 10-102052 10-160893 10-102052 10-102052 10-102052 10-102052 10-160893 10-102052 10-160893 10-160893 10-160893 10-349354-2 10-349354-2 10-349357-3 10-349357-3 10-349357-4 10-349357-2 10-349354-2 10-349354-2 10-349357-7 10-349354-7 10-349357-4

10-400167-4 10-400166-2 10-400167-4 10-400166-2 10-400167-4 10-400166-2 10-400167-4 10-400167-1 10-400167-1 10-400167-10 10-400166-6 10-400166-9 10-400167-10 10-400166-6 10-400167-10 10-400167-10 10-400166-6 10-400166-6 10-400167-10 10-400166-6 10-400167-10 10-400167-6 10-400166-4 10-400167-6 10-400167-6 10-400167-6 10-400167-6 10-400166-4 10-400167-6 10-400166-4 10-400166-4 10-400166-4 10-400166-5 10-400166-5 10-400167-7 10-400167-7 10-400167-8 10-400167-5 10-400166-5 10-400166-5 10-400167-2 10-400166-1 10-400167-8

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TABLE 1: IMPULSE COUPLING APPLICATIONS (continued)

MAGNETO P/N

10-382555-11 10-382555-12 10-382555-13 10-382555-14 10-382555-15 10-382555-16 10-382555-141 10-382555-151 10-382560-11 10-382560-13 10-682555-11 10-682555-12 10-682555-13 10-682555-14 10-682555-15 10-682555-16 10-682555-141 10-682555-151 10-682560-11 10-682560-13 10-682560-131

MAGNETO TYPE

RIVETED IMPULSE COUPLING P/N

SNAP RING IMPULSE COUPLING P/N

D4LN-2021 D4RN-2021 D4LN-2021 D4RN-2021 D4LN-2021 D4RN-2021 D4RN-2021 D4LN-2021 D6LN-2031 D6LN-2031 D4LN-3000 D4RN-3000 D4LN-3000 D4RN-3000 D4LN-3000 D4RN-3000 D4RN-3000 D4LN-3000 D6LN-3000 D6LN-3000 D6LN-3000

10-382753 10-382758 10-382752 10-382758 10-382756 10-382754 10-382758 10-382756 10-382953∆ 10-382962∆ 10-382753 10-382758 10-382752 10-382758 10-382756 10-382754 10-382758 10-382756 10-382953∆ 10-382962∆ 10-382962∆

10-400323 10-400311 10-400322 10-400311 10-400324 10-400310 10-400311 10-400324 10-400325∆ 10-400326∆ 10-400323 10-400311 10-400322 10-400311 10-400324 10-400310 10-400311 10-400324 10-400325∆ 10-400326∆ 10-400326∆

LAG ANGLE

25 20 15 20 20 15 20 20 15 10 25 20 15 20 20 15 20 20 15 10 10

BODY P/N

10-382747 10-382768 10-382748 10-382768 10-382767 10-382749 10-382768 10-382767 10-382952 10-382961 10-382747 10-382768 10-382748 10-382768 10-382767 10-382749 10-382768 10-382767 10-382952 10-382961 10-382961

OLD RIVETED CAM ASSY P/N

NEW SNAP RING CAM ASSY P/N

10-349357-6 10-349354-3 10-349357-3 10-349354-3 10-349357-4 10-349354-2 10-349354-3 10-349357-4 10-349357-8 10-349357-9 10-349357-6 10-349354-3 10-349357-3 10-349354-3 10-349357-4 10-349354-2 10-349354-3 10-349357-4 10-349357-8 10-349357-9 10-349357-9

10-400167-9 10-400166-7 10-400167-7 10-400166-7 10-400167-8 10-400166-5 10-400166-7 10-400167-8 10-400167-13 10-400167-12 10-400167-9 10-400166-7 10-400167-7 10-400166-7 10-400167-8 10-400166-5 10-400166-7 10-400167-8 10-400167-13 10-400167-12 10-400167-12

∆ Use Spring P/N 10-400042

PARTS REQUIRED: As determined by inspection or replacement. SPECIAL TOOLS REQURIED: For Inspection: Rotor holding tool 11-8465 Stiff wire (.050 Dia. Heavy Paper Clip) For Replacement: Refer to TCM Ignition Systems Master Service Manual, Form X40000 MANHOURS REQUIRED: For impulse coupling inspection, approximately 1 hour. For replacement of impulse coupling or cam assembly approximately 1 hour. WEIGHT CHANGE: None WARRANTY CONSIDERATION: The standard ignition systems warranty will apply to those units with less than 12 months or 1000 hours time in service (whichever comes first) since initial installation, but limited to 24 months since manufacture. One (1) hour labor will be authorized per coupling installation.

MO 04

ISSUED DAY YEAR 04

94

MO

REVISED DAY YEAR

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

MANDATORY SERVICE BULLETIN The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

CATEGORY 1

MSB93-12 FAA APPROVED

SUBJECT:

VALVE RETAINER KEY INSTALLATION INSPECTION

PURPOSE:

To verify proper valve retainer key installation.

COMPLIANCE:

Before further flight. NOTE...Those engines that have complied with TCM Special Service Notice SSN 2-93 are not affected by this service bulletin.

MODELS AFFECTED:

All engine models identified by the serial numbers listed below having less than 25 hours total time in service.

MODEL

SERIAL NUMBER

NEW ENGINES

MO 05

O200A

256034 thru 256037

O470R

466712 thru 466716

O470S

464585

O470U

470739 thru 470741

IO240A

806000 thru 806011, 806027

IO470L

468575 thru 468578

IO520BB

578883 thru 578886, 578892 thru 578914, 578923

IO520CB

576309, 576310

IO520D

575895 thru 575904

IO520F

579202, 579203, 579205 thru 579207

IO520K

557542, 557543

IO520L

577212, 577213

IO520MB

575054, 575055

IO550B

675772 thru 675799, 675801 thru 675811, 675813, 675814, 675823, 675829, 675830

IO550C

676651 thru 676674, 676680, 676682, 676683, 676686, 676688

IO550E

681008 thru 681012, 681016 thru 681018

IO550G

679050, 679061, 679062, 679065

ISSUED DAY YEAR 12

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MO

REVISED DAY YEAR

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MODEL

SERIAL NUMBER

LTSIO360KB

319129 thru 319159, 319162 thru 319173

TSIO360HB

308146

TSIO360KB

320129 thru 320159, 320162 thru 320172

TSIO520AE

523344

TSIO520BB

526038 thru 526041

TSIO520BE

528521

TSIO520C

501627

TSIO520CE

530158

TSIO520M

520995 thru 520999, 532000 thru 532004, 532006

TSIO520R

522657, 522658, 522660, 522662

TSIO520T

515433

TSIO520UB

527180 thru 527183, 527185

TSIO520VB

529098

TSIO550B

802027 thru 802038, 802040 thru 802042, 802044

TSIOL550A

800555 thru 800564

GTSIO520L

608751 thru 608753

GTSIO520M

613069, 613070

REBUILT ENGINES

MO 05

O200A

285136-R thru 285182-R, 285184-R thru 285192-R, 285195-R thru 285202-R

O300D

25631D-R thru 25634D-R, 25636D-R thru 25648D-R

O470J

202175-R thru 202178-R

O470K

049442-R thru 049446-R

O470L

069761-R thru 069768-R

O470R

288019-R thru 288043-R, 288045-R thru 288049-R, 288051-R thru 288057-R, 288059-R thru 288087-R, 288089-R thru 288093-R, 288097-R

O470S

269230-R, 269231-R, 269233-R thru 269250-R, 269252R thru 269262-R

O470U

286608-R, 286612-R, 286616-R thru 286643-R, 286646R thru 286648-R, 286650-R thru286668-R, 286670-R thru 286680-R

IO360C

060620-R thru 060623-R

IO360D

062959-R thru 062972-R

IO360DB

239734-R thru 239740-R, 239742-R thru 239750-R

IO360G

244566-R thru 244568-R, 244571-R, 244572-R

IO360GB

236674-R thru 236676-R, 236679-R, 236680-R

ISSUED DAY YEAR 12

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MO

REVISED DAY YEAR

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2 of 7

MO 05

MODEL

SERIAL NUMBER

IO360H

226554-R thru 226558-R, 226560-R

IO360HB

265183-R, 265184-R

IO360K

240113-R thru 240117-R

IO360KB

288506-R thru 288525-R, 288527-R, 288528-R

IO470C

242137-R, 242139-R, 242140-R

IO470D

105620-R, 105621-R

IO470E

088741-R thru 088744-R

IO470F

089837-R thru 089842-R

IO470K

092929-R thru 092938-R

IO470L

272876-R thru 272882-R, 272884-R thru272895-R, 272898-R, 272899-R

IO470N

096182-R, 096562-R, 096564-R thru 096574-R

IO470S

109340-R thru 109344-R

IO470U

118431-R thru 118436-R

IO470V

171056-R, 171057-R

IO520A

112665-R thru 112678-R, 112680-R

IO520B

234762-R

IO520BA

280787-R, 280790-R thru 280819-R, 280821-R thru280846-R

IO520BB

285655-R, 285657-R thru 285690-R, 285692-R thru285701-R, 285703-R, 285705-R thru 285735-R, 285738-R thru 285744-R, 285747-R

IO520C

287047-R, 287050-R thru 287092-R, 287094-R thru287102-R, 287104-R thru 287106-R

IO520CB

282217-R thru 282237-R, 282239-R thru 282262-R, 282264-R thru 282267-R, 282269-R thru 282275-R, 282277-R thru 282287-R, 282290-R thru 282294-R, 282296-R thru 282304-R

IO520D

282767-R thru 282817-R, 282819-R thru 282828-R, 282830-R thru 282834-R, 282836-R thru 282848-R, 282850-R thru 282857-R282859-R, 282860-R, 282862R, 282863-R

IO520E

215789-R thru 215794-R

IO520F

286271-R, 286272-R, 286277-R thru 286340-R, 286343R thru 286371-R, 286373-R thru 286378-R, 286381-R thru 286403-R, 286405-R thru 286420-R, 286422-R, 286423-R

IO520J

216519-R, 216520-R

IO520K

224072-R thru 224076-R, 224078-R

ISSUED DAY YEAR 12

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MO

REVISED DAY YEAR

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3 of 7

MO 05

MODEL

SERIAL NUMBER

IO520L

270339-R thru 270370-R, 270372-R thru 270380-R, 270382-R thru 270397-R, 270399-R, 270401-R, 270403R IO520M 270798-R thru 270803-R, 270806-R thru 270826-R, 270828-R thru 270831-R

IO520MB

277417-R thru 277441-R, 277443-R

IO550A

280331-R thru 280337-R

IO550B

281688-R, 281695-R thru 281698-R, 281700-R thru 281730-R, 281732-R thru 281741-R, 281744-R, 281746-R thru 281786-R

IO550C

271739-R thru 271742-R, 271750-R thru 271764-R, 271766-R thru 271791-R, 271793-R thru 271796-R

IO550D

284021-R thru 284039-R

IO550E

283278-R thru 283283-R

IO550F

283277-R, 284526-R thru 284549-R

IO550L

289002-R thru 289018-R

LTSIO360E

225645-R, 225646-R

LTSIO360EB

266365-R, 266367-R thru 266376-R, 266379-R thru266388-R, 266390-R thru 266392-R

LTSIO360KB

268382-R thru 268398-R

TSIO360A

197104-R, 197105-R

TSIO360C

283518-R thru 283523-R, 283525-R, 283526-R

TSIO360CB

236177-R thru 236186-R

TSIO360EB

265828-R thru 265837-R, 265839-R, 265841-R thru265852-R

TSIO360F

232809-R thru 232812-R

TSIO360FB

281109-R, 281111-R thru 281133-R, 281135-R

TSIO360HB

239970-R thru 239973-R

TSIO360KB

268144-R thru 268150-R, 268152-R thru 268157-R

TSIO360LB

247209-R thru 247226-R, 247228-R

TSIO360MB

279231-R thru 279233-R

LTSIO520AE

246609-R, 246611-R thru 246617-R

TSIO520AE

246111-R thru 246115-R, 246610-R

TSIO520AF

245217-R thru 245220-R

TSIO520B

176601-R thru 176604-R, 176606-R thru 176615-R

TSIO520BB

287507-R, 287509-R thru 287511-R, 287514-R thru287516-R

TSIO520BE

273719-R thru 273727-R, 272729-R thru 273731-R, 273734-R

ISSUED DAY YEAR 12

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MO

REVISED DAY YEAR

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4 of 7

MO 05

MODEL

SERIAL NUMBER

TSIO520C

178374-R thru 178388-R

TSIO520CE

268538-R thru 268543-R

TSIO520D

180097-R, 180098-R

TSIO520DB

242009-R, 242010-R

TSIO520E

275232-R, 275233-R, 275237-R thru 275244-R, 275246-R thru 275250-R, 275252-R thru 275275-R

TSIO520EB

271209-R thru 271213-R, 271216-R thru 271237-R, 271239-R

TSIO520G

216043-R

TSIO520H

217280-R thru 217291-R

TSIO520J

218956-R, 218957-R

TSIO520JB

237154-R, 237155-R

TSIO520K

224602-R, 224603-R

TSIO520L

241936-R thru 241940-R

TSIO520M

283163-R thru 283215-R, 283218-R thru 283222-R

TSIO520N

228590-R thru 228594-R

TSIO520NB

276955-R thru 276960-R 276962-R thru 276977-R, 276981-R, 276982-R, 276984-R thru 276986-R, 276989-R thru 276999-R, 290501-R thru 290515-R, 290517-R thru 290523-R, 290528-R thru 290534-R, 290536-R

TSIO520P

278611-R, 278613-R, 278614-R, 278616-R thru 278619-R, 278621-R, 278623-R thru 278638-R

TSIO520R

269847-R thru 269853-R, 269855-R thru 269858-R, 269860-R thru 269862-R, 269864-R, 269865-R, 269867R thru 269897-R, 269899-R

TSIO520T

239382-R thru 239388-R

TSIO520UB

248994-R thru 248999-R, 249000-R thru 249004-R, 249006-R thru 249016-R

TSIO520VB

278485-R thru 278487-R, 278490-R thru 278499-R, 290051-R thru 290086-R, 290088-R thru 290091-R, 290093-R thru 290121-R, 290123-R thru 290125-R

TSIO520WB

274237-R thru 274252-R

GTSIO520C

155562-R, 155563-R

GTSIO520D

219454-R, 219455-R

GTSIO520H

267251-R thru 267253-R, 267255-R thru 267282-R, 267284-R

GTSIO520K

226127-R

ISSUED DAY YEAR 12

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MO

REVISED DAY YEAR

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MODEL

SERIAL NUMBER

GTSIO520L

272412-R, 272413-R, 272415-R thru 272454-R, 272456-R, 272457-R, 272459-R, 272460-R, 272461-R, 272463-R

GTSIO520M

276274-R thru 276329-R, 276340-R

GTSIO520N

277120-R thru 277147-R

OVERHAUL ENGINES

MO 05

O470R

901224-H, 901264-H, 901274-H, 901275-H, 901299-H, 901319-H

O470S

901242-H, 901322-H

O470U

901237-H, 901255-H, 901335-H

IO360C

901331-H

IO360G

901279-H

IO470C

901298-H

IO470F

901238-H

IO470L

901214-H, 901329-H, 901332-H, 901333-H

IO470N

901336-H

IO520A

901226-H

IO520BA

901204-H, 901208-H, 901215-H, 901283-H

IO520BB

901343-H

IO520C

243665-H, 901246-H, 901303-H, 901304-H

IO520CB

901297-H, 901324-H, 901325-H, 901334-H

IO520D

901205-H, 901209-H, 901216-H, 901225-H, 901227-H, 901228-H, 901240-H, 901241-H, 901247-H, 901256-H, 901282-H, 901284-H, 901305-H 901312-H, 901321-H

IO520E

901280-H

IO520F

901217-H, 901266-H, 901276-H, 901292-H, 901326-H

IO520L

901218-H

IO520M

901211-H, 901248-H

IO520MB

901235-H, 901236-H, 901277-H, 901290-H

TSIO360EB

901230-H, 901257-H, 901309-H, 901320-H

LTSIO360KB

901219-H, 901265-H, 901294-H, 901328-H, 901337-H thru 901339-H, 901345-H

TSIO360E

901245-H, 901251-H

TSIO360EB

901220-H, 901243-H, 901258-H, 901271-H, 901272-H, 901287-H, 901288-H, 901300-H

TSIO360F

901293-H

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MODEL

SERIAL NUMBER

TSIO360FB

901221-H, 901231-H, 901244-H, 901259-H

TSIO360KB

901291-H, 901295-H, 901323-H, 901327-H, 901340-H thru 901342-H 901344-H

TSIO520E

901285-H, 901306-H, 901307-H, 901314-H, 901315-H

TSIO520H

506200-H

TSIO520J

901317-H, 901330-H

TSIO520K

901267-H, 901268-H

TSIO520M

901206-H, 901210-H, 901222-H, 901233-H, 901253-H, 901260-H

TSIO520N

901212-H

TSIO520NB

519163-H, 901213-H, 901223-H, 901234-H, 901254-H, 901261-H

TSIO520T

901278-H, 901308-H, 901316-H, 901318-H

INSPECTION: The following inspection must be performed on all cylinders on the affected engines. 1.

Remove engine cowling and appropriate baffling to gain access to each cylinder rocker valve cover.

2.

Remove all rocker valve cover attaching hardware. Remove rocker valve covers and discard gaskets.

3.

Using an inspection light, inspect each cylinder intake and exhaust valve retainer and/or rotocoil for proper installation of the valve retainer keys.

4.

Notify TCM (205-438-3411, ext. 305) immediately if any retainer keys are found to be missing or improperly installed.

5.

If all retainer keys are found in place and properly installed, clean rocker valve cover gasket surfaces and install new gaskets. Install rocker valve covers and attaching hardware. Torque all screws to 55 to 65 in. lbs. torque as listed in TCM "Torque Limits" Service Bulletin M92-15 or current revision as applicable.

6.

Reinstall the baffling and cowling.

7.

Operate engine until oil temperature is in the green arc. Shut down engine and inspect the engine for oil leaks.

8.

Make a logbook entry as to compliance with this service bulletin.

Warranty action required to comply with this bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. A labor allowance of 3 hours inspection time per engine will be allowed as well as replacement of the rocker valve cover gaskets.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 1

MANDATORY SERVICE BULLETIN

MSB94-4G

The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Issued Airworthiness Directive

FAA APPROVED SUPERSEDES MSB94-4F

SUBJECT:

STARTER ADAPTER SHAFTGEAR AND CRANKSHAFT GEAR INSPECTION

PURPOSE:

Since issuance of CSB94-4A, TCM has investigated instances of damaged starter adapter shaft gear and crankshaft gear teeth where there was no record of previous compliance with CSB94-4 or later revision. CSB94-4D was reissued as a Mandatory Service Bulletin, MSB94-4E, in conjunction with the issuance of a FAA Airworthiness Directive to. This bulletin provides inspection and replacement procedures for the starter adapter assembly and crankshaft gear. These procedures are intended to preclude the possibility of a gear failure. Instructions are also provided for the replacement of needle bearing P/N 537721 with bushing P/N 654472. These required inspections must be continued on a repetitive basis until further notice. Service kits EQ 6642 (New) or EQ 6642R (Rebuilt) and bushing P/N 654472 are available at a special exchange price. Refer page 16 of this bulletin for special ordering instructions. WARNING Compliance with this bulletin is required to prevent possible failure of the starter adapter shaftgear and/or crankshaft gear, which can result in metal contamination and/or engine failure.

COMPLIANCE:

1. Unscheduled maintenance inspection due to rough engine operation (Part 1). 2. At every 100 hour or annual inspection (which ever occurs first) perform the inspections detailed in Part 2, “STARTER ADAPTER VISCOUS DAMPER and SHAFTGEAR BACKLASH INSPECTION”. 3. Starter adapters with less than 400 hours total time in service must be inspected in accordance with the "VISUAL INSPECTION PROCEDURE" set forth in Part 3 of this bulletin upon the accumulation of 400 hours total time in service and every 400 hours time in service thereafter. 4. Starter adapters with more than 400 hours total time in service must be inspected in accordance with the "VISUAL INSPECTION PROCEDURES" set forth in Part 3 of this bulletin within the next 25 hours of operation and every 400 hours thereafter. 5. If needle bearing P/N 537721 is installed in the crankcase, it must be removed and replaced with bushing P/N 654472. Refer to Part 3, paragraph 9 and also Part 4 on page 10 for installation instruction. Order bushing P/N 654472 separately, if required. 6. If service kit P/N EQ 6642R has not been installed prior to engine overhaul it must be installed at the next engine overhaul or at the time of starter adapter

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replacement, whichever occurs first. Refer to the latest revision of TCM SB97-6 or mandatory replacement parts. Refer to Part 5 for instructions for installing service kit EQ 6642R. NOTE: Both the crankshaft gear and the starter adapter assembly, included in EQ6642R, must be replaced at the same time if the tooth wear of either the crankshaft gear or the starter adapter shaft gear is unacceptable in accordance with this bulletin. MODELS AFFECTED:

All GTSIO-520 and GIO-550 engine models.

REASON FOR REVISION: Availability of kit EQ 6642 in new or used configuration GENERAL INFORMATION Read this bulletin in its entirety prior to performing any inspections, repairs or replacements. If, after reading this bulletin, you are uncertain about the procedures or actions required to comply with this bulletin, contact your TCM Service Representative or TCM Customer Service at 251-436-8299. This service bulletin provides maintenance, inspection and replacement information for all GTSIO-520 and GIO-550 engine starter adapter shaft gears and crankshaft gears. Continued operation of GTSIO-520 and GIO-550 series engines with starter adapter viscous dampers that have been overheated can lead to distress and possible failure of the starter adapter shaft gear and crankshaft gear teeth. Overheating of the starter adapter viscous damper can be caused by exhaust gas leakage in the nacelle area and in particular, the engine accessory section of the engine nacelle. Operation of a rough running engine as a result of, but not limited to, ignition system misfiring will cause overheating of the starter adapter viscous damper.

WARNING Any report of rough engine operation requires inspection of the starter adapter shaft gear, crankshaft gear and viscous damper.

PART 1 UNSCHEDULED MAINTENANCE INSPECTION: ROUGH ENGINE Any report of rough engine operation requires inspection of the starter adapter shaftgear and crankshaft gear in accordance with Part 3 of this bulletin. In addition perform the following inspections. NOTE: an engine is considered rough if there is a sudden increase in the perceived vibration levels that cannot be cleared by adjustment of the engine controls. Particularly the fuel mixture setting. Reference the aircraft manufacturer’s AFM/POH.

WARNING To prevent the possibility of serious bodily injury or death, before moving the propeller accomplish the following: a. b. c. d. e. f.

Verify aircraft master and magneto switches are in the OFF position. Throttle Position CLOSED Mixture control to IDLE CUT-OFF Set brakes and block aircraft wheels. Insure that aircraft tie-downs are installed and verify that the cabin door latch is open. Do not stand within arc of the propeller blades while turning the propeller.

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1. Remove the engine cowling to provide access to the engine and starter adapter. 2. Disconnect all spark plug leads and remove the lower spark plugs. 3. Remove, induction system components as required to gain access to the magnetos. 4. Remove attaching hardware for the left and right magneto. 5. Remove the left and right magnetos and discard the magneto gaskets.

CAUTION: Magnetos must be overhauled every four (4) calendar years or at engine TBO, whichever occurs first. Additionally, all magnetos require a 500 hour periodic inspection. Refer to TCM’s Ignition Systems Master Manual Form X40000. 6. Remove the left and right magneto drive gear assemblies. 7. Inspect the left and right magneto drive rubber bushings for damage. Refer to Figure 1 on page 3 for typical wear signatures. If there is no visible damage to the magneto rubber drive bushings, lubricate the magneto drive gear needle bearing with Molyshield Grease, P/N 656817, and reinstall the left and right magneto drive gear assemblies and magnetos in the reverse order of removal. Time the magnetos to the engine in accordance with the instructions detailed in the latest revision of TCM Mandatory Service Bulletin MSB94-8. Torque attaching hardware to the values specified in the latest revision of TCM Service Bulletin SB96-7. If there is visible damage to the magneto rubber drive bushings, proceed with step number 8. 8. Remove the propeller from the engine in accordance with the aircraft manufacturer’s instructions.

Acceptable wear indications FIGURE 1. MAGNETO DRIVE RUBBER BUSHINGS 9. Remove the hardware that secures the quill shaft cover plate to the left and right crankcase halves and remove the quill shaft cover plate. 10. Remove the snap ring that secures the quill shaft in the reduction gear. Refer to Figure 3 on page 5. 11. Remove the quill shaft from the engine by pulling the quill shaft forward.

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WARNING Do not rotate the engine with the quill shaft removed. 12. Visually inspect the quill shaft for discoloration and perform a magnetic particle inspection of the quill shaft in accordance with ASTM E 1444, wet continuous method using full wave rectified alternating current and fluorescent particles. 13. If there is no discoloration of the quill shaft and no indications of abnormalities during magnetic particle inspection, reinstall the quill shaft, cover plate and propeller in the reverse order of removal. Replace the magneto drive rubber bushings with new bushings. Insure that the rubber bushings are installed with the beveled edge facing out. Lubricate the magneto drive gear needle bearing with Molyshield Grease, TCM P/N 656817, and reinstall the left and right magneto drive gear assemblies and magnetos in the reverse order of removal. Time the magnetos to the engine in accordance with the instructions detailed in the latest revision of TCM Mandatory Service Bulletin MSB94-8. Torque attaching hardware to the value specified in the latest revision of TCM Service Bulletin SB96-7. Torque all hardware to the values specified in the latest revision of TCM Service Bulletin SB 96-7. Install and torque the propeller hardware in accordance with the aircraft manufacturer’s instructions. 14. If the quill shaft is discolored, or magnetic particle inspection reveals any abnormalities, completely disassemble the engine for inspection of the counterweights, propeller drive, and reduction gear teeth. Additionally, replace starter adapter assembly, viscous damper and crankshaft gear by installing Kit EQ 6642R.

NOTE…. Ensure that the quill shaft is installed with the two timing marks on the quill shaft straddling the timing mark on the reduction gear. See Figure 2 on page 4. Install retaining plate and torque bolts to 90 – 110 in. lbs. Install snap ring in propeller drive gear snap ring slot with flat side facing out. Ensure snap ring is completely seated. See Figure 3 on page 5.

Quill Shaft Timing Marks

Reduction Gear Timing Mark

FIGURE 2. QUILL SHAFT & REDUCTION GEAR TIMING MARKS MO

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Typical Quill Shaft Installation. Remove Snap ring, then remove quill shaft and retaining plate.

FIGURE 3. QUILL SHAFT INSTALLATION PART 2 STARTER ADAPTER VISCOUS DAMPER and SHAFTGEAR BACKLASH INSPECTION Perform this inspection every 100 hours of engine operation.

WARNING To prevent the possibility of serious bodily injury or death, before moving the propeller accomplish the following: a. Verify aircraft master switch and magneto switches are in the OFF position. b. Throttle Position CLOSED c. Mixture control to IDLE CUT-OFF d. Set brakes and block aircraft wheels. e. Insure that aircraft tie-downs are installed and verify that the cabin door latch is open. f. Do not stand within arc of the propeller blades while turning the propeller. A. Visual Inspection of Damper 1. Remove the engine cowling to provide access to the engine and starter adapter. 2. Disconnect all spark plug leads and remove the lower spark plugs. 3. Visually inspect the starter adapter viscous damper for blistered paint, exhaust stains and residue. If any of these conditions are present comply with Part 1 and Part 3 of this service bulletin. Also repair or replace exhaust system component(s) as necessary to eliminate leakage of exhaust gases in the engine nacelle area. If the starter adapter viscous damper is free of blistered paint, exhaust stains, or residue proceed to step 4.

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4. Using a clean shop towel and acetone, thoroughly clean the entire O.D. of the starter adapter viscous damper. 5. Fabricate a wire pointer from one sixteenth (1/16) inch brazing rod, or similar material, approximately 6 inches long. Make a loop on one end of the wire and sharpen the other end into a pointer. 6. Loosen the starter adapter bolt at the 12 o’clock position. Secure the looped end of the wire under the bolt head and position the pointer over the center of the viscous damper OD. Moderately snug the bolt to hold the pointer stationary. See Figure 4 on page 7. 7. Fabricate a measuring strip 1 inch long, graduated in .02 inch increments, from heavy paper stock. Then secure the measuring strip to the previously cleaned OD of the viscous damper using Scotch Tape. See Figure 4 on page 7. 8. Measure the amount of gear backlash by rotating the viscous damper by hand through its full range of travel. Record the maximum gear backlash measured and remove the graduated measuring strip. 9. Rotate the propeller by hand to reposition the viscous damper approximately 90 degrees from the previous measurement. 10. Reinstall the graduated measuring strip and repeat steps 8 & 9, until four backlash measurements have been made at increments of 90 degrees. 11. If none of the four measurements exceeded .06 inches, proceed to step 13. 12. If any of the four measurements exceed .06 inches, remove the starter adapter and perform the inspection specified in Part 3, “VISUAL INSPECTION PROCEDURE” section of this bulletin. 13. Remove the graduated measuring strip from the viscous damper and the pointer from under the bolt head. Torque the loosened starter adapter bolt to 155-175 inch pounds. 14. Lubricate spark plug threads with Champion Thread Lubricant No. 2612. Using new spark plug gaskets reinstall the 6 lower spark plugs removed in step 2. Torque spark plugs to 300 - 360 inch lbs. 15. Reinstall all spark plugs leads and torque “B” nuts to 110 to 120 inch lbs. 16. Reinstall any other engine or aircraft components that may have been removed to facilitate this inspection. 17. Reinstall engine cowling in accordance with the aircraft manufacturer’s instructions. 18. Make an engine logbook entry recording the 4 backlash measurements and compliance with PART 2 of MSB94-4G. Specify the time of the next 100 hour and 400 hour inspections required by this Mandatory Service Bulletin.

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Secure pointer under bolt head Position pointer over OD of damper and secure graduated strip to damper OD.

FIGURE 4. DAMPER SHAFT BACKLASH MEASUREMENT PART 3 VISUAL INSPECTION PROCEDURE In addition to the inspection required by PART 2, perform the following visual inspection every 400 hours time in service. 1. Remove engine cowling and any airframe supplied parts or components as necessary to facilitate starter and starter adapter assembly removal from the engine. 2. Disconnect all spark plug leads and remove the lower spark plugs. 3. Remove the two nuts P/N 2441 and washers P/N 539058 that attach the starter to the adapter. See Figure 5 on page 8. 4. To remove the starter adapter from the engine, remove two sets of nuts P/N AN315-5R, lock washers P/N MS35338-45, and plain washers P/N AN960-516. Remove the top starter adapter bolt P/N 537742, lock washer P/N MS35338-45, and plain washer P/N AN960-516. Loosen the three starter adapter through-bolts located between the starter adapter housing and torsional damper that are positioned at the two, five and seven o'clock positions. Loosen each of these through-bolts until they contact the torsional damper. Pull the starter adapter away from the engine crankcase as far as possible. Repeat this procedure until the bolt threads are no longer engaged in the crankcase. See Figure 5 on page 8 for location of hardware.

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AN960-516 washer 2473 WASHER MS35338-45 Lock Washer MS35338-45 WASHER 537742 Bolt 537742 SCREW Torque 155-175 in.lbs.

534728 Pin, Idler PIN, Gear IDLER Support 652189 Gasket, Idler Pin GEAR SUPPORT

MS35338-44 Washer MS35337-44 WASHER AN 315-4R 646605 NUTNut Torque 90-100 in.lbs.

AN 960-516 Washer MS 35338-45 Lock Washer 2473 WASHER AN 315-5R Nut MS3538-45 WASHER Torque 180-220 in.lbs. 2439 NUT

TELEDYNE CONTINENTAL

MS9021-038 O-Ring 539058 Washer 539058 WASHER 24412441 Nut NUT Torque 200-220 in.lbs. STARTER ADAPTER Starter Adapter Through Bolts THROUGH BOLTS Torque 155-175 in.lbs.

FIGURE 5. STARTER ADAPTER ASSEMBLY 5. Remove the starter adapter from the engine. Using a clean, lint free cloth wipe the oil from crankshaft gear and starter adapter gear teeth to allow inspection. 6. Visually inspect the starter adapter shaft gear and crankshaft gear teeth using an inspection light and 10X magnifying glass for evidence of heavy spalling, pitting or wear that alters the gear tooth profile.

7. If the starter adapter shaft gear or crankshaft gear exhibits unacceptable tooth wear as indicated in Figure 6 on page 9, TCM service kit P/N EQ6642R must be installed prior to further flight. Proceed to Part 5 of this Mandatory Service Bulletin.

WARNING The crankshaft gear, starter adapter assembly and viscous damper must be replaced at the same time if the tooth wear of either gear is unacceptable in accordance with this bulletin. 8. If the condition of the crankshaft gear and starter adapter shaft gear teeth are acceptable, as indicated in Figure 7 on page 9, they may be continued in service. Comply with the recurring inspections listed in the “COMPLIANCE” section of this bulletin.

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UNACCEPTABLE HEAVY WEAR, SPALLING AND PITTING FULL TOOTH WIDTH

UNACCEPTABLE HEAVY WEAR, SPALLING AND PITTING PARTIAL WIDTH

FIGURE 6

ACCEPTABLE LIGHT WEAR LINE, FULL TOOTH WIDTH UP TO .01 INCH WIDE

ACCEPTABLE MODERATE WEAR LINE, NO MORE THAN 50% TOOTH LENGTH AND .05 INCH WIDE

FIGURE 7

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9. If needle bearing P/N 537721 is installed, replace it with bushing P/N 654472 prior to reinstalling the starter adapter assembly. Refer to Part 4 for bushing installation instructions. 10. If previously installed, inspect bushing P/N 654472 for signs of damage or distress. Replace the bushing if any signs of damage or distress are evident. Refer to Part 4 for bushing installation instructions. 11. Using a new gasket reinstall starter adapter in the reverse order of removal. Reinstall starter motor using new O-ring. Refer to Figure 5 on page 8 for attaching hardware torque values. 12. Reinstall the 6 lower spark plugs removed in step 2. Lubricate spark plug threads with Champion Thread Lubricant No. 2612 or equivalent. Install new spark plug gaskets and torque spark plugs 300 to 360 in lbs. 13. Reinstall all spark plug leads and torque “B” nuts to 110 - 120 inch lbs. 14. Install all airframe supplied parts and accessories that were removed to facilitate the inspection / replacement requirements PART 3 of this MSB. Torque all airframe attaching hardware to the values provided by the aircraft manufacturer. For engine torque values not provided in this Critical Service Bulletin, refer to the latest revision of TCM Bulletin SB96-7. 15. Install the engine cowling and perform a complete engine ground run-up, including magneto check, in accordance with the aircraft manufacturer’s maintenance manual and AFM / POH. 16. Perform a complete visual inspection of the engine and engine accessory area for fuel, oil and hydraulic leaks. Verify the security of all components and accessories. 17. Correct any discrepancies noted and repeat steps 15 and 16. 18. Make an engine logbook entry showing compliance with PART 3 of MSB 94-4G. Record the engine time of the next 100 hour and 400 hour inspections required by this Critical Service Bulletin.

PART 4 STARTER ADAPTER SHAFTGEAR BUSHING INSTALLATION 1. Remove existing needle bearing P/N 537721 or bushing P/N 654472 using a 1 (one) inch blind bushing/bearing remover and a slide hammer. 2. Clean bushing bore in crankcase using lint free towel dampened with solvent. 3. Measure crankcase bushing bore ID and uninstalled bushing OD to ensure correct fit. After installation measure installed bushing ID and starter shaftgear pilot OD to ensure correct fit of starter shaftgear pilot in bushing. See Table 1. TABLE 1 ITEM

NEW DIMENSIONS

SERVICE DIMENSIONS

Crankcase Bearing Bore:

ID

.9990 – 1.0000

1.001

Bushing P/N 654472 :

OD

1.0015 – 1.0025

N/A

Starter Shaftgear:

OD

.7495 - .7500

N/A

Starter Shaftgear pilot:

In Bushing

.001 - .003 Loose

.0035 Loose

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4. To facilitate installation of bushing P/N 654472, place bushing on installation tool and submerse bushing in a container of Al-Co-Sol. Place the container of Al-Co-Sol with driver and submersed bushing in dry ice for 15 minutes prior to installation. 5. Install bushing into crankcase bushing bore using a bushing driver equivalent to the one shown in Figure 8 below. Ensure that bushing is firmly seated against the stop surface of the bushing bore. A bushing driver may be locally manufactured from SAE 6150, AISI S7, or equivalent round stock tool steel using the dimensions provided in Figure 8 on page 11.

FIGURE 8. STARTER ADAPTER BUSHING INSTALLATION TOOL 6. Visually inspect the bushing for damage, rolled edges or other deformation. Replace the bushing if any of these conditions exists. 7. Coat the bushing ID with Molyshield Grease TCM P/N 656817. 8. Using a new gasket reinstall starter adapter in the reverse order of removal. Reinstall starter using new O-ring in the reverse order of removal. Refer to Figure 5 on page 8 for attaching hardware torque values. 9. Install all airframe supplied parts and accessories that were removed to facilitate replacement of needle bearing P/N 537721 with bushing P/N 654472 . Torque all airframe attaching hardware to the torque value provided by the aircraft manufacturer. For engine torque values not provided in this Critical Service Bulletin, refer to the latest revision of TCM Bulletin SB96-7. 10. Install the engine cowling and perform a complete engine ground run-up, including magneto check, in accordance with the aircraft manufacturer’s maintenance manual and AFM/POH. 11. Perform a complete visual inspection of the engine and engine accessory area for fuel, oil and hydraulic leaks and for security of all components and accessories. 12. Correct any discrepancies noted and repeat step 10 and 11.

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13. Make an engine logbook entry indicating compliance with PART 4 of MSB94-4G and the time of the next 100 hour and 400 hour inspections required by this Critical Service Bulletin. PART 5 SERVICE KIT EQ 6642 INSTALLATION INSTRUCTIONS Verify that starter adapter shaftgear support bushing P/N 654472 is installed. If not, complete Part 4 of this Mandatory Service Bulletin prior to proceeding with Part 5. The following instructions are provided as a guide for installation of service kit EQ6642. You will find it necessary to refer to the aircraft manufacturer’s maintenance manual and TCM’s GTSIO-520 engine overhaul manual, Form X30045A, for additional information to complete this installation. If you find that you require technical assistance, contact your local TCM service representative or factory service department at (251) 436-8299 or 888-826-5465 Option 2. 1. Insure that the master switch and magneto switches are in the OFF position. 2. Remove the engine cowling. 3. Remove induction system components as required to gain access to the magnetos and starter adapter. 4. Remove the lower spark plug in each cylinder. 5. Remove the magnetos and discard the gaskets. 6. Remove the left and right magneto drive bushings, retainers and gear assemblies. Clearly identify the location from which these items were removed so that they may be reinstalled in their original position. 7. Remove the starter from the starter adapter. Refer to Part 3, Step 3. 8. Remove the starter adapter from the engine. Refer to Part 3, Step 4. 9. Remove and discard the safety wire from the crankshaft gear bolts. Rotate the crankshaft until the timing marks on the crankshaft gear and camshaft gear align. Continue to rotate the crankshaft until the dowel pin is located in the three o'clock position. Remove the crankshaft gear bolts P/N 536379 and discard.

WARNING Do not move the propeller after the crank gear is removed. Rotation of the propeller / crankshaft after removal of the crankshaft gear will result in loss of internal engine timing, damage to internal engine components and possible engine failure. 10. Install the two .250-28 bolts P/N 24251 in the tapped holes of the crank gear that are located 180 degrees apart. Tighten bolts alternately to remove the gear from the crankshaft. Light tapping on the gear with a rubber mallet will assist in the removal process. Once the gear is loose from the crankshaft, remove the gear from the crankcase by holding the gear aft against the crankcase and rotate the gear clockwise to the right. Remove the gear through the starter adapter mount location on the rear of the crankcase. With the crankshaft gear removed from the crankcase, proceed to paragraphs 11 through 29. If difficulty is experienced in the removal of the crank gear due to crankcase interference, proceed as follows: A. Remove the components, (vacuum pump, hydraulic pump, etc.) that are attached to the left and right accessory drives. Remove the four sets of nuts and washers that attach the two accessory drives to the crankcase. Remove the accessory drive assemblies and discard the gaskets. MO

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B. Remove the two nuts P/N AN315-4R and lock washers P/N MS35338-44 that retain the idler gear support pin. Remove the idler gear support pin by applying pressure on both sides of the pin flange simultaneously while keeping the flange holes centered on the studs. Tapping the pin back in after it has moved out a small amount with a soft mallet will assist in loosening the pin for removal. After the pin is removed, discard the pin flange gasket. C. With the pin removed, hold the idler gear toward the top of the accessory case to allow for additional clearance to remove the crankshaft gear. Remove the crankshaft gear as instructed in paragraph 10. If the crankshaft gear can not be removed from the engine due to the gear contacting the interior of the crankcase prior to clearing the end of the crankshaft proceed with the following: 1) Inspect the crankcase interior at the left and right crankcase half split line. You will notice that one crankcase half will be slightly forward of the other. To facilitate removal of the crankshaft gear, material will need to be removed from the most forward (thicker) crankcase half. 2) Place clean shop towels into the crankcase to prevent material from contaminating the engine interior. 3) Using a die grinder or equivalent tool and a fine grinding stone, removed only enough material from the most forward (thicker) crankcase half so that it blends with the opposite half. 4) Smooth surface with 400 wet/dry sandpaper. 5) Using a shop vacuum, carefully clean foreign debris from engine interior. 6) Remove shop towels from engine interior. 7) Remove the crankshaft gear from the crankcase by holding the gear aft against the crankcase and rotate the gear clockwise to the right. Remove the gear through the starter adapter mount location on the rear of the crankcase. 11. With the crankshaft gear removed, clean the gear end of the crankshaft to ensure positive seating of the replacement gear. 12. Heat the replacement crankshaft gear P/N 653580 to 300°F for one hour. Using a suitable pair of insulating gloves, install the gear onto the crankshaft by rotating the gear counterclockwise and to the left so that it is positioned properly with the crankshaft dowel pin. Ensure that the gear seats tightly against the end of the crankshaft by tapping lightly with a brass hammer.

WARNING Do not heat the crankshaft gear longer than the time specified. Damage to the gear will result, and engine failure may occur. 13. Install new crank gear bolts P/N 536379 and torque in an alternating sequence to 380 - 420 inch pounds. 14. Verify correct cam to crank timing by positioning the number two cylinder piston at top dead center on the compression stroke. With the piston in this position, the timing marks must be aligned between the crankshaft and camshaft gears. Refer to Figure 9 on page 14. Remove and reposition the crankshaft gear if alignment of the timing marks is incorrect. 15. With the camshaft gear correctly timed with the crankshaft gear and the crankshaft gear bolts correctly torqued, safety wire the crankshaft gear bolts per the latest revision of TCM Service Bulletin SIL93-15.

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16. Align the idler gear with the idler pin bore in the crankcase. Install new gasket P/N 652189 onto the idler pin and insert the pin into the crankcase and through the idler gear until the pin flange is seated against the crankcase. Install the attaching lock washers P/N MS35338-44 and nuts P/N AN315-4R and torque to 90 - 100 inch pounds. 17. Install new gaskets P/N 649955 onto the accessory drive assemblies and install the assemblies onto the crankcase. Install the attaching washers and nuts and torque the 5/16-24 nuts to 180 - 220 inch pounds and the 3/8-24 nuts to 275 - 325 inch pounds. 18. Rotate the crankshaft in the direction of normal rotation until the piston in the number one cylinder is at its full advance firing position. Remove the timing inspection window from the top of each magneto. Rotate each magneto shaft until the painted timing marks on the distributor gears are aligned in the center of the inspection window. 19. Install accessory drive gear(s) P/N 632799 into their position and mesh gear(s) with idler gear. 20. Install magneto drive coupling retainers onto the magneto drive gears. Install the magneto drive rubber bushings into retainers with the large radius or taper facing out. Lubricate rubber bushings and magneto drive gear needle bearings with Molyshield grease (TCM P/N 656817).

CAMSHAFT TIMING MARK

CRANKSHAFT TIMING MARKS

FIGURE 9

21. Install the magneto drive gears, with magneto drive bushings and retainers installed, into their respective accessory drive gears. Position magneto drive gear to allow the magnetos to be installed horizontally and allow clearance for the induction system manifold/inter-cooler. Mesh magneto drive gears with their respective idler gear.

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22. With gears positioned properly, place new gaskets P/N 649954 onto the magnetos and install the magnetos onto the engine using the retaining plates, lock washers and nuts. Moderately snug magneto attach nuts. Time magnetos to engine in accordance with the latest revision of TCM Bulletin MSB94-8. Torque magneto retaining nuts to 100-120 inch pounds. Install spark plugs and torque to 300 - 360 inch pounds. Install and torque ignition harness lead “B” nuts to 110-120 inch. pounds. 23. Install starter adapter assembly using new gasket P/N 653749 in the reverse order in which it was removed. Torque starter adapter and starter motor attaching hardware to values provided in Figure 5. 24. Install all airframe supplied parts and accessories that were removed to facilitate the inspection/ replacement requirements of this MSB. Torque all airframe attaching hardware to the torque value provided by the aircraft manufacturer. For engine torque values not provided in the Critical Service Bulletin, refer to the latest revision of TCM Bulletin SB96-7. 25. Install the engine cowling and perform a complete engine ground runup, including magneto check, in accordance with the aircraft manufacturer’s maintenance manual, AFM/POH. 26. Perform a complete visual inspection of the engine and engine accessory area for fuel, oil and hydraulic leaks and for security of all components and accessories. 27. Correct any discrepancies noted and repeat steps 28 and 29. 28. Make a log book entry showing compliance with the applicable PARTS (1,2,3,4 and 5) of this Mandatory Service Bulletin. Document in the logbook entry all applicable component serial numbers and part numbers. 29. Specify in the logbook the engine time and aircraft total time of the next 100-hour damper backlash inspection and 400 hour visual inspection of the crankshaft gear and starter adapter shaft gear. WARRANTY COVERAGE Warranty coverage for performance of the maintenance and inspection procedures required by this bulletin will only be applicable to engines currently covered by the TCM New Engine or Rebuilt Engine warranty policies. Verification of warranty coverage can be made by contacting TCM’s Customer Service Department at 251-436-8610 or 888-826-5465 Option 2. Have the engine model, serial number and total time in service available for the Customer Service Representative. If warranty coverage is applicable, labor will be paid at the following rates: Inspection Only............................................................................................. Up to1 hour per starter adapter. Starter Adapter and Crankgear Replacement......................................... Up to 6 hours per adapter and gear. All labor will be paid at no more than the posted shop rate.

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PARTS AVAILABILITY TCM is making Kit P/N EQ 6642 (New) or EQ6642R (Rebuilt) and Bushing P/N 654472 available on an exchange basis at a significantly reduced price. To facilitate product traceability requirements it is necessary for TCM to acquire owner registration and bulletin compliance information on all starter adapter replacements. In order to take advantage of the reduced kit pricing the feedback form attached to this bulletin must be completely filled out and submitted to TCM at the time of the order. All kit orders must be submitted to: Teledyne Mattituck Service Center - Fairhope, Alabama: Phone Number: 1-251-990-5080 or 1-888-876-6809 Option 2 Fax: 1-251-436-8680

NOTE…..If the compliance feedback form is not submitted at the time of the order, the special exchange price will not be available TABLE 2 – SERVICE KIT CONTENTS QTY 1

PART NUMBER DESCRIPTION EQ6642 (New) or EQ 6642R Service Kit, (includes the following) (Rebuilt) Gasket, Adapter to Crankcase •653749 Adapter Assembly, Starter (with viscous damper) •643259A43(R) | Gear, Crankshaft •653580 Screw, Gear to Crankshaft •536379 O-ring, Starter to Adapter •MS9021-038 Washer, (Starter) •539058 Nut, (Starter) •2441 Washer, (Starter Adapter) •AN960-516 Washer - Lock, (Starter Adapter) •MS35338-45 Nut, (Starter Adapter) •AN315-5R Screw, (Starter Adapter) •537742 Gasket, Idler Support Pin •654828 Washer, (Idler Support Pin) •MS35338-44 Nut, (Idler Support Pin) •646605 Gasket, Accessory •653487 Gasket, Magneto •649954 Gasket, Accessory Adapter to Crankcase •654012 O-ring, Intake Manifold •MS9021-252 Screw, 1/4-28 •24251 }

1 1 1 6 1 2 2 3 3 2 1 1 2 2 3 2 2 1 2

Bushing P/N 654472 is not included in kits EQ6642 or EQ 6642R and must be ordered separately if required. Early production kits were supplied with P/N 643259A16 & A16(R), A17 & A17(R), A24 & A24(R), A28 & A28(R) and A40 & A40(R). Any starter adapter of the part numbers listed above or subsequent (superseding) part numbers will satisfy the adapter replacement requirements of this service bulletin, provided they have a new starter adapter shaft gear and new viscous damper. These screws are used only for the removal of the crankshaft gear.

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COMPLIANCE FORM MSB94-4G Owner Name:

Phone:

Date:

Address: City:

State/Country:

FBO Name:

Zip Code: Phone:

FAX:

Address: City:

State/Country:

Zip Code:

Aircraft Registration #:

Airframe Make/Model:

Airframe S/N:

Engine Model:

Serial Number:

Position:

Engine Total Time:

Date Engine Placed in Service:

Engine Model:

Serial Number :

Engine Total Time:

Date Engine Placed in Service:

Position:

Inspection / Repair Results and Comments:

Signature:_______________________________________________ NOTE….In order to receive the special exchange price for Kit P/N EQ6642 (New) or EQ 6642R (Rebuilt) and Bushing P/N 655472 this form must accompany the order.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 1

MANDATORY SERVICE BULLETIN

MSB94-8C

The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Issued Airworthiness Directive

SUPERSEDES MSB94-8, MSB94-8A, MSB94-8B Technical Portions FAA Approved

SUBJECT: MAGNETO TO ENGINE TIMING

PURPOSE: A. To provide magneto to engine timing procedures for all TCM engines. The importance of establishing and maintaining correct magneto to engine timing cannot be over-emphasized. Incorrect timing, in addition to producing a rough running engine, can lead to detonation, pre-ignition and internal engine damage or failure. B. To provide O-200-A and –B engine models that are eligible for magneto timing advance. See timing table Note 5 and Figures 1 and 2. COMPLIANCE: At every 100 hour inspection, annual inspection, progressive inspection, whenever magneto maintenance is performed or whenever magnetos are removed or replaced. Magneto maintenance and internal magneto timing must be conducted in accordance with magneto manufacturers instructions. MODELS AFFECTED: ALL Magneto Equipped Engine REASON FOR REVISION: Correction to Figure 3 WARNING Magneto-to-engine timing maintenance does not assure magneto, harness and spark plug performance. Failure to properly maintain the magneto, harness and spark plugs will lead to internal engine damage and failure. Magneto, ignition harness and spark plugs must be maintained in accordance with the manufacturer's instructions. NOTE: This bulletin contains updates to the Manufacturer's Instructions For Continued Airworthiness as required by FAR43.13 and FAR 33-4. A copy of this bulletin must be inserted into the applicable TCM Maintenance and Overhaul and Manuals. See TABLE 3 for a list of the affected manuals. CAUTION: A single “kick back” while cranking can cause failure of components of the cranking system. Kick back can be caused by intermittent operation of the impulse couplings or shower of sparks system. Perform the following operational test at the specified intervals to ensure that these systems are functioning properly. It is important to note that these operational tests (paragraph I and II) do not supersede inspection, maintenance and overhaul instructions set forth in current manufacturer’s service bulletins and overhaul manuals. ISSUED

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I.

As part of the routine 100 hour, annual or progressive inspection, whichever occurs most often, for all TCM engine incorporating impulse coupled magnetos, perform the following “Magneto impulse coupling operational test”. WARNING Failure to properly ground magnetos will result in ignition and possible injury to personnel. 1. Assure that both magnetos are properly grounded. With all spark plugs installed in all cylinders, remove all spark plug harness lead ends from the spark plugs and ground to the engine to prevent ignition. 2. a. Magneto switch, if separate from starter switch – OFF. b. Mixture – IDLE CUTOFF. c. Throttle – CLOSED. d. Fuel Selector – OFF. e. Master switch - ON. 3. Crank engine several revolutions. WARNING Use extreme caution in the area of the propeller while performing this test. a. Impulse coupling operation is audible and can also be felt through the magneto housings. They should click together and consistently while cranking the engine. b. If “no clicking” or “intermittent clicking” is discovered, remove the magnetos and service per manufacturers instructions. NOTE: Some engine installations incorporate only one impulse coupling on the left magneto, with the right magneto grounded through the ignition switch during starting. Verify the number of impulse couplings that are used for the particular magneto/engine installation. For those that use only one impulse coupling, verify that the non-impulse coupling magneto is grounded during starting. See paragraph II, 1.

II.

As part of the routine 100 hour, annual or progressive inspection, whichever occurs most often, for all TCM engines incorporating a shower of sparks ignition system, perform the following tests: WARNING Use extreme caution in the area of the propeller while performing this test. 1. Confirm that the right magneto is grounded during start: a. Remove the P-lead from the right magneto and connect an ohmmeter between the P-lead and ground. b. With the starter motor disconnected from the aircraft power, actuate the aircraft start switch to the “start” position and confirm that the P-lead has continuity with ground as long as the switch is in the start position. ISSUED

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c. If the P-lead does not show continuity during “start”, repair or replace the P-lead assembly and/or the ignition switch. 2. Confirm retard timing and vibrator circuit operation: a. Verify that the magnetos are timed to the engine at the proper degrees before top center on number one cylinder. See timing table. b. Disconnect the starter motor from the aircraft power. Move the propeller/crankshaft to top dead center compression stroke on number one cylinder. c. Remove the number one cylinder bottom spark plug lead and position the lead end tip 3/16” from engine ground. Turn aircraft master switch “on” and turn the start switch to he “start” position for a maximum of twenty seconds. CAUTION: Do not operate the starting vibrator for longer than twenty seconds in a two minute period as overheating will occur. d. Verify a constant, strong blue spark and confirm that the spark begins a few degrees (8 degrees max) before top dead center on the compression stroke. e. If no spark is observed during the test, test magneto starting circuit and components so that the problem can be isolated and repairs can be accomplished. If a spark is observed before the maximum advanced position, inspect the left magneto for the main and retard contact point timing. All tests and repairs must be accomplished in accordance with the applicable ignition system maintenance manual.

MAGNETO TO ENGINE TIMING PROCEDURE In conducting magneto timing checks, the use of a positive Top Dead Center (TDC) locator, protractor and pointer such as the Eastern Electronics Model E25 Timing Indicator, or equivalent, are the most accurate tools to use. (Reference the applicable tool manufacturer’s instructions for use.) Tools which call for a specific arm on the piston dome are more susceptible to error due to bending or excessive carbon buildup. The following basic timing procedure must be used to assure that timing is accomplished in accordance with the required specifications. CAUTION: When using a positive TDC locator, the propeller / crankshaft must be rotated slowly to prevent damage to the piston. A. DIRECT DRIVE ENGINES CAUTION: Prior to checking or adjusting engine magneto timing, the aircraft must be situated in a normal attitude on a level surface. If the engine has been removed from the airframe, then the engine must be verified to be level prior to performing magneto timing. 1. When utilizing the Eastern Electronics Model E25 Timing Indicator, use the Eastern Electronics E25 operating instructions. A copy of these instructions are attached to this bulletin. (Reference Figure 3) 2. When using a timing tool other than the Eastern Electronics Model E25 Timing Indicator, contact the applicable tool manufacturer for magneto timing instructions. ISSUED

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B. GEARED ENGINES CAUTION: Prior to checking or adjusting engine magneto timing, the aircraft must be situated in a normal attitude on a level surface. If the engine has been removed from the airframe, then the engine must be verified to be level prior to performing magneto timing. 1. Remove all spark plugs. Rotate piston to the start of the compression stroke on No. 1 cylinder. Install the TDC locator into the No. 1 cylinder top spark plug hole. Torque the TDC locator tool to 15 inch-pounds. 2. Install the timing disc of the indicator being used on the crankshaft flange, propeller spinner, hub or blade. Ensure that the timing disc support is stationary throughout the timing procedure to prevent error. 3. Turn the propeller slowly in the direction of normal rotation until the piston lightly but positively touches the TDC locator. 4. Rotate the disc of the timing indicator until 0 degrees aligns with the pointer. A light tap of the finger against the dial will ensure that the pointer is centered. 5. Slowly turn the propeller in the opposite direction of normal rotation until the piston lightly but positively touches the TDC locator. Observe the reading, (total degrees of travel) and record. This is the “X” value. 6. Rotate the disc to align 0 degrees with the pointer. Use the following formula, as applicable, to determined the TDC. GO-300, GIO-470, GTSIO-520-C

X Degrees Divided By 2 + 135 Degrees = Y Degrees

GTSIO-520-D,H,F,K,L,M,N

X Degrees Divided By 2 + 120 Degrees = Y Degrees

Tiara 6-285, 6-320

X Degrees Divided By 2 + 90 Degrees = Y Degrees

Y = DEGREES OF PROP ROTATION FROM 0 DEGREES (PARAGRAPH 6) TO TDC. 7. Remove the TDC locator from the cylinder. 8. With the Y degrees determined, move the propeller that number of degrees (Y degrees) in the direction of normal rotation. This will place the piston at TDC. 9. Once the TDC has been established and set, reset the timing disc to 0 degrees at TDC. 10. Now the correct timing can be set by using the appropriate propeller shaft angle for the corresponding engine model. Move the propeller in the opposite direction of normal rotation past the specified “propeller shaft angle” magneto timing setting and then back in the direction of normal rotation until the specified “propeller shaft angle” before TDC is under the pointer. (This removes the factor of gear backlash) reference the following example and TABLE 1 for “propeller shaft angle”. EXAMPLE: For a geared engine with a .75 propeller to crankshaft RPM ratio and timing specification of 24 degrees BTC, the propeller shaft angle would be .75 x 24 degrees, or 18 degrees BTC. If the propeller shaft to crankshaft ratio was .667, then the propeller shaft timing angle would be .667 x 24 degrees, or 16 degrees BTC. ISSUED

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ENGINE MODEL

CRANKSHAFT ANGLE 28 DEGREES BTC 24 DEGREES BTC 22 DEGREES BTC 20 DEGREES BTC 24 DEGREES BTC

GO-300 GIO-470 GTSIO-520-C GTSIO-520-D,H,F,K GTSIO-520-L,M,N GIO-550 TIARA 6-285 TIARA 6-285

30 DEGREES BTC 30 DEGREES BTC

PROPELLER GEAR RATIO .75 .75 .75 .667 .667 .667 .500 .500

PROPELLER SHAFT ANGLE 21 DEGREES BTC 18 DEGREES BTC 16.5 DEGREES BTC 13.3 DEGREES BTC 16 DEGREES BTC 15 DEGREES BTC 15 DEGREES BTC

TABLE 1 MAGNETO TIMING SPECIFICATIONS FOR GEARED ENGINE MODELS. MODEL

A65 A75, A80 C75, C85 C90 O-200-A, B IO-240-A IO-240-B C-125 C-145, O-300 E165, E185, E225 O-470-A, E O-470-B, G, M, P & U O-470-J O-470-K, L, R & S IO-346 IO-360 IO-360-ES IO-470-C, G, R & P IO-470-D,E,F,H,L,M,N,S,U,V & VO IO-470-J,K IO-520-SERIES IO-550-SERIES LTSIO & TSIO-360-SERIES TSIO-470 LTSIO-520-AE TSIO-520-B,C,D,E,H,J,K,L,N VB,WB,AE & CE

RIGHT MAG [3] 30 DEGREES BTC 29 DEGREES BTC 28 DEGREES BTC 26 DEGREES BTC 24 DEGREES BTC 22 DEGREES BTC 26 DEGREES BTC 28 DEGREES BTC 26 DEGREES BTC 26 DEGREES BTC 26 DEGREES BTC 24 DEGREES BTC 20 DEGREES BTC 22 DEGREES BTC 24 DEGREES BTC 20 DEGREES BTC 24 DEGREES BTC 26 DEGREES BTC 20 DEGREES BTC

LEFT MAG [3] 30 DEGREES BTC 32 DEGREES BTC 30 DEGREES BTC 28 DEGREES BTC 24 DEGREES BTC 22 DEGREES BTC 26 DEGREES BTC 30 DEGREES BTC 28 DEGREES BTC 26 DEGREES BTC 26 DEGREES BTC 24 DEGREES BTC 20 DEGREES BTC 22 DEGREES BTC 24 DEGREES BTC 20 DEGREES BTC 24 DEGREES BTC 26 DEGREES BTC 20 DEGREES BTC

22 DEGREES BTC 22 DEGREES BTC 22 DEGREES BTC 20 DEGREES BTC 22 DEGREES BTC 20 DEGREES BTC 20 DEGREES BTC

22 DEGREES BTC 22 DEGREES BTC 22 DEGREES BTC 20 DEGREES BTC 22 DEGREES BTC 20 DEGREES BTC 20 DEGREES BTC

NOTES

[5]

[1]

[1] [1]

[1]

TABLE 2 MAGNETO TIMING SPECIFICATIONS FOR DIRECT DRIVE ENGINE MODELS ISSUED

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MODEL TSIO-520-M,R,T,UB,AF &P TSIO-520-BE TSIO-550-A,B,C,E,G TSIOL-550-A,C TSIOL-550-B W-670 W-670-23

RIGHT MAG [3] LEFT MAG [3] NOTES 22 DEGREES BTC 22 DEGREES BTC [1][4] 24 DEGREES BTC 24 DEGREES BTC 24 DEGREES BTC 24 DEGREES BTC 20 DEGREES BTC 20 DEGREES BTC 24 DEGREES BTC 24 DEGREES BTC 32 DEGREES BTC 32 DEGREES BTC 5 DEGREES BTC 14 DEGREES BTC [2] TABLE 2 MAGNETO TIMING SPECIFICATIONS FOR DIRECT DRIVE ENGINE MODELS

NOTES: [1] “B” Models (ie IO-360-DB, etc) same as standard models. [2] This engine has one magneto on left position and battery ignition on right. Both have automatic advance and are in retarded position. [3] Magneto setting tolerance to be plus or minus one (1) degree unless otherwise noted. [4] Magneto setting tolerance of TSIO-520-P to be plus zero (0) or minus one (1) degree. [5] O-200-A and –B model engines that have a complete set (4 each) of P/N 641917 or subsequent (higher) part number cylinders installed are eligible to have the timing advanced to 28 degrees BTC. This may include a combination of 641917, 649543, 653246, 654377, 653816, 655483 or subsequent (higher) part number cylinders. The cylinders P/N 641917 were first produced beginning in 1977. The cylinder part number is stamped on the barrel flange. The absence of a cylinder part number usually indicates cylinders manufactured prior to P/N 641917. Visual acceptance can be determined by the exampled listed in FIGURES 1 and 2. For those engine that have the applicable cylinders and timing advanced, restamp the engine data plate to indicate magneto timing of 28 degrees BTC and make a log book entry noting the change and the part number of the qualifying TCM cylinders installed. Subsequent installation of cylinders must be of the part numbers listed above to retain the advanced (28 degree BTC) timing. Only cylinders manufactured by TCM qualify for the advanced timing under this service bulletin.

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Model E-25 TIMING INDICATOR INSTRUCTIONS CAUTION: Prior to checking or adjusting engine magneto timing, the aircraft must be situated in a normal cruise flight attitude on a level surface. If the engine has been removed from the airframe, then the engine must be verified to be level and secure prior to performing magneto timing. 1) Remove all top spark plugs. Rotate the piston to the start of the compression stroke on #1 cylinder. Install the piston stop into the #1 cylinder top spark plug hole. Torque the piston stop to 15 inch-pounds. 2) Install the timing disc indicator on aircraft propeller spinner, propeller blades or hub using the supplied rubber bands. Make sure the timing disc indicator is securely fastened to prevent movement during the timing test. 3) Turn the propeller slowly in the direction of rotation until the piston lightly touches piston stop. 4) Rotate the disc of the timing indicator until Top Center (T.C.) mark is under the point of the weighted pendulum pointer. Ensure that the timing indicator base (aluminum flower pot) does not move. 5) Slowly turn the propeller in the opposite direction of normal rotation until the piston again lightly touches the piston stop. Observe the reading on the indicator disc under the pointer and rotate the disc to exactly one half of the number of degrees toward the Top Center (T.C.) mark. Ensure that the timing indicator base (aluminum flower pot) does not move. 6) Remove the piston stop from the cylinder. Move the propeller in the direction of normal rotation and verify the engine is on the compression stroke of #1 cylinder by placing a finger over the spark plug hole until building pressure is felt. Continue the rotation until the pointer is under T.C. You now have found top center on the compression stroke. 7) To confirm the magneto timing or to time the magnetos to the engine, move the propeller opposite direction of rotation past the specified magneto timing setting and then back in direction of rotation until the desired setting before top center is under the pointer (this removes the factor of gear backlash). NOTE: Engines equipped with impulse couplings must be turned in the direction of rotation until the impulse coupling(s) trip prior to centering the pointer on the desired timing setting. 8) The breaker points should just be starting to open at this setting. Breaker points opening should be checked with an Eastern Model E-50 Synchronizer. Note: A. A light tap of the finger against the dial will insure absolute correct timing. B. An occasional drop of oil at the pointer bushing is all that’s required to keep the timer in good operating condition. WARRANTY Eastern Technology Corporation agrees to repair or replace any of its products (parts and labor) if there is a defect in materials or workmanship within one year of the date of purchase. Eastern Technology Corporation limits its obligation to repair or replacement, the choice of which is at its sole discretion. This warranty does not apply to equipment that has been damaged by accident, negligence or misuse, or altered or modified in any way. For repairs return to:

42 Nelson Street · East Hartford · Connecticut · 06108 Phone: 860-528-9821 Fax: 860-289-7639

FIGURE 3 E-25 TIMING INDICATOR INSTRUCTIONS ISSUED

REVISED

PAGE NO REVISION TM

MO 09

DAY 14

YEAR 1994

MO 04

DAY 25

YEAR 2007

T e le d y n e C o n t in e n t a l M o t o r s, In c . P.O. BOX 90 MOBILE, AL 36601 251-438-3411

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TABLE 3 AFFECTED PUBLICATIONS This Service Bulletin contains updates to the manufacturer’s Instructions for Continued Airworthiness (ICA) as required by FAR 43.13(a). A copy of this bulletin must be inserted into the specified locations in the manuals listed in TABLE 3 until the manual is updated or the bulletin is superseded or cancelled. MANUAL MANUAL TYPE ENGINE MODEL SECTION SECTION NUMBER X30008 OVERHAUL A-65, A-75, 8 11 X30010A OVERHAUL C-75, C-85, C-90, 10 --O-200A, O-200B X30013 OVERHAUL C-125, C-145, O-300 9 12 X30019 OVERHAUL GO-300 6 12 X30016 OVERHAUL E-165, E-185, E-225 12 --X30586A OVERHAUL O-470 72-60-15 74 X30621A MAINTENANCE IO-240 12 --X30622A OVERHAUL IO-240 19 --X30027 OVERHAUL IO-346 3 --X30594A OVERHAUL IO-360 72-60-14 74 X30588A OVERHAUL IO-470 72-60-15 74 X30039A OVERHAUL IO-520 8 --M-11 MAINTENANCE IO-520 PERMOLD 12 --X30607A OVERHAUL IO-550 SANDCAST 72-60-15 74 X30634A MAINTENANCE IO-550 PERMOLD 12 --X30568A OVERHAUL IO-550 PERMOLD 18 --X30045A OVERHAUL GTSIO-520 12 --X30596A OVERHAUL L/TSIO360 72-60-14 74 EXCEPT -RB X30672A MAINTENANCE TSIO-360-MB, -SB 12 --X30645A MAINTENANCE L/TSIO-360-RB 12 --X30596A1 OVERHAUL L/TSIO-360-RB 19 --X30033 OVERHAUL TSIO-470 4 5 X30574A OVERHAUL TSIO-520 72-60-15 74 PERMOLD X30575A OVERHAUL TSIO-520 72-60-15 74 SANDCAST M-18 MAINTENANCE/ TSIO-550 9 17 OVERHAUL X-30600A OVERHAUL TSIOL-550-A 72-60-15 74 OH-15 OVERHAUL TSIOL-550-C 8 19 OMI-15 MAINTENANCE TSIOL-550-C 8 --X30144 OVERHAUL TIARA 9 --X30009 OVERHAUL W-670 13 --ISSUED

REVISED

PAGE NO REVISION TM

MO 09

DAY 14

YEAR 1994

MO 04

DAY 25

YEAR 2007

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 1

MANDATORY SERVICE BULLETIN MSB94-9 The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

FAA APPROVED Supersedes M92-13

SUBJECT:

INSPECTION OF ENGINE MOUNT BRACKET, PART NUMBER 630695; REPLACEMENT OF ENGINE MOUNT BRACKETS, PART NUMBERS 630694 AND 630695

PURPOSE:

TCM has investigated instances of cracks located in the left lower engine mount bracket P/N 630695 used on the affected engine models. This bulletin requires inspection of this bracket at specified intervals until the left and right lower brackets are replaced at the recommended engine TBO. The current TCM replacement brackets incorporate an improved design that increases its strength. Positive identification of affected mount brackets is provided in Table 1.

COMPLIANCE:

Inspect engine mount bracket, P/N 630695, within the next 50 hours of operation and at 500 hour intervals thereafter until engine reaches the next recommended TBO. Inspection is not required on new mount legs that have not reached recommended engine TBO. Replace brackets, P/N 630695 and P/N 630694, at the next recommended TBO on all affected engine models.

MODELS AFFECTED:

IO-346-A, IO-520-C and CB, and IO-550-C model engines 1. All Rebuilt IO-520-C with engine S/N 287051-R and prior. All Rebuilt IO-520-CB with engine S/N 282226-R and prior. All Rebuilt IO-550-C with engine S/N 271742-R and prior. 2. All Factory Overhauled IO-520-C, CB and IO-550-C with a build date prior to August 6, 1992. 3. All Factory New engines are supplied with new mount brackets and therefore, do not require inspection of the P/N 630695 bracket until the engine reaches the recommended TBO. 4. TCM no longer manufactures the IO-346-A model engine. Therefore, all engine serial numbers must comply with the requirements set forth in this bulletin.

MO 10

ISSUED DAY YEAR 21

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS PAGE NO REVISION P.O. Box 90 MOBILE ALABAMA 36601 1 of 2 (205)-438-3411

INSPECTION AND REPLACEMENT INSTRUCTIONS Within the next 50 hours of operation, the lower left engine mount bracket, P/N 630695, must be inspected for cracks using dye penetrant or Eddy Current inspection techniques. The specific area of inspection is shown in Figure 1. The bracket may be inspected in place by opening the engine cowling and observing the bracket at the lower left of the engine. If a crack is detected in the lower left mount bracket, replace the lower left, P/N 630695, and lower right, P/N 630694, engine mounting brackets with new engine mount brackets, P/N's 653306 and 653305 respectively. If a crack is not detected, the left engine mount bracket should be inspected at 500 hour intervals until the engine reaches the next recommended TBO, at which time the subject engine mount brackets, P/N 630694 and 630695, must be replaced with new engine mount brackets, P/N 653305 and 653306. Installation of engine mount brackets, P/N 653305 and 653306, will relieve the requirement for further inspection under this bulletin.

TABLE 1 - ENGINE MOUNT BRACKET IDENTIFICATION. If the ink stamped part number is not visible, the mount bracket can be identified by the casting number as shown below. This number is cast into the mount bracket. MOUNT BRACKET PART NUMBER

CORRESPONDING CASTING NUMBER

630694

630723

630695

630724

653305

653298

653306

653299

Note compliance with this Service Bulletin in the engine log book and return aircraft to service. Warranty action required to comply with this bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

MO 10

ISSUED DAY YEAR 21

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS PAGE NO REVISION P.O. Box 90 MOBILE ALABAMA 36601 2 of 2 (205)-438-3411

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 1

MANDATORY SERVICE BULLETIN MSB95-6 The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

FAA APPROVED SUPERSEDES M93-9 Rev.1

SUBJECT:

FUEL PUMP DRIVE COUPLING

PURPOSE:

TO INSURE PROPER ENGAGEMENT OF THE FUEL PUMP DRIVE COUPLING.

COMPLIANCE: MODELS AFFECTED:

Within the next 30 hours of operation.

IO-346-A. IO-520-B, BA, BB, C, CB, M, MB. IO-550-A, B, C, G. TSIO-520-B, BB, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB. TSIO-550-B. TSIOL-550-A, B. All models listed above which utilize the fuel pumps listed below are affected. Also, any fuel pump, (regardless of the part number) that has been field overhauled and had the P/N 646176 fuel pump shaft installed.

EQUIPMENT AFFECTED:

MO 10

ISSUED DAY YEAR 19

95

FUEL PUMP PART NUMBERS 646210-1, -2, -8, -10, -11 646212-2, -5, -16, -17 646758-5, -7, -8, -9 646764-1 646765-6, -7 646766-1, -2 646767-1 649368-19

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 4 MSB95-6

THE FOLLOWING ENGINES ARE NOT AFFECTED BY THIS SERVICE BULLETIN. MODEL

SERIAL NUMBER NEW ENGINES BB 578917 and Subsequent IO-520 CB 576311 and Subsequent MB 575056 and Subsequent IO-550 B 675816 and Subsequent 676443, 676675 and Subsequent 679061 and Subsequent TSIO-520 BB 526042 and Subsequent D 505016 and Subsequent EB 510835 and Subsequent J 503629 and Subsequent K 504317 and Subsequent KB 531001 and Subsequent L 508734 and Subsequent NB 521654 and Subsequent UB 527187 and Subsequent VB 529099 and Subsequent WB 518922, 518923, 518927 and Subsequent TSIO-550 B 802030, 802031, 802033 thru 802035, 802038 thru 802042, 802044 and Subsequent TSIOL-550 A 800511, 800512, 800561 and Subsequent B 801500 and Subsequent REBUILT ENGINES IO-520 B 234763-R and Subsequent BA 280830-R, 280831-R, 280833 and Subsequent BB 285680-R, 285725-R, 285726-R, 285729-R, 285730-R, 285732-R and Subsequent C 287084-R, 287086-R and Subsequent CB 282268-R, 282271-R, 282283-R and Subsequent M 270823-R, 270825-R and Subsequent MB 277437-R and Subsequent IO-550 A 280336-R, 280338-R and Subsequent B 281750-R, 281759-R, 281766-R, 281771-R and Subsequent C 271785-R and Subsequent TSIO-520 B 176610-R and Subsequent BB 287517-R and Subsequent D 180099-R and Subsequent

MO 10

ISSUED DAY YEAR 19

95

MO

REVISED DAY YEAR

MODEL TSIO-520 DB (cont’d) E EB

TSIOL-550 IO-520

IO-550 TSIO-520

SERIAL NUMBER 242011-R and Subsequent

275265-R and Subsequent 271322-R, 271234-R and Subsequent J 218958-R and Subsequent JB 237156-R and Subsequent K 224603-R and Subsequent KB 245709-R and Subsequent L 241940-R and Subsequent LB 237276-R and Subsequent N 228593-R and Subsequent NB 290512-R and Subsequent UB 249012-R and Subsequent VB 290106-R and Subsequent WB 274213-R, 274236-R, 274247-R and Subsequent B 290003-R and Subsequent OVERHAUL ENGINES BA 122274-H, 901239-H, 901302-H, 901311-H BB 578897-H C 243884-H CB 576311-H M 232142-H, 901284-H MB 575054-H B 675782-H C 676654-H G 679061-H BB 526040-H D 180048-H, 505016-H E 206408-H, 275028-H EB 510835-H J 503629-H K 504317-H KB 531001-H L 508353-H, 508424-H, 508477-H, 508500-H, 508734-H N 228398-H, 901212-H, 901262-H NB 521654-H, 901207-H UB 527182-H VB 242317-H, 248445-H, 266732-H, 266932-H, 266951-H, 266957-H, 516365-H, 516424-H, 516677-H, 518603-H, 529098-H, 901263-H WB 518473-H, 518789-H, 518830-H, 518848-H, 518859-H, 518867-H, 518927-H

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 4 MSB95-6

Teledyne Continental Motors fuel pump drive coupling P/N 631263 is used on all models affected. There are two fuel pump shafts, P/N 643689 and 646176 used in early and current design fuel pump assemblies. Due to the tolerance range in the fuel pump drive train, there is the possibility of having less than the required minimum coupling engagement. To ensure proper drive coupling engagement, TCM has replaced coupling P/N 631263 with a longer coupling P/N 653359. See Figure 2. The new coupling can be used with both fuel pump shafts. CAUTION...The old coupling can only be used with shaft P/N 643689. See Figure 1. Couplings P/N 631263 that are continued in service with the P/N 643689 fuel pump shaft, must be replaced at engine overhaul. Perform the following inspection on the affected engines at the indicated time of compliance: 1. Remove engine cowling to gain access to the fuel pump. 2. Remove fuel lines from fuel pump and cap lines to prevent contamination. Identify fuel line location for proper reinstallation. 3. Remove fuel pump and drive coupling. 4. Determine which fuel pump shaft is installed in the pump by visual inspection of the shaft drive end. See Figure 1. 5. Install new fuel pump gasket. 6. Reinstall fuel pump with the proper coupling. Install hold down washers, lock washers and nuts. 7. Torque nuts to 180-220 in/lbs. 8. Reinstall fuel lines in their proper locations and pressurize fuel system to check for leaks. 9. Ground run engine and verify correct fuel flow indications. 10. Make logbook entry as to compliance with this service bulletin. Warranty action required to comply with this bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

MO 10

ISSUED DAY YEAR 19

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

3 of 4 MSB95-6

MO 10

ISSUED DAY YEAR 19

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

4 of 4 MSB95-6

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 1

MANDATORY SERVICE BULLETIN MSB96-10A The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In An FAA Airworthiness Directive

FAA APPROVED Supersedes M87-5 Rev.1,MSB96-10

SUBJECT:

CRANKSHAFT ULTRASONIC INSPECTION.

PURPOSE:

To provide crankshaft ultrasonic inspection requirements for all crankshafts utilized in the affected engine models.

COMPLIANCE:

At the next and each subsequent removal of the crankshaft from the crankcase for inspection or overhaul, the crankshaft must be ultrasonically inspected by a "qualified inspector" as mandated by this service bulletin. NOTE: The ultrasonic inspection requirements set forth in this Service Bulletin must be performed on replacement crankshafts prior to installation. Ultrasonic inspection is NOT required on TCM Factory new crankshafts prior to initial installation, but must be performed at each subsequent removal as stated above.

MODELS AFFECTED:

All TCM six cylinder engine models.

Although a high level of reliability has been attained in the design and manufacture of aircraft engine crankshafts, experience shows that fractures can and do occur. Such fractures are frequently attributed to operational or maintenance conditions of the type discussed in F. A. A. Advisory Circular AC20-103 dated March 7, 1978, which addresses these conditions and details preventive measures that can be practiced to alleviate them. In addition to crankshaft fractures of known causes, some engine models have experienced unexplained subsurface origin fatigue cracks initiating below the intermediate main bearing fillets. These cracks can propagate in fatigue through the short cheek of the crank pin, resulting in crankshaft fracture. In an effort to detect such cracks, TCM has established an ultrasonic test procedure TCM Specification MHS 200. Utilization of this test procedure has resulted in the detection of subsurface cracks in the intermediate main bearing fillet area of crankshafts which could not be detected using the standard magnetic particle inspection method. NOTE: Any crankshaft listed in the latest revision of TCM Service Bulletin CSB96-8 that is NOT verified as being a VAR forging must be replaced. INSPECTOR QUALIFICATION The ultrasonic inspection of the crankshaft must be performed in accordance with TCM specification MHS 200 and only by individuals that have:

MO 08

ISSUED DAY YEAR 15

96

MO 09

REVISED DAY YEAR 30

2008

© 2008 TELEDYNE INDUSTRIES, INC.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 3 MSB96-10

A

1. Attended the complete 40 hour ultrasonic training course presented by Teledyne Continental Motors' designated representative within the last 36 months or; 2. Been certified to a minimum of NDT UT Level II inspector in accordance with MIL-STD410 and received specialized training from Teledyne Continental Motors' designated representative, specific to this ultrasonic inspection procedure. Any person interested in training and qualification should request information by writing to: Teledyne Continental Motors ATTN. Technical Customer Service P.O. Box 90 Mobile, AL 36601 QUALIFIED INSPECTORS For the facility nearest you that employs a qualified inspector, contact TCM Customer Service at 251-438-3411. CRANKSHAFT INSPECTION AND ACCEPTANCE CRITERIA 1. Prior to the installation of a crankshaft in an affected engine model, verify that the crankshaft has been inspected by a "qualified inspector" as set forth in this service bulletin and has been found to be in an acceptable condition. 2. Any crankshaft that is verified as unacceptable by ultrasonic, magnetic particle, dimensional or visual inspection methods set forth in this service bulletin and the appropriate TCM overhaul manual must be replaced. 3. Any crankshaft listed in the latest revision of TCM Service Bulletin CSB96-8 that is NOT verified as being a VAR forging must be replaced. AFFECTED PUBLICATIONS: Insert a copy of this Service Bulletin into the latest publication of the following manuals: C125, C145 & O-300 Overhaul Manual. GO-300 Overhaul Manual. IO-360 Overhaul Manual. L/TSIO-360 Overhaul Manual. E-165, E-185 & E-225 Overhaul Manual. O-470 Overhaul Manual. IO-470 Overhaul Manual. TSIO-470 Overhaul Manual. IO-520 Overhaul Manual.

MO 08

ISSUED DAY YEAR 15

96

MO 09

REVISED DAY YEAR 30

2008

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

MSB96-10

2 of 3

A

TSIO-520 Sandcast Series Overhaul Manual. TSIO-520 Permold Series Overhaul Manual. GTSIO-520 Overhaul Manual. IO-550 Permold Series Overhaul Manual. IO-550 Sandcast Series Overhaul Manual. TSIOL-550 Overhaul Manual. Tiara Overhaul Manual. * - This manual is obsolete with the issuance of this service bulletin.

MO 08

ISSUED DAY YEAR 15

96

MO 09

REVISED DAY YEAR 30

2008

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

MSB96-10

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

MANDATORY SERVICE BULLETIN The Subject Matter of This Service Bulletin Is Incorporated In Whole Or In Part in an FAA Airworthiness Directive

CATEGORY 1

MSB 99-3C TECHNICAL PORTIONS FAA APPROVED

SUBJECT: CRANKSHAFT INSPECTION BACKGROUND: Teledyne Continental Motors (TCM) has become aware of eight (8) crankshaft fractures which have occurred on straight drive engines manufactured or processed during 1998. Additionally, a similar fracture has occurred on one (1) GTSIO-520 engine crankshaft processed during 1998. The cause of the fractures have been identified as a discrepancy in the counterweight bushing installation process. These fractures have occurred in crankshafts that have been grouped around discreet manufacturing periods. Crankshaft fractures have occurred in engines with 45 to 340 hours of operation since new, factory rebuilt or field overhauled. TCM has implemented an inspection program that covers new and rebuilt straight drive engine crankshafts processed from January 1, 1998 through December 31, 1998. Review of the manufacturing processes, basic metallurgy, nitride characteristics, dimensional characteristics and supplier practices have not identified any other contributing causes. PURPOSE: To provide instructions for the inspection of the number two and five crankshaft cheeks of crankshafts manufactured or rebuilt in 1998.

WARNING Inspection is required since undetected cracks can lead to engine failure. The inspection requires the removal of two cylinders, two connecting rods and four counterweights to facilitate the visual and ultrasonic inspection of specific areas of the number two and five crankshaft cheeks. All inspections will be performed by TCM representatives. Call TCM at 1-888200-7565 to schedule inspection of your aircraft engine crankshaft. COMPLIANCE:

For affected engines or crankshafts with 500 hours or less, the inspection must be performed within the next 10 hours of operation. For affected engines or crankshafts with over 500 hours, the inspection must be performed within the next 50 hours of operation or at the next scheduled maintenance, whichever occurs first. Uninstalled service spare crankshafts of the affected serial number range must be inspected prior to installation in any engine in accordance with DETAILED INSPECTION, Section C, of this bulletin.

ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

 TELEDYNE INDUSTRIES, INC. 1999

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

1 of 26 MSB99-3

C

ENGINES AFFECTED:

O-470, IO-470, TSIO-470, IO-520, TSIO-520, LTSIO-520, IO-550, TSIO-550 and TSIOL-550 Series new and rebuilt direct drive engines assembled utilizing a new or rebuilt crankshaft that was manufactured or rebuilt between January, 1998 and December, 1998. Affected engine serial numbers are specified below. This listing includes 1999 model engines assembled with crankshafts processed in 1998. Any of the preceding series engines that have had a 1998 manufactured new crankshaft installed during field overhaul or repair. See Crankshaft Serial Number Identification below for identification of affected 1998 crankshafts.

Note: Engines that have previously complied with CSB99-3, CSB99-3A or MSB99-3B are considered to be in compliance with MSB99-3C. This service bulletin was upgraded from a Critical Service Bulletin to a Mandatory Service Bulletin to reflect the issuance of AD 99-09-17. Note: Rebuilt engines assembled utilizing rebuilt crankshafts processed between January 1,1998 and December 31, 1998 may not contain the “98” identification as a part of the crankshaft serial number. These affected engines are identified by engine model and engine serial number in the following tabular listing and must comply with this Critical Service Bulletin. Note: If your engine has recently had a crankshaft installed that may have been manufactured from January 1, 1998 through December 31, 1998 the crankshaft serial number must be verified to determine if this inspection procedure applies.

CRANKSHAFT SERIAL NUMBER IDENTIFICATION Crankshaft serial numbers incorporate a manufacturing date. Crankshafts produced in 1998 may be identified as follows: Code: Month

Day

Year

Sequence

Denotes Crankshaft

AXX98XXN

All crankshafts with serial numbers beginning with the letters A through L (Jan. through Dec.) in the first position and the year code 98 in the fourth and fifth position are affected. This serial number is stamped on the propeller flange.

ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

 TELEDYNE INDUSTRIES, INC. 1999

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

2 of 26 MSB99-3

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1998 ENGINES MODELS AND SERIAL NUMBER: ENGINE MODEL 0470GCI1B 0470J11F 0470J18B 0470K17F 0470K27B 0470L10F 0470L16F 0470L32B 0470L34B 0470L9F 0470M27B 0470R15B

0470R25B

0470R25F 0470R25M 0470R25U 0470R35B 0470R39B 0470R41B 0470R42B

0470R43B 0470R44B

0470R45B 0470R46B

ENGINE SERIAL NUMBER 817751 202212 202209, 202210 049497, through 049498, 049500, 049502 049501, 049504 069890 069889, 069894, 069895 069884, through 069888, 069891, 069893, 069897 069881, 069882 069896, 069898 054155, 054156 815762, 815767, 815770, 815776, 815802, 815814, 815828, 815841, 811962, 811996, 811997 466730, 466731, 811968, 811976, 811994, 815761,815764, 815766, 815768, 815769, 815771, 815775, 815779, 815781, 815782, 815783, 815790, 815792, 815796, 815801, 815813, 815815, 815820, 815817, 815825, 815829, 815837, 811973, 815834, 815787 815812 815756, 815757, 815758, 815780 811986, 811991, 811993, 815760, 815786, 815795, 815797 811989, 815827, 811978 811995, 815816 466729, 811959, 811969, 811970, 811971, 811972, 811974, 811975, 811987, 815765, 815773, 815774, 815793, 815794, 815805, 815806, 815807, 815808, 815819 811988 811958, 811961, 811963, 811981, 811992, 811998, 811999, 815759, 815772, 815784, 815800, 815804, 815809, 815824, 815826 811956, 811983, 811990, 812000, 815753, 815755, 815810 811977, 815763

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL 0470R52B 0470R55B 0470R56B 0470R57B 0470R58B 0470R60B 0470R61B 0470R65B 0470R66B 0470S1B

0470S2B 0470S3B 0470S6B 0470S7B

0470S8B 0470S9B 0470S11B 0470U11B 0470U13B

0470U14B 0470U17B

0470U18B

0470U19B 0470U20B 0470U21B 0470U22B 0470U23B 0470U24B

ENGINE SERIAL NUMBER 815751, 811967, 811980 815778 815785, 815818 811964, 811984, 815752 815822 815798 815754, 815791, 815823 815788, 815830, 815835 815811, 815836 269453, 269456, 269461, 269463, 269464, 269472, 269474, 269480, 269485 269454, 269458, 269470, 269473, 269476, 269479, 269487 269452, 269482 269460, 269466, 269465, 269471, 269481, 269484 269450, 269455, 269457, 269459, 269467, 269468, 269469, 269483, 269486 269475 269477, 269478 269462 813331, 813356, 813416 813344, 813358, 813367, 813370, 813372, 813381, 813413, 813334, 813339, 813388, 813420, 813421, 813440 813339 813340, 813348, 813353, 813355, 813361, 813377, 813380, 813395, 813396, 813398, 813399, 813400, 813404, 813417, 813425, 813427, 813434, 813437 470756, 470758, 813349, 813364, 813366, 813382, 813383, 813402, 813414, 813422, 813424, 813431, 813439 813410 813335, 813401, 813342 813390, 813435 813345 813338, 813362 813409, 813438

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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ENGINE MODEL 0470U25B

0470U26B 0470U27B

0470U28B 0470U29B 0470U31B 0470U37B 0470U45B I0470C8B I0470C9B I0470D44B I0470D53B I0470D55B I0470E17B I0470E19B I0470E20B I0470F18B I0470F19K I0470F26B I0470F27B I0470F29B I0470F31B I0470F36B I0470H6B I0470K3B I0470K11B I0470K17B I0470K18B I0470K21B I0470K22B I0470L12B I0470L15B I0470L21B

I0470L21B

ENGINE SERIAL NUMBER 813341, 813346, 813352, 813354, 813357, 813378, 813406, 813407, 813412, 813419, 813428, 813429, 813441 813371 813332, 813337, 813347, 813373, 813374, 813375, 813397, 813403, 813411, 813423, 813426, 813432 813418, 813433 813365, 813391, 813392 813328 813376, 813442 813360, 813386, 813393, 813405, 813415, 813436 295549, 295550, 295551, 295553 295552, 295554, 295555 105643, 105644 105645 105642 088764, 088763, 088766 088765 088767 089920, 089926 089927 089916 089915, 089917, 089918, 089921, 089923, 089924 089919 089922 089925 087344 092994, 092995 092991 092990, 092992, 092999 092993, 092998 092989 092997 297825 297845, 297846 468607, 468608, 468611, 297793, 297794, 297797, 297798, 297800, 297803, 297807, 297812, 297814, 297815, 297818, 297826, 297827, 297828, 297830, 297832, 297833, 297835, 297836, 297839 through 297843

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL I0470L22B I0470L23B I0470L24B

I0470L25B I0470L26B I0470L27B I0470L28B I0470L29B I0470N10K I0470N11B I0470N13B I0470N14B I0470N16B I0470N17B I0470N21B I0470S10B I0470S14B I0470U4B I0470V6B I0470V9B I0470V15B I0470V16B I0520A5B I0520A14B I0520A21B I0520A23B I0520A29B I0520A32B I0520A33B I0520A37B I0520A38B I0520B6B I0520BA2B

I0520BA3B

ENGINE SERIAL NUMBER 297790, 297796, 297810, 297823, 297824 297817, 297820, 297834, 297844 297801, 297802, 297804, 297809 297829, 297831, 297837, 297838, 297847 297795, 297811, 297816 297813 297819 297791, 297792 297805 096711 096701, 096704, 096707 096721 096700, 096703, 096713, 096714, 096715, 096719, 096720 096705, 096712, 096718, 096722 096702, 096708, 096716, 096717 096710 109384, 109385, 109386, 109388 109387 118454 171198, 171205 171195, 171196, 171199, 171207 171204 171202, 171206 112825, 112827, 112830, 112840, 112841, 112842, 112845 112838, 112851 112828, 112832, 112850 112821, 112822, 112833, 112839, 112849, 112848 112836, 112837, 112846 112834, 112844, 112847 112823, 112831, 112843 112826 112829 234783, 234784, 234785 814286, 814288, 814289, 814292, 814305, 814306, 814311, 814316, 814318, 814320, 814321, 814332, 814344, 814349, 814350, 814358 814293

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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ENGINE MODEL I0520BA6B I0520BA10B

I0520BA11B I0520BA12B

I0520BA14B I0520BA14M I0520BA23B I0520BA26B I0520BA32B I0520BA37B I0520BA38B I0520BB3B I0520BB6B I0520BB10B

I0520BB12B

I0520BB14B I0520BB15B I0520BB16B I0520BB16U I0520BB18B I0520BB18U I0520BB19B I0520BB21B I0520BB23B I0520BB29B I0520BB31B I0520BB37B I0520BB52B I0520BB54B I0520BB56B

ENGINE SERIAL NUMBER 814301, 814312, 814338, 814356 814280, 814283, 814291, 814296, 814299, 814304, 814307, 814309, 814314, 814317, 814323, through, 814326, 814328, 814330, 814343, 814345, 814346, 814351, 814353, 814354, 814357, 814360, 814362 814302 814279, 814297, 814298, 814313, 814300, 814322, 814331, 814333, 814335, 814342, 814359, 814361, 814364, 814366, 814368 814336, 814337, 814341 814319 814303, 814329 814365 814315 814294, 814339, 814347, 814355 814293, 814295, 814327, 814348, 814352, 814363 813856, 813859, 813893 813826, 813840, 813880, 813891, 813896, 813900, 813906 813849, 813852, 813857, 813870, 813871, 813875, 813879, 813886, 813890, 813892, 813899, 813902, 813908, 813913 813829, 813838, 813845, 813846, 813850, 813855, 813858, 813862, 813869, 813877 813839, 813847, 813865, 813876 813832, 813837, 813873, 813889, 813894, 813897, 813914, 813915 813888, 813898, 813907, 813912 813831, 813841 813844, 813878 813860 813848, 813866, 813904 813835, 813910 813836, 813867 813853, 813863 813843, 813861, 813864, 813884, 813903 813854, 813905, 813921 813833, 813874, 813895 813885 813909

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL I0520BB58B I0520BB61B I0520C3B I0520C7B

I0520C10B

I0520C13B I0520C15B

I0520C16B I0520CB3B I0520CB7B

I0520CB8B I0520CB8F I0520CB8W I0520CB9F

I0520CB12B I0520CB17B I0520CB19B

ENGINE SERIAL NUMBER 813911, 813920 813842, 813872, 813882, 813883, 813901, 813919 810968, 810977, 810979, 810980, 810992 810949, 810961, 810962, 810964, through 810967, 810970, 810972, 810973, 810974, 810976, 810978, 810986, 810987, 810988, 810990, 810995, 810996, 810997, 816754, 816755, 816756, 816761, 816762, 816763, 816765, 816768, through 816777, 816780, through 816784, 816786, through 816789 810958, 810959, 810960, 810969, 810971, 810981, 810982, 816752, 816753, 816759, 816764, 816766, 816778 816785 810963, 810984, 810985, 810989, 810991, 810993, 810994, 810998, 816767 816760, 810954, 810983, 810999 298983, 299044, 299045, 299061, 299066, 576321 298965, 298966, 298968, 298971, 298977, 298979, 298985, 298986, 298987, 298990, 298993, 298996, 299007, 299008, 299015, 299016, 299017, 299025, 299030, 299031, 299033, 299034, 299040, 299043, 299046, 299048, 299052, 299057, 299058, 299062, 299071, 299072, 299073, 299076, 299079, 299085, 299086, 299088, 299092 298997, 298998, 299009, 299010, 299014, 299077, 299083 299020, 299023, 299029, 299039 298984, 299000, 299001, 299005, 299006, 299049 298972 298973 299012 299013 299019 299021 299022 299054 299055 299056 299063 299068 299069 299070 299011 298995, 299027, 299028 299059, 299060

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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ENGINE MODEL I0520CB21B I0520CB22B I0520CB40B

I0520CB41B I0520D10B I0520D22B I0520D23B

I0520D24B I0520D24M I0520D24N I0520D26B I0520D27B I0520D29B I0520D30B I0520D31B I0520D32B I0520D35B I0520D39B I0520D40B I0520D44B I0520D45B I0520D48B I0520D51B I0520D56B

I0520D70B I0520D75B I0520D79B I0520D7B I0520D84B I0520D90B I0520D91B I0520D95B I0520D96B I0520D9B

ENGINE SERIAL NUMBER 298969, 298970, 298976 298991, 298992, 299018, 299074 298974, 298981, 298982, 298988, 298989, 299003, 299004, 299035, 299036, 299037, 299038, 299041, 299042, 299050, 299051, 299067, 299080, 299081, 299082 298978, 298999, 299026, 299032, 299047, 299064, 299075, 299078 816511, 816525, 816543 812945, 812987, 816532 812918 812962 812963 812980 812996 816508 816515 816522 816527 816533 816547 816554 812991, 812940, 816564 816502 812954 575935 812947 812961 816503 816524 816536 816550 812977, 816526 812924 816510, 816518, 816531, 816544 812992 812968, 816506, 816507 575934 812966 812919, 812943, 812979, 816512, 816545 575938, 812934, 816546 816560 812917 812933, 812939, 812958, 812981 812927, 812929, 812944, 812948, 812949, 812952, 812957, 812959, 812990, 816523, 816529, 816553, 816555, 816557, 816563 816513 812928 816539 812997, 812998, 812999 816530, 816534 812937 812989 816517, 816559 816501 812922, 812931, 812973, 816548

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL I0520D100B I0520D113B I0520D116B

I0520D117B I0520D119B I0520D120B I0520D124B I0520D139B I0520D142B I0520D149B I0520D152B I0520D173B I0520D177B I0520E2B I0520E7B I0520E9B I0520E11B I0520E14B I0520F3B

I0520F4B I0520F6B I0520F7B I0520F9B

I0520F12B

I0520F13B

I0520F13U I0520F16B I0520F17B I0520F18B

ENGINE SERIAL NUMBER 816516 816561 812930, 812938, 812941, 812950, 812951, 812969, 812975, 812976, 816505, 816514, 816520, 816537, 816540, 816558, 816565 812956 816538, 812993 812982, 812984, 816567 812960, 812985, 812986, 812988, 813000, 816521, 816535, 816549 812942, 812946, 812983, 816519, 816528, 816541, 816542, 816556 812994, 816509, 816552 812955 816504, 816551 812935, 816566 812932, 812972 215906, 215907, 215918, 215919, 215921, 215922 215914, 215915, 215916, 215917 215920 215904, 215905 215908, through 215913 814787, 814795, 814806, 814817, 814851, 814856, 814858, 814882, 814898, 814905, 814952 814836, 814825, 814826, 814925, 814852 579256, 814837, 814946, 814949 814783, 814810, 814820, 814832, 814835, 814838, 814839, 814894, 814916 579247, 579248, 579250, 579257, 814814, 814815, 814848, 814850, 814876, 814903, 814907, 814919, 814937, 814953, 814961 579251, 579253, 814770, 814777, 814788, 814831, 814877, 814880, 814885, 814890 814791 814822, 814857, 814899, 814910, 814926, 814938 814768, 814775, 814865, 814883, 814884, 814906, 814950, 814956 814873

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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ENGINE MODEL I0520F20B I0520F21B I0520F22B I0520F23B I0520F24B

I0520F26B I0520F27B

I0520F39B I0520F42B I0520F43B I0520F46B I0520F47B I0520F48B

I0520F56B I0520F57B

I0520F59B I0520F60B I0520F61B I0520F64B I0520F67B I0520F68B I0520F69B I0520F70B I0520J1B I0520J2B I0520K1B I0520L1B I0520L5B I0520L7B

ENGINE SERIAL NUMBER 814887, 814936 814803, 814935 814844, 814902 814913, 814914 814891 814785 814790 814801 814802 814823 814862 814863 814867 579254, 579255, 814849, 814872, 814924 814765, 814766, 814767, 814794, 814811, 814812, 814818, 814819, 814833, 814855, 814861, 814871, 814875, 814911, 814933, 814934, 814940, 814942, 814948, 814954 814878, 814799 814792, 814816, 814824, 814827, 814868, 814879, 814889 814840, 814853, 814859 814796 814784 814771, 814778, 814779, 814781, 814782, 814786, 814797, 814800, 814828, 814830, 814834, 814854, 814908, 814912, 814923, 814929, 814939, 814941 814789, 814793, 814843, 814845, 814846, 814886, 814944, 814945 814776, 814805, 814847, 814864, 814869, 814874, 814909, 814920, 814921, 814943 814813, 814915 814808 814893, 814897, 814900 814780, 814807, 814821 579252 814804, 814896 814842 814947 216532, 216533, 216536, 216537 216535 224133 through 224136 294874, 294902, 294905, 294913 294919 294878, 294885, 294887, 294888, 294889, 294899, 294909, 294912, 294914, 294918, 294935, 294940, 294943, 294954

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL I0520L8B

I0520L12B I0520L13B I0520L14B I0520L16B I0520L17B I0520L18B I0520L19B I0520L1B I0520L32B I0520L46B I0520L47B I0520L48B I0520L51B

I0520L53B I0520L54B I0520M1B I0520M2B I0520MB1B

I0520MB2B I0550A2B I0550A3B

I0550A5B I0550B1F I0550B4F I0550B5F I0550B6F

ENGINE SERIAL NUMBER 294880, 294883, 294884, 294886, 294921, 294930, 294936, 294937, 294938, 294950 294906, 294932 294894, 294907, 294910, 294939 294893, 294917, 294931 294879, 577231 294882, 294904, 294933 294945 294908 294941 294920 294890, 294897, 294923, 294944, 294951, 294953 294911, 294922 294875, 294881, 294895, 294901 294891, 294892, 294896, 294898, 294903, 294915, 294924, 294925, 294926, 294927, 294928, 294929, 294934, 294947 294952 294946 811590, through 811630 811601, 811613 277683, 277685, 277688, through 277702, 277703 through 277717, 277719, 277721, 277723, through 277728 277684, 277686, 277687, 277718 280478, 280479, 817005 280475 through 280477, 280480 through 280483, 280485, 280486, 280488 through 280493, 280496 through 280500, 817001, 817002, 817003 280494, 280495, 280487, 817004 297048, 297050, 297074, 297115 297039, 297059, 297101, 297105, 297108, 297118 297037, 297040, 297041, 297042, 297043, 297057, 297064, 297066, 297069, 297070, 297071, 297072, 297077, 297078, 297083, 297084, 297085,

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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ENGINE MODEL I0550B6F

I0550B9F I0550B12B

I0550B13B

I0550B14B I0550B15B I0550B22B I0550B23B I0550B37B

I0550B39B I0550B40B I0550C1F

I0550C2F I0550C3F I0550C6F

I0550C8B I0550C9B

ENGINE SERIAL NUMBER 297086, 297087, 297091, 297095, 297116, 297117, 297143, 683996, 684001, 684110 297047, 297102 297046, 297051, 297052, 297055, 297056, 297058, 297060, 297062, 297063, 297073, 297079, 297081, 297082, 297088, 297089, 297090, 297094, 297096, 297097, 297100, 297103, 297104, 297113, 297114, 297119, 297120, 297121, 297124, 297125 297049, 297068, 297080, 297093, 297098, 297109, 297110, 297122, 297123 297076 684014 297044 297092, 297107 682983 through 682992, 682993, 682995 through 683003, 683005, 683008 through 683011, 683013, 683015, 683016, 683017, 683019, 683020, 683023, 683025 through 683033, 683941, 683942, 683944, 683995, 683997, 683998, 683999, 684000, 684002 684004 through 684013, 684015 through 684022, 684745 297106 810500, 815251, 815252, 815255 through 815258, 815260, 815261, 815272, 815277, 815278, 815279, 815282, 815286, 815313 815280, 815281, 815318 810479 through 810483, 815289 through 815294, 815301, 815302 684222, 684223, 684232, 684233, 684370, 684371, 810489, 810490, 810494, 810495, 810496, 810497, 810499, 815253, 815254, 815259, 815262, 815263, 815264, 815265, 815266, 815270, 815271, 815273, 815275, 815276, 815283, 815284, 815298, 815299, 815305, 815306, 815307, 815308, 815309, 815310 815285, 815287, 815288, 815311 815269, 815304

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL I0550C11B I0550C30B

I0550C31B

I0550D2B I0550D9B I0550D10B I0550D13B I0550D14B I0550D15B I0550D16B I0550D17B I0550D1B I0550D20B I0550D22B I0550E1B I0550F1B I0550F2B I0550F3B I0550F4B I0550F6B I0550F7B I0550F8B I0550F9B

I0550F10B I0550F11B I0550F13B I0550F14B I0550F15B I0550F16B I0550F17B I0550F19B I0550F20B

ENGINE SERIAL NUMBER 815267, 815268 683723 through 683741, 683744 through 683767, 683887 through 683891, 684159 through 684166, 684168 through 684175, 684368, 684369 684234, 684235, 684237 through 684241, 684243 through 684253, 684255 through 684265, 684534 284287, 284291 284282 284296 284279, 284284, 284285, 284288, 284293, 284307, 680017 284280, 284289 284277, 284278, 284281, 284290 284276, 284286, 284298 284300 284283, 284306 284292, 284294, 284295, 284299, 284301, 284302 284297 283382, through 283389 284870, 284882 284845 284847, 284846, 284865, 284875, 284889 284879 284857 284874 284897 284839, 284841, 284842, 284850, 284854, 284855, 284860, 284869, 284876, 284887, 284891 284866, 284872, 284878, 284894 284849, 284871 284843, 284862, 284880, 284892, 284895 284844, 284861, 284864, 284893 284848 284885 679521 284886 284856, 284863, 284881, 284883, 284896

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

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ENGINE MODEL I0550F21B I0550F24B I0550G1B I0550G2B I0550G6B

ENGINE SERIAL NUMBER

I0550L1B I0550L3B I0550L6B I0550L7B I0550L11B

I0550L15B I0550N1B I0550N2B LTSI0520AE2B LTSI0520AE3B LTSI0520AE4B LTSI0520AE5B TSI0520AE2B TSI0520AE3B TSI0520AE4B TSI0520AE5B TSI0520AF3B TSI0520B5B TSI0520B9B TSI0520B10B TSI0520B11B TSI0520B12B TSI0520BB9B TSI0520BB10B TSI0520BB17B TSI0520BB18B TSI0520BB21B TSI0520BB22B TSI0520BB23B TSI0520BB24B TSI0520BE2F

284859, 284873, 284888, 284890 284851 679341 679340, 679373 679316 through 679319, 679323 through 679325, 679328 through 679337, 679343, 679346 through 679353, 679363 through 679372, 679377, 679381, 679393, 808508 289142 289136 289140, 289145 289134, 289141 289127, 289130, 289131, 289133, 289137, 289138, 289139, 289143, 289144 289135 683355 683354 246667, 246668 246666, 246669, 246670, 246671, 246672, 246673 246662 246663 246166 246160, 246165, 246168, 246169, 246171 246170 246161, 246163 245244, 245246 through 245251 176754 176751, 176755, 176756, 176757, 176758, 176762, 176763 176750, 176752, 176761 176753, 176759 176760 287592, 287598, 287600, 287607, 287611 287591, 287597, 287599, 287602, 287605, 287608 287593 287594 287595, 287606 287596 287610 287609 273809

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL TSI0520BE2G TSI0520C2B TSI0520C3B TSI0520C5B TSI0520C6B TSI0520C7B TSI0520C8B TSI0520C9B TSI0520C11B TSI0520CE1F TSI0520CE2B TSI0520D3B TSI0520DB1B TSI0520E4B TSI0520E5B TSI0520E8B

TSI0520E9B

TSI0520E14B TSI0520E17B TSI0520E19B TSI0520E23B TSI0520EB2B TSI0520EB4B TSI0520EB5B TSI0520EB8B

TSI0520EB9B

TSI0520EB17B TSI0520G1B TSI0520G3B TSI0520H1B TSI0520H4B

ENGINE SERIAL NUMBER 273810, 273813, 273814, 273815, 273816 178534, 178543, 178545 178541, 178546, 178549 178542, 178553 178552 178528, 178530, 178535, 178538, 178539, 178551 178540, 178544 178536, 178547, 178550 178548 268576, 530168 268575 180109, 180110 242015 812578, 812587, 812603, 812606 812593, 812602, 812607, 812618 812575, 812579, 812586, 812589, 812591, 812596, 812598, 812600, 812601, 812612, 812615, 812617, 812619 812569 812574 812576 812577 812581 through 812585 812590 812592 812594 812597 812599 812608 812609 812611 812613 812614 812616 812580 812610 812571 812588 271498 815005 815004, 815006 271499, 815001, 815010, 815011, 815012, 815015, 815020, 815021, 815024, 815025, 815028, 815030, 815031 271496, 271497, 815007, 815009, 815013, 815014, 815016, 815017, 815018, 815019, 815022, 815026, 815027, 815029, 815032 815023 216051 216052, 216053 217400, 217410 217402, 217404, through 217409, 217411, through 217414, 217416

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ENGINE MODEL TSI0520H6B TSI0520J1B TSI0520J2B TSI0520JB1B TSI0520JB2B TSI0520KB1B TSI0520KB2B TSI0520L1B TSI0520L4B TSI0520LB1B TSI0520LB4B TSI0520LB6B TSI0520M6B TSI0520M7B

ENGINE SERIAL NUMBER

TSI0520M8B TSI0520M9B TSI0520M10B

TSI0520M11B TSI0520N1B TSI0520NB1B

TSI0520NB2B

TSI0520NB4B TSI0520NB5B TSI0520NB6B TSI0520NB8B TSI0520NB10B TSI0520NB12B

217401, 217403, 217415, 506894 218988, 218990, 218991 218989 237189, 237186, 237191 237187, 237188, 237190 245711 245712 241970, 241971, 241972 241969 237300 815502, 815503 237299, 815501 291944, 291957, 291962, 291996 291929 through 291929, 291931, 291934, 291938 through 291939, 291943, 291945, 291946, 291948, 291949, 291952 through 291956, 291958, 291959, 291960, 291963, 291964, 291965, 291970, 291971, 291973, 291976, 291979, 291980, 291981, 291982, 291985, through 291989, 291991, 291992, 291994, 291995, 291998, 291999, 292000, 532083 532085 532086, 532087, 532088, 291961, 291984 291932, 291967, 291968 291937, 291947, 291975, 291977, 291978, 291983, 291990, 291993, 291997, 818001 291969 228639 521665, 813564, 813568, 813571, 813575, 813582, 813588, 813589, 813592, 813600, 813608, 813614, 813617, 813618, 813621, 813627, 813628 521666, 813565, 813572, 813573, 813576, 813585, 813601, 813615, 813619, 813622, 813623 813586, 813593, 813603, 813606, 813616, 813629, 813632 813578, 813594, 813607, 813610, 813611 813569, 813613, 813624 813583, 813605, 813620, 813631 813579, 813598, 813612 813595

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL TSI0520NB13B TSI0520NB14B TSI0520NB16B TSI0520NB17B TSI0520NB31B TSI0520NB32B TSI0520P5B TSI0520P6B TSI0520P7B TSI0520P8B TSI0520R7B TSI0520R9B

TSI0520R10B TSI0520R11B TSI0520R12B

TSI0520R13B TSI0520T1B

TSI0520T3B TSI0520UB1B TSI0520UB2F TSI0520UB3F TSI0520UB4F TSI0520UB5F TSI0520UB6B

ENGINE SERIAL NUMBER 813597 813626 813577 813566, 813567, 813581, 813584, 813630 813602 813599 278818, 278825 278812, 278815, 278816, 278819, 278820, 278823, 278826 278810, 278813, 278824, 278828 278814, 278817, 278821 293992, 294016, 294025 293950, 293955, 293956, 293959, 293961, 293964, 293965, 293969, 293970, 293972, 293975, 293976, 293977, 293979, 293984, 293985, 293987, 293991, 293993, 293994, 293995, 293997, 293998, 293999, 294004, 294007, 294008, 294011, 294014, 294018, 294022, 294023, 294024, 294026, 294027, 294029, 294031, 294032, 294036, through 294039, 522696, 522697, 522698, 522699, 522700 293958, 294005, 294035 293978, 294000, 294019 293957, 293960, 293962, 293963, 293967, 293973, 293974, 293982, 293986, 293988, 293990, 294001, 294003, 294006, 294010, 294013, 294015, 294021, 294030, 294033, 294034 293983 239460 through 239462, 239464 through 239471, 515439 through 515442 239463, 239472 809335, 809340 809327, 809331, 809333, 809339 527447, 809334, 809341, 809345, 809346 809330, 809347 809350 809328, 809329, 809332, 809336, 809337, 809344, 809349

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ENGINE MODEL TSI0520UB8B TSI0520UB11B TSI0520UB12B TSI0520UB16B

TSI0520UB17B TSI0520VB1B

TSI0520VB2B

TSI0520VB2F

ENGINE SERIAL NUMBER 809348 809338 809342 527365, 527366, 527367, 527369, 527370, 527372, 527373, 527374, 527393, 527408, 527412, through 527418 527420 through 527426 529113, 811197, through 811201, 811205, 811208, 811209, 811213, 811228, 811229, 811232, 811242, 811247, 811248, 811249, 816001, 816005, 816008, 816010, 816011, 816014, 816016, 816017, 816018, 816020, 816025, 816027, 816033 529112, 811202, 811206, 811236, 811238, 811244, 811250, 816007, 816030, 816031, 816032 811196, 811204, 811214, 811231, 811235, 816006, 816019, 816024, 816028, 816036, 816040

ENGINE MODEL TSI0520VB4B TSI0520VB4F

TSI0520WB3F TSI0520WB5F TSI0550C1B

TSI0550E1B

TSI0550E3B TSI0L550A1G

ENGINE SERIAL NUMBER 811194, 811237, 816012, 816026, 816039, 816041 811195, 811207, 811210, 811211, 811212, 811217, 811218, 811220, through 811227, 811230, 811233, 811234, 811239, 811240, 811241, 811243, 811245, 816002, 816003, 816004, 816009, 816013, 816021, 816022, 816034, 816035, 816037, 816038, 816044 274416 through 274427, 274430, through 274436, 274439 274428, 274429 802576 through 802590, 814502, 814503, 814504, 814505 through 814509 803057, 803059, 803061, 803062, 803065, 803067, 803069, 803070, 803079, 803080, 803056, 803066, 803068 809259

1999 ENGINE MODELS AND SERIAL NUMBER: with 1998 manufactured crankshafts ENGINE MODEL 0470R15B 0470R25B 0470R25F 0470R25U 0470R44B 0470R55B 0470S2K 0470U18B 0470U25B I0470C8B I0470F27B I0470K18B I0470L15B I0470L21B I0470L23B I0470N11B I0470N14B I0470N20B I0470V15B

ENGINE SERIAL NUMBER 815843 815839, 815846, 815860 815838 815840 815842, 815844 815845 269489 813444, 813445 813448 295556 089928 093000 297856, 297857 297848, 297850, 297851, 297852 297854 096727 096724, 096726 096725 171208

ISSUED MO 04

DAY 19

REVISED YEAR 99

MO 07

DAY 27

YEAR 99

 TELEDYNE INDUSTRIES, INC. 1999

ENGINE MODEL I0520BA10B I0520BA22B I0520BA23B I0520BB15B I0520C15B I0520C7B I0520CB3B I0520CB7B I0520CB8B I0520CB8W I0520D13B I0520D142B I0520D56B I0520F21B I0520F47B I0520F64B I0520F70B I0520L27B I0520L7B

ENGINE SERIAL NUMBER 814374, 814373, 814369 814372 814370, 814371 813918 816791, 816799 816792 299112 299091, 299096, 299097 299090 299093, 299094 816570 816569 816572 814960 814959 814957 818766 294955 294956

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ENGINE MODEL I0520MB1B I0550B13B I0550B15B I0550B39B I0550B4F I0550B5F I0550B6F I0550C2F I0550C31B I0550C6F I0550C8B I0550D13B I0550D14B I0550D15B I0550D18B I0550F5B I0550G6B I0550L3B LTSI0520AE2B TSI0520AE2B TSI0520BB10B

ENGINE SERIAL NUMBER

ENGINE MODEL TSI0520E19B TSI0520E4B TSI0520E5B TSI0520E8B TSI0520E9B TSI0520EB8B TSI0520M6B TSI0520M7B TSI0520NB9B TSI0520P6B TSI0520R10B TSI0520R11B TSI0520R12B TSI0520R9B TSI0520UB17B TSI0520UB1B TSI0520VB1B TSI0520VB2F TSI0520VB4B TSI0550C1B TSI0550E1B

277730 297133, 297134, 297136, 297137, 297138, 297153 684113 684023, 684024, 684025 297131 297130 297128, 297129 815316 684266, 684267, 684268, 684273 815314, 815315 815319 680019 680018 284311 284312 284898 679378, 679382 289147 246675, 524343 523349 287616

ENGINE SERIAL NUMBER 812621 812622 812623 812630 812620, 812626 815033 818002, 818011 818003, 818005, 818013 813634 278830 294044 294043 294050 294046 527427 809352 816046 816047 816045 802591 803077

ENGINES REPAIRED UTILIZING CRANKSHAFTS PROCESSED IN 1998 (SSI98-1)

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ENGINE MODEL

ENGINE SERIAL NUMBER

O470R66B O470S1B O470S5B IO520BA14B IO520C7B IO520C10B IO520D140B IO520F16B IO520F59B TSIO520T1B

811812 269415 269419 807209 810845 810857 293339 812266 812368 239441

REVISED YEAR 99

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GENERAL INFORMATION: INSPECTION OF NEW AND REBUILT AFFECTED ENGINES AND ENGINES THAT HAVE BEEN OVERHAULED OR REPAIRED UTILIZING THE SERIAL NUMBERED CRANKSHAFTS SPECIFIED IN THIS CRITICAL SERVICE BULLETIN.

WARNING The inspection required by this service bulletin is intended to detect conditions which if present and left uncorrected can result in engine failure. PRE-INSPECTION: b. Turn magneto switches off. c. Close the throttle. d. Place mixture control in the idle cutoff position. 2. To gain access to the engine remove the engine cowling in accordance with the aircraft manufacturer's maintenance manual. 3. Disconnect all spark plug leads from spark plugs to prevent engine firing. 4. Remove engine baffling and engine mounted equipment, as required, to facilitate removal of cylinders number one and three. 5. Remove cylinders number one and three in accordance with the applicable engine maintenance manual, overhaul manual or aircraft manufacturer's maintenance manual. Remove the cylinder only far enough to expose the piston pin. Push the piston pin out of the connecting rod bushing only far enough to release the piston and piston pin from the connecting rod, leaving the piston in the cylinder. 6. The numbers one and three connecting rods and all counterweights will have to be removed to perform the inspection. Note: Place a clean shop towel through the cylinder opening below the crankshaft to catch any items that may be dropped.

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Anything dropped in the engine must be removed. 7. Position the connecting rod to be removed (number one or number three) at or near top center. See Figure 1. Note: The 470, 520 and 550 series engines may have connecting rod nuts secured with cotter pins or they may have Spiralock nuts which do not have cotter pins. When removing Spiralock nuts, you may find it necessary to tighten the nut slightly to release the self-locking feature. 8. Remove, if utilized, the connecting rod nut cotter pins and discard them. Remove the connecting rod nuts.

1. a. Turn the master switch off.

ISSUED

WARNING

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9. Carefully separate the connecting rod from the connecting rod cap. Support the connecting rod cap while removing the connecting rod from the crankshaft. Repeat this procedure for the other connecting rod. 10. Position the crankshaft so that the rearward retaining rings and plates of a counterweight on the number two crankshaft cheek can be removed. Using a pair of snap ring pliers, remove and discard two retaining rings. Using a long, blunted tip awl and ball peen hammer tap the retaining plates to loosen them. Remove retaining plates with a pair of 90° offset snap ring pliers, a scribe with a hook fashioned into its end or a retrieval magnet. See Figure 2. Discard the retaining plates. Using a retrieval magnet, remove the counterweight pins. See Figure 3. Document the pin positions. They must be placed back in the same position from which they were removed. Counterweight and counterweight blade positions are identified as leading or trailing based on the position of the number one connecting rod journal. With the number one connecting rod journal at the 6 o’clock position (as viewed from the rear of the engine), the number two crankshaft cheek counterweight and blade at the 3 o’clock position and the number 5 crankshaft cheek counterweight and blade at the 2 o’clock position are identified as the trailing

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counterweight and blade. The opposite counterweight and blade are identified as the leading counterweight and blade. When removing counterweights and counterweight pins identify the counterweights as leading or trailing and the counterweight pins leading (first pin in the direction of engine rotation) or trailing (second pin in the direction of engine rotation). Again, the counterweights and counterweight pins must be reinstalled in same location from which they were removed. 11. Looking from the rear of the engine forward, turn the crankshaft in the counterclockwise direction far enough that the lower end of the counterweight can be started out through the cylinder opening by hand. See Figure 4. Now turn the crankshaft in the clockwise direction and remove the counterweight. See Figures 4, 5, 6 and 7. 12. Using the procedure in steps 10 and 11 remove the remaining counterweight on the number two crankshaft cheek and remove the two counterweights on the number five crankcheek. 13. Some counterweights may not clear the crankcase and cannot be removed. If so, position as shown in Figure 8 for the inspection. CAUTION Be careful when turning crankshaft with a loose counterweight. Note: Document positions of counterweights so they are returned to the original positions. DETAILED INSPECTION: A. VISUAL INSPECTION: 1. Using a soft shop towel dampened with solvent, remove any surface residue from the aft side of the number two and five crankshaft cheeks. The outboard area at the edge of crankshaft cheek next to the counterweight is the area to be inspected. See Figures 9, 10 and 11. 2. Using a flashlight and mirror or a borescope visually inspect the aft side of the number two and five crankshaft cheek for indications of a crack or mechanical damage. The inspection area is between the counterweight blade bushing holes at the chamfered edge of blade shoulder on

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both sides of the crankshaft cheek. See Figure 10 and Figure 11. 3. If the visual inspection does not clearly reveal a crack, perform an ultrasonic inspection of the aft side of number two and five crankshaft cheek in accordance with Section “B” ULTRASONIC INSPECTION. 4. If visual inspection reveals a crack the engine must be removed from service until repaired or replaced. B. ULTRASONIC INSPECTION: An ultrasonic inspection must be performed in accordance with TCM procedure MHS 244. This procedure must be done with the equipment and trained personnel as indicated in MHS 244. Deviations from this procedure must be approved in writing from TCM. If a crack or a crack indication is detected during this inspection, the engine must be removed from service until repaired or replaced. C. SERVICE SPARE CRANKSHAFTS: 1. Uninstalled service spare crankshafts must have the visual and ultrasonic inspections performed in accordance with sections A and B. Additionally, perform a magnaflux inspection in accordance with ASTM E 1444. The wet continuous method utilizing full wave rectified alternating current and fluorescent particles is required. 2. Crankshafts meeting the inspection criteria in “C” part 1 must be identified by vibropeening 99-3 after the crankshaft serial number i.e. AXX98XXN 99-3. RETURN TO SERVICE: 1. Ensure that no debris is left in the engine interior.

WARNING Failure to remove all debris from the engine interior can result in engine damage and possible failure. 2. Drain the engine oil into an approved container.

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3. Install the counterweights and pins in the exact locations from which they were removed in accordance with the following:

9. Lubricate the threads of the connecting rod bolts and nuts with clean 50-weight aviation grade oil and thread the nuts onto the bolts.

Note: The counterweight plates have a small extruded point which provides an interference fit of .001 to .007. Before installation, check the counterweight plates for an actual interference fit in the bushing bore. An interference fit is required.

NOTE: Spiralock nuts are self locking fasteners and thread freely onto the connecting rod bolt.

4. Install the two counterweights removed from the number two crankshaft cheek hanger blades in their original position and install the counterweight pins in their original position. Install new plates and snap rings with sharp edge (flat surface) facing outboard. If new pins are installed, pins with the same part number and dash number must be installed in each counterweight. Repeat the above process for the counterweights on the number five crankshaft cheek.

CAUTION The snap rings, plates and pins must be installed as shown in Figure 12. "Counterweight Inspection, and Installation."

WARNING Do not use plates that have a loose fit. Failure to properly install counterweight retaining plates and snap rings may result in engine damage and possible failure. 5. Visually and dimensionally inspect all snap rings to insure the snap ring is correctly installed and fully seated in its groove. See Figure 12. 6. Apply 50-weight Aviation grade oil to the number one and three crankshaft connecting rod journals. 7. Position the number one and three connecting rod caps with bearing insert and bolts installed (position number facing up) on the respective crankshaft connecting rod journals. 8. Install the number one and three connecting rods, with bearing insert in place, on the respective crankshaft connecting rod journal while supporting the connecting rod cap and bolts.

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9. Torque connecting rod nuts to the torque value specified in Table 1 as follows. For connecting rods using either P/N 643215 or P/N 654490 self-locking connecting rod nut (Spiralock nut), torque to the value specified in Table 1. See Figure 13. For connecting rods using P/N 628109 castellated nuts and P/N629340 bolt, initially torque nut to the specified low limit in Table 1 or TCM Service Bulletin SB96-7B. If the cotter pin hole in the bolt and the castellations of the nut do not align, set the torque wrench to the specified maximum torque limit and continue to torque the nut until the castellations align or the specified maximum torque limit is reached. If the specified maximum torque limit is reached before the castellations align with the cotter pin hole in the bolt, the nut will have to be removed and a new nut installed and torqued as specified above. 10. Install new cotter pin in each nut and secure by seating the cotter pin head in nut castellations and bending one leg of the cotter pin up over the con-rod bolt and back toward the head of the cotter pin. Trim leg so that its end is centered with the center of the bolt diameter. Bend the other leg down and trim it so that its end is mid way between the nut base and the nut castellation. See Figure 14. 11. Prior to installing number one and three cylinders, ensure that the engine interior is free of any debris and tools. 12. Install a new cylinder base “O” ring on each cylinder. 13. Lubricate the exposed portion of the piston and piston pin on each cylinder with clean 50-weight aviation oil. 14. With the aid of an assistant, install number one and three cylinders in accordance with the TCM Maintenance Manual, Overhaul Manual and Service Bulletins.

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15. Lubricate all cylinder deck stud threads, through bolt threads and nuts with clean 50 weight engine oil prior to installation and torquing. 16. Torque cylinder deck stud nuts and through bolt nuts to the value specified in Table 2. CAUTION Proper cylinder installation requires a multiple step torquing process. Cylinder base stud threads, through bolt threads and nuts must be lubricated with clean 50-weight aviation oil. a. Torque cylinder base nuts to 1/2 of the specified torque value for the fastener. b. Torque the cylinder through bolt nuts and cylinder base stud nuts to the specified torque value for the cylinder base stud nuts. Through bolt nuts must be torqued on both sides of the engine.

WARNING Failure to torque through bolt nuts on both sides of the engine can result in a loss of main bearing crush, main bearing shift and engine failure. c. Torque through bolt nuts on both sides of the engine to the specified value for the fastener. d. On engines which incorporate the 7th cylinder deck stud, lubricate threads and install the 7th stud cylinder bracket and conical stud nut. Torque the stud nut to the value specified for the fastener. NOTE: Through bolt nuts P/N’s 634505 and 649496 have been superseded by nut P/N 652541. Nut P/N 634505 is a flanged 6 point (hex) nut requiring a torque value of 690-710 inch pounds. Nut P/N 649496 is a flanged 6 point (hex) nut requiring a torque value of 790-810. Nut P/N 652541 is a flanged 12-point nut requiring a torque value of 790-810 inch lbs. At engine overhaul all P/N 634505 and 649496 flanged through bolt nuts must be replaced with P/N 652541 flanged 12 point nuts. If replacing P/N 634505 or 649496 nuts in less than a complete set prior to engine overhaul torque ISSUED MO

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04

19

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nut P/N 652541 to the required value of the original fastener (P/N 634505 or 649496). 17. Reinstall all engine components and baffles removed to facilitate this inspection in accordance with the aircraft manufacturer’s maintenance manual. 18. Remove and replace the engine oil filter. 19. Reinstall the oil sump drain plug with a new gasket; torque to the specified torque and safety wire. On engines equipped with an oil sump quick drain, close and secure the quick drain in accordance with the applicable instructions. 20. Service the engine with the correct type and grade of oil. 21. Install ignition leads on the proper spark plugs and screw on. Torque the ignition lead coupling nuts to 110 to 120 inch pounds. 22. Perform a complete engine ground run up and ensure the engine meets the manufacturer’s specified operations limits. 23. Thoroughly inspect the engine for oil and fuel leaks, broken, missing or loose hardware. 24. Correct all discrepancies prior to returning the engine and aircraft to service. 25. Make a logbook entry indicating compliance with this inspection. The entry must include the crankshaft serial number. WARRANTY Warranty claims for labor and material used to comply with this Critical Service Bulletin must be submitted to: Teledyne Continental Motors P.O. Box 90 Mobile, Al. 36601 Attn.: Warranty Administration CSB99-3 All warranty claims must have a copy of the repair work order attached. Failure to attach a copy of the repair work order will delay the processing of your warranty claim.

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TCM will allow a labor allowance up to $700.00 for naturally aspirated engines and $900.00 for turbocharged engines to comply with this Critical Service Bulletin. TCM reserves the right to audit and review any claim beyond the stated allowances.

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FIGURE 1. CONNECTING ROD IN POSITION FOR REMOVAL

FIGURE 2. REMOVING COUNTERWEIGHT RETAINING PLATES

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FIGURE 3. REMOVING COUNTERWEIGHT PINS

FIGURE 4. STARTING COUNTERWEIGHT THROUGH CYLINDER OPENING

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FIGURE 5. GUIDING COUNTERWEIGHT THROUGH CYLINDER OPENING

FIGURE 6. COUNTERWEIGHT REMOVED

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FIGURE 7. CRANKSHAFT COUNTERWEIGHT BLADE

FIGURE 8. CRANKSHAFT COUNTERWEIGHT PARTIALLY REMOVED

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Chamfered edge of the aft side of number two and five crankshaft cheek centered between counterweight blade bushing holes on both sides

FIGURE 9. FOCUS INSPECTION IN THIS AREA

Inspect area of aft side of cheek between counterweight bushing holes at chamfered edge of blade shoulder on both sides

FIGURE 10. CRANKSHAFT IN INSPECTION POSITION #2 CRANKCHEEK CONNECTING ROD REMOVED

ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

22 of 26 MSB99-3

C

Inspect area of aft side of cheek between counterweight bushing holes at edge of blade shoulder on both sides

FIGURE 11. CRANKSHAFT IN INSPECTION POSITION #5 CRANKCHEEK CONNECTING ROD REMOVED

FIGURE 12 COUNTERWEIGHT INSTALLATION Note: Use an inspection mirror and flashlight to verify that the entire circumference of each snap ring is fully seated in the counterweight snap ring groove. ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

23 of 26 MSB99-3

C

TABLE 1 CONNECTING ROD TORQUE (FROM SB 96-7B) SIZE .44-20

FASTENER Nut-Connecting rodSpiralock (Nut hex P/N 643215 with bolt P/N 643112) Nut-Connecting rod Spiralock (12 Point Nut P/N 654490 with bolt P/N 643112 Nut-Connecting rod Spiralock (12 Point Nut P/N 654490 with bolt P/N 654068) Nut-Connecting Rod (rod P/N 646476, bolt P/N 629340 nut-P/N 628109

7/16-20

.44-20 7/16-20 .44-20 7/16-20 .44-28 7/16-28

IN/LBS.

FT/LBS.

550-600

45.8-50.0

690-710

57.5-59.2

690-710

57.5-59.2

475-525

39.6-43.8

ROD P/N 655000 (Nut 654490 & Bolt 643112) IO-520-P LIO-520-P

ROD P/N 655001 (Nut 654490 & Bolt 643112) IO-550-A, B, C, D, E, F, G, L, N

TSIO-520-AE LTSIO-520-AE

TSIOL-550-A, B, C TSIO-520-CE TSIO-550A, B, C, E

ROD P/N 655004 (Nut 654490 & Bolt 654068)

ROD P/N 655005 (Nut 654490 & Bolt 654068)

O-470-J, R, S, U IO-470-C, D, E, F, K, L, M, N, S, U, V, IO-520-A, BA, C, D, E, F, J, K, L, M, TSIO-520-A, B, C, D, E, G, H, J, L, M, N, P, R, T

IO-520-BB, CB, MB, TSIO-520-BB, BE, DB, EB, JB, KB, LB, NB, UB, VB, WB

MODELS AFFECTED L & IO-520-P, L & TSIO-520 AE & CE, IO-550, TSIO-550, TSIOL-550

FOR SPECIFIC APPLICATION BY ROD PART NUMBER AND ENGINE SEE BELOW FOR SPECIFIC APPLICATION BY ROD PART NUMBER AND ENGINE SEE BELOW IO-346, O-470, IO-470, TSIO-470, IO-520, TSIO-520 (except L/TSIO-520 AE & CE)

ROD P/N 655003 (SET OF 6 BALANCED P/N 655001 Con-rods) (Nut 654490 & Bolt 643112) IO-550-B29, B33, B37, B39 B44 IO-550-C25, C29, C30, C31 ROD P/N 655007 (SETOF 6 BALANCED P/N 655005 Con-rods) (Nut 654490 & Bolt 654068) TSIO-520-UB SPEC.13, 16, 17

Note: Connecting rod nut P/N 643215 has been superseded by 12 point nut P/N 654490. Connecting rod bolt P/N 629340 has been superseded by bolt P/N 654068. Bolt P/N 654068 and Nut P/N 654490 must go into effect together.

ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

24 of 26 MSB99-3

C

12 point spiralock nut.

FIGURE 13. TWELVE POINT SPIRALOCK NUT

Bend one leg of cotter pin up and back toward cotter pin head. Trim leg so that it ends in the center of the bolts diameter. Bend the other leg down toward the nuts base and trim leg so that it ends half the distance between the bottom of the nut castelation and nut base.

Seat head of cotter pin into nut castellations

WARNING ANYTHING DROPPED INTO THE ENGINE MUST BE REMOVED.

FIGURE 14. CASTELLATED NUT WITH COTTER PIN INSTALLED

ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

25 of 26 MSB99-3

C

TABLE 2 CYLINDER STUD NUT AND THROUGH BOLT NUT TORQUE SIZE .44-20

FASTENER Nut-Cyl. to crankcase studs.(includes 7th stud) Nut-Cyl. To crankcase studs. Nut-Thru bolts at cad plated washer Nut-Thru bolt at cad plated washer Nut-6 Point-Thru bolt at cylinder flange (P/N 634505 .33 in. high) Nut-Thru bolt at plated washers Nut-12 Point-Thru bolt at cylinder flange (P/N 652541) Nut-Tall 6 point-thru bolt at cylinder flange. (P/N 649496 .43 inch high) Nut-Crankcase tie bolts-nose

.44-20 .44-20 .50-20 .50-20

.50-20 .50-20

.50-20 .50-20

ISSUED MO

DAY

04

19

REVISED YEAR 99

MO

DAY

YEAR

07

27

99

IN/LBS. 490-510

FT/LBS. 40.8-42.5

MODELS AFFECTED All models (except TSIOL-550)

590-610 440-460

49.2-50.8 36.6-38.3

TSIOL-550 All models (AR)

615-635 690-710

51.2-52.9 57.5-59.2

IO-520, L/TSIO-520, IO-550, TSIO-550 All 520, 550, (Except TSIOL-550)

690-710

57.5-59.2

TSIOL-550

790-810

65.8-67.5

All 520 & 550.

790-810

65.8-67.5

TSIOL-550.

640-660

53.3-55.0

All models(AR)

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

26 of 26 MSB99-3

C

Bendix

Engine Products Division

SERVICE BULLETIN NO. 556C Engineering Aspects are FAA Approved Printed July 1975 Page 1 of 3 Pages

AIRCRAFT SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

Shouldered magneto drive shaft bushing, change from sintered iron to machined steel. To inform users of subject change required on certain magnetos to reduce the possibility of bushing flange failure during service.

S4LN-21 S4LN-21 S4LN-21 S4LN-21 S4LN-21 S4RN-21 S6RN-21 S6LN-21 S6LN-21

P/N 10-51360-25 P/N 10-51360-26 P/N 10-51360-30 P/N 10-51360-31 P/N 10-51360-45 P/N 10-51360-46 P/N 10-51365-35 P/N 10-51365-39 P/N 10-51365-42

S4LN-200 S4LN-200 S4LN-200 S4LN-204 S6LN-200 S6RN-200 S6LN-200 S6LN-204 S6RN-204

P/N 10-163005-3 P/N 10-163005-5 P/N 10-163005-7 P/N 10-163045-1 P/N 10-163010-3 P/N 10-163010-7 P/N 10-163010-11 P/N 10-163050-2 P/N 10-163050-6

S4LN-1208 S4LN-1208 S4LN-1209 S4LN-1227 S4LN-1227 S4RN-1227 S6RN-1208 S6LN-1208 S6LN-1209 S6RN-1209 S6RN-1227 S6LN-1227

P/N 10-349285-2 P/N 10-349285-4 P/N 10-349305-2 P/N 10-349365-1 P/N 10-349365-2 P/N 10-349365-6 P/N 10-349290-6 P/N 10-349290-7 P/N 10-349310-5 P/N 10-349310-6 P/N 10-349370-5 P/N 10-349370-6

Maintenance (Spare) Parts Affected: 10-51659 Bushing, sintered iron 10-51655 Bushing, sintered iron 10-56591 Bushing, sintered iron Compliance: At next inspection period or at next magneto overhaul period, whichever is scheduled first. Detailed Instructions: 1. Field reports indicate that sintered iron bushings now installed on the drive end of the magneto rotating magnet shafts are breaking away at the bushing flange. Therefore, all shouldered sintered iron bushings now in use should be replaced with machined steel bushings.

SINTERED IRON

MACHINED STEEL

OLD

NEW Figure 1

2. The machined steel bushings have an undercut .062 x .005 deep immediately behind the bushing flange. The sintered iron bushings do not have this undercut. See figure 1.

Bendix

Engine Products Division

SERVICE BULLETIN NO. 556C Engineering Aspects are FAA Approved Printed July 1975 Page 2 of 3 Pages

3.

Magnetos having the following name plate color and data already have the machined steel bushing installed and require no additional compliance with this bulletin. (a) Red name plate magnetos having the change designation listed in table 1. (b) Red name plate magnetos having change designation after that listed in table 1. (ex: magneto P/N 10-51360-25 with G1 is OK, also G2, G3, H1, etc.) (c) Blue name plate magnetos having serial number 349001 or higher (i.e. 349002, 349003) (d) Magnetos stamped with an 1/8" high letter "B" in the lower left hand corner of the nameplate.

4.

The following magnetos must be removed from the engine to visually determine the type of bushing installed. (a) All Black name plate magnetos. (b) All 10-51360-30 and 10-349365-2 magnetos must have new bushing 10-163049 installed and be reidentified per paragraph 7a. (c) Red name plate magnetos before change designation listed in table 1. (d) Blue name plate magnetos before serial number 349001.

5.

6.

If a machined steel bushing is found on a magneto listed in paragraph 4, stamp magneto name plate in accordance with paragraph 7. Reinstall and time magneto to engine following engine manufacturers instructions. If a sintered iron bushing is presently installed on a magneto, it must be replaced immediately with a machined steel bushing as follows: (a) Remove cotter pin from magnet shaft. Hold drive member with a pair of padded jaw pliers and remove nut, lockwasher and sintered iron bushing. Discard bushing. (b) Using table 1, determine the correct machined steel bushing to be used on the magneto and assemble bushing (shouldered end last), lockwasher and nut on magnet shaft. Torque nut to 15 to 25 lb. ft. and install cotter pin.

(c) Stamp magneto name plate in accordance with paragraph 7. Reinstall and time magneto to the engine following engine manufacturers instructions. TABLE 1

Magneto P/N 10-51360-25 10-51360-26 10-51360-31 10-51360-45 10-51360-46 10-51365-35 10-51365-39 10-51365-42 10-163005-3 10-163005-5 10-163005-7 10-163045-1 10-163010-3 10-163010-7 10-163010-11 10-163050-2 10-163050-6 10-349285-2 10-349235-4 10-349305-2 10-349365-1 10-349365-6 10-349290-6 10-349290-7 10-349310-5 10-349310-6 10-349370-5 10-349370-6

New Machined Steel Bushing P/N (S-20 Series) 10-163049 10-163049 10-163049 10-163049 10-163049 10-357193 10-357193 10-391421 (S-200 Series) 10-163049 10-163049 10-163049 10-163049 10-357193 10-357193 10-357193 10-357193 10-357193 (S-1200 Series) 10-163049 10-163049 10-163049 10-163049 10-163049 10-357193 10-357193 10-357193 10-357193 10-357193 10-357193

Red Name Plate Change Designation G1 F1 F1 C1 B1 G1 G1 G1 E1 E1 F1 E1 F1 F1 E1 F1 F1 D1 D1 D1 D1 B1 D1 D1 D1 D1 D1 D1

Bendix

Engine Products Division

SERVICE BULLETIN NO. 556C Engineering Aspects are FAA Approved Printed July 1975 Page 3 of 3 Pages

7.

Stamp magnetos which required the bushing to be looked at (ref. para. 4) as follows: Note: Magnetos listed in paragraph 3 require no identification change. (a) Magnetos P/N 10-51360-30 and 10-349365-2 become new part numbers 10-51360-37 and 10349365-3 respectively. Overstamp the magneto name plate with the new part number suffix, -37 or -3 as applicable. (b) All other part number magnetos shall be identified by stamping a 1/8" high letter "B" in the lower left corner of the name plate.

8.

Make appropriate log entry in the engine log book as soon as compliance with this bulletin is accomplished.

Part Required Per Article: 10-163049 Bushing, machined steel, replaces 10-51659. 10-357193 Bushing, machined steel, replaces 10-51655. 10-391421 Bushing, machined steel, replaces 10-56591. Special Tools Required: None Man Hours Required: Negligible at overhaul. Less 1/2 hr. per magneto at inspection period Weight Change: Negligible

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 Printed April 1976 Page 1 of 7 Pages

Sidney, New York 13838

AIRCRAFT SUBJECT:

REASON FOR BULLETIN:

IGNITION SWITCHES, ROTARY ACTION, KEY OR LEVER ACTUATED, TWIST-TO-START, PUSH-TOSTART, TWIST-TO-START/PUSH-TO-PRIME TYPES. I To alert all users of above Bendix Switch Types of possible personnel hazard. II To provide a check procedure to detect a faulty Switch. III To provide Field Repair and Replacement Instructions and Identification.

EQUIPMENT AFFECTED:

Ignition Switches; Refer to Table 1

TABLE I. BENDIX AIRCRAFT IGNITION SWITCHES, ROTARY ACTION, KEY OR LEVER ACTUATED. Switch Function

Key

Lever

X Twist-To-Start

10-357200-1 X

10-126690-1

X

10-357210-1 X

X

10-357240-1, 10-357270-1 10-126680-2

X X

10-157440-1, -2, -3, -4, -21 10-357220-1

X Push-To-Prime

10-357230-1, -2, 10-357260-1 10-126630-1

X Push-To-Start

Twist-To-Start

Switch Part Number

X

10-357250-1, 10-357280-1 10-126680-1

X

10-126660-1, -4

NOTE: “SWITCH FUNCTION,” TABLE I ABOVE IS USED AS AN APPLICABLE MEANS FOR INITIAL FRONT VIEW SWITCH IDENTIFICATION SINCE ACTUAL PART NUMBERS ARE ON THE SWITCH HOUSING AND BECOME VISIBLE ONLY AFTER SWITCH BECOMES ACCESSIBLE FOR EXAMINATION. Maintenance (Spare) Parts Affected: Same as in Table 1. Compliance: Parts I and II - Immediate Part III -As soon as practicable after accomplishment of Part II. Detailed Instructions: This bulletin (I) alerts all users and holders of Bendix Aircraft Ignition Switches listed by function and Part Numbers in

Table 1 to a possible personnel hazard, (II) provides a way by which a faulty switch can be detected and (III) provides instructions to cover field repair/replacement of the switch and identification of switches once repaired or replaced. PART I. Possible Hazard Description Field reports indicate that occasionally switches performing the "Switch Function" listed in Table 1 have been found to leave the right magneto "Live" or "Hot."

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 Printed April 1976 Page 2 of 7 Pages

Sidney, New York 13838

The condition may exist when the switch Key/Lever is rotated slightly past the normal indicated "OFF" position. It has also been reported that the switch may stick in this position. WARNING Should the propeller be moved by hand (as during preflight) and a "Hot" magneto condition exist, the engine may fire and cause injury to personnel. All appropriate precautions shall be exercised by all personnel associated with an aircraft having the switch

condition described until the switch has been replaced or repaired. As an added precautionary measure, positive ignition grounding prior to correction of a switch fault can be accomplished by fabricating a jumper lead and temporarily installing it between the magneto primary ground outlet or terminal of the magneto to a clean engine ground point. Using the applicable primary grounding terminal kit selected from Table II, assemble a grounding lead.

TABLE II. APPLICABLE PRIMARY GROUNDING TERMINAL KITS. Magneto Series

Repair Kit Part Number or Wire.

S-20 Series

Use Kit P/N 10-52305 for magneto P/N’s 10-51365-1, -2, -7, -13, -14, -15, -16, -17, -20, -25, -26, -27, -28, -29, -30, -31, -32, -33, -34, -35, -40, -42, -43, -44, -46, -47, -48, -53, -54. 10-79020-5, -6, -8, -10, -13, -14, -16. Use Kit P/N 10-52305-1 for magnetos P/N’s 10-51360-1 ,-10, -11, -25, -26, -29. Use Kit P/N 10-52306 for magnetos P/N’s 10-51365-2, -5, -6, -7, -8, -15, 17, -18, -19, -20, -21, -22, -23, 24, -25, -41. Use Kit P/N 10-157209 for magneto P/N’s 10-51360-45, -47, -48, -49. 10-51365-57. 10-79020-11, -17, 18, -19.

S-200, S-600 Series

Use Kit P/N 10-157209 all magneto P/N’s.

S-700 Series

Use Kit P/N 10-171192 all magneto P/N’s.

S-1200 Series

Use jumper wire with No. 10 eyed terminal at magneto end, alligator clip at engine ground end.

D-2000 Series

Use Kit P/N 10-382698 all magneto P/N’s.

Remove the regular aircraft switch lead at the magneto. Install the jumper lead to the magneto and connect the other end to a convenient clean engine grounding point. The engine will now be inoperative until the jumper leads are removed and the regular switch leads reinstalled.

A log book entry must then be made signifying that the condition has been corrected.

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 Printed April 1976 Page 3 of 7 Pages

Sidney, New York 13838

PART II. Switch Fault Detection Procedures. Procedure to accomplish compliance and detection of the problem described in Part I is as follows. Procedure A may be accomplished by observing engine operating during switch positioning. Procedure B may be accomplished by checking, using a continuity devise such as an ohmmeter or timing light.

3.

Rotate the switch key or lever to the extreme limit of its travel in the "OFF" position direction. (This may be slightly past the normal "OFF" position of the switch.) Manually hold the switch control there and observe the continuity device indication.

4.

Reaction of the continuity device should indicate that continuity exists between ground and each individual switch (magneto primary) lead.

5.

When the switch key or lever is released from the manually held "Past OFF" position, it should automatically return to the normal "OFF" position. Each switch (magneto primary) lead should indicate continuity from the lead to ground.

Procedure A - Check using engine reactions. 1.

1.Observing the engine manufacturers ground run-up procedures allow the engine to reach operating temperatures and perform a normal magneto check. 2. With the engine at normal idle, rotate the switch key or lever through the "OFF" detent to the extreme limit of its travel in the "OFF" position direction. 3. If the engine continues to run with the switch manually held in the "Past OFF" position, it is an indication that one magneto is still "Hot" or ungrounded. 4. When the switch key or lever is released from the manually held "Past OFF" position, it should automatically return to the normal "OFF" position where the "Hot" magneto condition should no longer exist and the engine should die. 5. Any switch exhibiting a "Hot" magneto condition when in the "Past OFF" position should be repaired or replaced (Ref. Part III) at the earliest possible opportunity. Procedure B - Using Continuity Device 1.

Remove the switch (magneto primary) leads from both magnetos. WARNING

During switch continuity checks, removal, repair or replacement, both magnetos are "Hot." Should the propeller be moved by hand during this time, the engine may fire and cause injury to personnel. 2.

Connect a continuity device between each switch (magneto primary) lead at the magneto end and a good ground on the engine.

Any switch exhibiting a "Hot" magneto condition detected using either Procedure A or B, should be repaired or replaced at the earliest opportunity. Light Aircraft Ignition Switches of the rotary action type are primarily mechanical in construction, consisting of springs, contactors, a contact plate and rotating parts within a housing. As is true with most mechanical assemblies, switches are subject to wear. Use of either Procedure A or B will detect a switch wear malfunction as well as provide a check on switch-to-magneto circuitry. The procedures therefore would be appropriate for inclusion in aircraft operating routines at periodic check periods. Part III. Repair or Replacement A.

Switches identified by 10-126XXX and 10-157XXX Series Part Numbers are no longer manufactured and are superseded by the 10-357XXX series switches. Field repair of any of these series switches is not recommended beyond replacement of the support plate and switch contacts. It is also recommended that if a new support plate is installed, new contacts (3 required per switch) also be installed at the same time.

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 Printed April 1976 Page 4 of 7 Pages

Sidney, New York 13838

Table III provides superseding Switch Assembly Part Numbers as well as Repair Kit Numbers.

Each Repair Kit contains a new support plate and three new contacts.

TABLE III. PART NUMBER APPLICABILITY. Switch Function

Switch P/N

Superseded By

Twist-To-Start

10-357200-1 10-357230-1, -2 10-357260-1 10-126690-1 10-126630-1

---------------------------10-357200-1 10-357230-1

10-357510

10-357210-1 10-357240-1 10-357270-1 10-126680-2 10-157440-1 10-157440-2 10-157440-3 10-157440-4 10-157440-21

---------------------------10-357210-1 10-357270-1 10-357270-2 10-357270-2 10-357240-1 10-357270-1

10-357515

10-357220-1 10-357250-1 10-357280-1 10-126680-1 10-126660-1 10-126660-4

---------------------------10-357220-1 10-357250-1 10-357280-2

10-357510

Push-To-Start

Twist-To-Start Pust-To-Prime

B.

To install a new Support Plate and Contacts, proceed as follows using Figure 1 as a guide for parts identification. 1.

Repair Kit P/N

c.

Directly beneath the support plate are three contacts, spring loaded against the support plate. Carefully separate the support plate from the main switch assembly and remove the three contacts and springs (3 or 9).

d.

Retain the springs for use during reassembly. Discard the old support plate and contacts.

e.

Inspect remainder of switch assembly for smoothness of operation

Disassembly and Inspection a. b.

Hold switch in a vertical position, support plate up. Using firm finger pressure, hold the support plate against the switch housing while removing the two self tapping screws. Retain screws for use during reassembly.

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 Printed April 1976 Page 5 of 7 Pages

Sidney, New York 13838

Figure 1. Identification of Switch Parts. and check the rotor for any visible defects. If any faults are found, replacement of the complete switch assembly is recommended using Table III for replacement part number information. 2.

Reassembly NOTE The support plate contact surface and contacts in kits 10-357510 and 10-357515 are prelubricated with Beacon P-290 lubricant and no additional grease is required. a.

Reinstall contact loading springs (3 or 9) in rotor. Position new contacts over springs so contacts will move into triangular recesses when pressure is applied.

b.

Locate boss on new support plate over locating slot in switch housing

and carefully install support plate to housing, observing that contacts move in recesses. c.

Holding plate against housing, turn key or lever through all switch positions. If it does not turn freely through the detent position, recheck contact, springs, and support assembly.

d.

Once switch operation is satisfactory, reinstall and tighten self tapping screws holding support plate to switch housing.

e.

After switch has been completely reassembled, check it for ease of operation. There shall be little or no drag between stops. Check for positive stops in all positions. Check switch action for a positive and free spring return from the "START" position to the "BOTH" position. The switch shall not spring back beyond or "overtravel" the "BOTH" position.

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 suitable electrical continuity indicating device, check the switch for proper electrical operation. Refer to Table IV, V, or VI for the switch type being tested. There must be a continuity indication between the terminals listed for each switch position. There must be NO continuity between these terminals and any other terminal, between any other terminals or between any terminal and the switch housing.

Sidney, New York 13838

f.

3.

For switches with "Push" features, check lever or key for a free pushing action in proper switch positions and for proper spring return from pushed position.

Testing a.

Remove any wires or jumpers which may be present on the terminals at the rear of the switch.

b.

Using an ohmmeter, timing light or other

TABLE IV. CONTINUTIY TEST, TWIST TO START.

TABLE V. CONTINUTIY TEST, PUSH TO START.

Switch Position

Continuity Only Between Terminals

Switch Position

Continuity Only Between Terminals

OFF

R and GRD L and GRD L and R S and PR

OFF

R and GRD L and GRD

R

L and GRD R and unmarked next to R

L

R and GRD R and unmarked next to R GRD and unmarked next to R

BOTH

R and unmarked next to R

START (twist and hold, do not push)

GRD and unmarked next to R L and BO L and LR BO and LR

START (twist, push and hold)

Same as above, plus BAT and unmarked next to BO/

R

L and GRD R and unmarked

L

R and GRD R and unmarked GRD and unmarked

BOTH

R and unmarked

START

GRD and unmarked S and BAT L and BO L and LR BO and LR

Bendix

Engine Components Division

SERVICE BULLETIN NO. 583 Printed April 1976 Page 7 of 7 Pages

Sidney, New York 13838

TABLE VI. CONTINUTIY TEST, TWIST TO START PUSH TO PRIME. Switch Position

Continuity Only Between Terminals

OFF

R and GRD L and GRD L and R S and PR

R

L and GRD R and unmarked

L

R and GRD R and unmarked GRD and unmarked

BOTH

R and unmarked

START

GRD and unmarked S and BAT L and BO L and LR BO and LR

PRIME (twist, push and hold)

Same as above, plus BAT and PR

b.

Switches repaired under Part III utilizing Repair Kits, P/N 10-357510 or 10-357515 which have a white dot on the plate adjacent to the Bendix marking will be in compliance with this Bulletin and a log book entry signifying Bulletin compliance shall be made.

c.

New replacement switches are identified by a four digit date code stamped on the switch housing under the Bendix part number. Installation of a switch so identified should be noted by an accompanying log book entry as being in compliance.

Parts Required Per Article: As required, Part III, Table III. Special Tools Required: None. Man Hours Required: 1. Check Procedure – Negligible. 2. Repair Procedure - 1/2 Hour Weight Change: None.

4.

Identification a.

Switches checked and found satisfactory for continued use; make log book entry signifying compliance with this bulletin.

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 587 Engineering Aspects are FAA Approved Printed February 1977 Page 1 of 4 Pages

Sidney, New York 13838

AIRCRAFT SUBJECT:

INSPECTION OF D-2000 SERIES MAGNETO CAPACITORS AND CAPACITOR LEAD CRIMP TERMINALS

REASON FOR BULLETIN:

To recommend the following: I. Inspection and repair of capacitor crimp terminals and provide instructions for accomplishment. II. Capacitor replacement if breaker spring lift side of cam follower indicates melting. III. Replacement of Brass housing capacitors.

EQUIPMENT AFFECTED:

Parts I & II All D-2000 Series Magneto Ignition Systems below Serial Number 11,744. Part III D-2000 Magneto/Series with Serial Numbers between 8618 and 9823 for 4 cylinder versions and between 7544 and 9823 for 6 cylinder versions.

Maintenance (Spare) Parts Affected: All spare D-2000 Series Magnetos and Dual Ignition Systems and D-2000 Series Capacitors.

General Information: Parts I & II

Field reports indicate that occasionally a breaker assembly will be found closed up due to melting of the cam follower directly under the breaker main spring as illustrated by figure 1, view "B" (view "A" shows normal condition of cam follower.) BREAKER ASSEMBLY

Compliance: At first opportunity but not later than the next regularly scheduled inspection.

Figure 1

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 587 Engineering Aspects are FAA Approved Printed February 1977 Page 2 of 4 Pages

Sidney, New York 13838

Cam follower melting may be caused (1) by deterioration of the crimp joint at the capacitor lead flag terminal or (2) by a capacitor internal failure. Either of these capacitor failures causes excessive breaker point arcing. Arcing results in heating of the breaker assembly main spring thus causing the follower to melt. Parts I & II of this bulletin detail the action to be taken to prevent this occurrence and instructions to correct this condition, if it exists. Part III. It has been discovered that some D2000 Magneto Capacitors P/N 10-382681 (6 cyl.), 10-382681-1 (8 cyl.) and 10-382807 (4 cyl.) have brass tubular housings. It is recommended that the brass housing capacitors be identified, removed from service and replaced with the steel housed capacitors. (Figure 6 illustrates the method for identifying capacitors with brass housings.) Detailed Instructions: Part I. Disassembly, Inspection and Corrective Action. A. Remove cover from magneto and capacitor from the cover. B. Visually inspect the flag terminal crimp joint for the following conditions. Inspection will be aided by using magnification, 4 power or greater. 1. Examine crimp joint for evidence of a tinned wire bundle as illustrated in figure 2.

Figure 3 2.

If condition 2 is discovered, replace with a new steel housing capacitor.

3.

If condition 3 is evident, carefully attempt to move the insulation back from the crimp area to expose bare wire strands as shown in figure 4. Use a non metallic probe for this operation. If bare strands can be exposed as shown in figure 4, solder conductors to crimp area of flag terminal per soldering procedures outlined in paragraph D. If wire strands cannot be exposed and insulation appears to be caught within the conductor crimp area, replace the capacitor. WIRE STRANDS

Figure 2 2.

Look for evidence of a burning or an arcing appearance around the outline confinements of the wire bundle in the crimp area. 3. Inspect the wire to flag terminal for evidence of conductor insulation extending within the confines of the wire crimp area. See figure 3. C. Corrective Action. 1. If condition 1 is present, solder the conductor to the flag terminal following the soldering procedure outlined in paragraph D.

Figure 4

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 587 Engineering Aspects are FAA Approved Printed February 1977 Page 3 of 4 Pages

Sidney, New York 13838

D. Soldering Procedure. 1. Thoroughly clean the conductor crimp area of the flag terminal. Use a stiff bristle brush and an oil free solvent such as alcohol, methylethylketone or chlorethane. Allow terminal to air dry. 2. Sparingly apply an activated liquid rosin flux to the conductor crimp area. Do not use an acid base liquid or paste flux which is corrosive in nature. 3. Using a soldering iron of 60 watt maximum rating, hold the tip firmly against the side of the flag terminal. Apply the heat under the conductor wire crimp area. 4. Apply 50/50 or 60/40 solder of the rosin core type to the heated crimp area, feeding the solder in at the open end of the crimp. Stop when molten solder appears in the area between the wire crimp and the insulation crimp. Do not use so much solder that it wicks into the wire within the insulation crimp. A properly soldered flag terminal should appear as shown in figure 5. 5. Thoroughly clean the completed soldered flag terminal of all flux residue with a brush and solvent as called out in step 1. WIRE STRANDS SOLDERED TO TERMINAL

Part II. Capacitor Replacement when breaker cam follower has melted. A.

In the event it is determined the nylon cam follower material is melted in the location where the cam follower contacts the breaker main spring as shown in figure 1, the breaker assembly and the associated capacitor must be replaced with new parts. CAUTION Do not reuse a capacitor associated with a melted cam follower breaker assembly.

Part III. Capacitor Replacement, Brass Housing Types, Magneto Serial Numbers as listed under General Information of EQUIPMENT AFFECTED, Part III. A.

When complying with inspection requirements outlined in Part I also perform a check for housing material of the capacitor as follows: 1. Using a small magnet, determine if the tubular housing of the capacitor is steel. 2. Apply the magnet to the housing just above the upper edge of the rubber stabilizing boot as shown in figure 6.

Figure 5 E.

Reassembly 1. Reinstall the capacitors in the magneto cover forming the leads as shown in figure 6. Torque the capacitor securing nuts to 60-75 inch pounds. 2. An Engine Log Book entry indicating compliance with this bulletin is recommended.

Figure 6 3.

4.

If the housing is not magnetic, the housing is brass and the entire capacitor should be replaced with one known to have a steel housing verified by the magnet checks described in 1 & 2 above. Replacement for the brass housing capacitors can be procured through arrangements with recognized

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 587 Engineering Aspects are FAA Approved Printed February 1977 Page 4 of 4 Pages

Sidney, New York 13838

Bendix Central Distributors or their outlets. Replacement will be on a no-charge/direct exchange basis through June 30, 1978. 5.

After compliance with this Bulletin metal stamp the letter "S" in the lower right corner of the magneto name plate and also make an appropriate Engine Log Book entry.

Parts Required: As determined by inspection.

Special Tools Required: None Man Hours Required: Approximately 1/2 hour after cover is removed during an inspection procedure. Weight Change: Negligible.

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 590A Engineering Aspects are FAA Approved Printed May 1978 Page 1 of 3 Pages

Sidney, New York 13838

AIRCRAFT SUBJECT: REASON FOR BULLETIN:

Rotating magnet to housing clearance, D-2000/D2200 series magnetos. Part 1: To alert users of D-2000/D2200 magnetos of a possible problem and to provide a procedure for detection. Part 2: To provide instructions for return of magnetos when factory repair is required. NOTE This Service Bulletin supersedes S.B. 590 dated May, 1977 and changes are indicated by black margin lines. The major change is in the magneto serial number range and all serial numbers specified under EQUIPMENT AFFECTED are involved, regardless of accumulated "in service" time, unless they have previous compliance to S. B. 590.

EQUIPMENT AFFECTED:

Part 1: D-2000/D2200 Series Magnetos with red name plates, having serial numbers of 5145 through serial number 11744 and X2484 through X-2562 with 4 hex head cap screws as indicated in figure 1, without the letter A or R preceding the serial number. Part 2: D-2000/D2200 Series Magnetos with blue nameplates having serial numbers below 701001, with 4 hex head cap screws as indicated in figure 1 without the letter A or R preceding the serial number.

Figure 1. Position of 4 Hex Socket Head Cap Screws Note The A serial number prefix indicates that the aspects of this bulletin have been accomplished by Bendix. The R prefix indicates that aspects of this bulletin have been previously accomplished in the field.

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 590A Engineering Aspects are FAA Approved Printed May 1978 Page 2 of 3 Pages

Sidney, New York 13838

Maintenance (Spare) Parts Affected: Same as information in Equipment Affected section.

5.

Compliance: 1. All subject magnetos covered by "Equipment Affected" no later than 10 hours in service after receipt of this Service Bulletin.

Inspect the rotating magnet for presence of score marks around its diameter. If score marks are seen, the rotor has been rubbing and the magneto must be removed from service and the complete magneto returned to the manufacturer for repair.

6.

2. All subject spare magnetos covered by "Equipment Affected" upon receipt of this Service Bulletin.

If no score marks are seen, place the rotating magnet in any one of its neutral positions.

7.

Check rotor-to-housing pole shoe clearance by attempting to insert at the same time four pieces of .007" shim stock* between the rotor outside diameter and the housing pole shoes. One piece should be at each of the 4 locations shown in figure 2.

General Information: Part 1. Investigation has revealed the possibility that a small percentage of D-2000 & D-2200 Series magnetos using a "wedge" coil retention device may have insufficient clearance between the magneto rotor and the housing pole shoes. If interference should occur between these parts, complete loss of ignition can result. To guard against such failure, compliance with the instructions in this bulletin, should be followed. Part 2. When it is found that a magneto does not have adequate rotor-to-housing pole shoe clearance, return the complete magneto along with the two capacitors from the magneto cover, directly to the factory for no charge warranty repair. Shipment should be by fastest surface transportation and the parcel clearly addressed and identified as follows to assure rapid handling when received. Do not return the Ignition Harness. SHIP TO: The Bendix Corporation Electrical Components Division Sidney, New York 13838 Attention: Product Support Manager D-2000 Warranty, Service Bulletin No. 590A Detailed Instructions: 1.

Remove cover from magneto and magneto from engine.

2.

Remove magneto breaker cam or cams using offset screwdriver to release main cam from shaft.

3.

Remove distributor block hold down screws and associated parts.

4.

Lift off distributor block together with the breaker assemblies.

Figure 2. Positions for Inserted Pieces of .007” Shim Stock The shim stock should be wide enough to span the width of each housing pole shoe and insertion should be able to be accomplished at all positions for the full depth of the rotor. When all 4 pieces of shim stock are in position, it indicates that the rotor-to-housing pole shoe clearance is at least .007" all around. 8. If step 7 can be accomplished, assemble the distributor block to the housing, install the cam or cams and time the magneto following instructions in the D-2000 & D2200 Series Magneto Ignition Systems Overhaul manual, Bendix Form L-945. *Non-magnetic shim stock is recommended. (Experience has shown that IBM punch card stock is normally .007" thick and can be used for this operation. Check card thickness with micrometer before use.)

Bendix

Electrical Components Division

SERVICE BULLETIN NO. 590A Engineering Aspects are FAA Approved Printed May 1978 Page 3 of 3 Pages

Sidney, New York 13838

9.

If step 7 cannot be accomplished, the rotor-to-housing pole shoe clearance is insufficient and the entire magneto with the two capacitors from the magneto cover must be returned directly to the factory as detailed by General Information part 2. CAUTION Under no circumstances should a magneto having less than .007" clearance all around, be returned to service.

10. After satisfactory completion of steps 7 and 8, identify compliance with the Service Bulletin by stamping the letter R ahead of the serial number on the magneto data plate and make appropriate engine log book entry. 11. Compensation for the work involved in complying with the provisions of Service Bulletin No. 590A will be

made upon submission of a warranty claim. The claim must be submitted through a currently authorized Bendix distributor or Bendix service station. Reimbursement for expenses incurred in accomplishing compliance with Service Bulletin No. 590A will be made in accordance with established Bendix Warranty procedures. Parts Required: As determined by inspection. Special Tools Required: Timing light, Bendix 11-9110-1 or equivalent. .007" shim stock. Man Hours Required: 2 1/2 hours maximum. Weight Change: None.

Electrical Components Division

SERVICE BULLETIN NO. 600 Supersedes Service Bulletin N. 589 Engineering Aspects are FAA Approved Printed May 1978 Page 1 of 2 Pages

Sidney, N. Y. 13838

AIRCRAFT SUBJECT: REASON FOR BULLETIN:

10-353110 bearing in D-2000/D-2200 Series Magneto. Part 1. Part 2.

EQUIPMENT AFFECTED:

Part 1.

To alert users of D-2000/D-2200 Series Magnetos of possible bearing difficulty. To provide a procedure for inspection of subject bearing. D-2000/D-2200 magnetos with Red name plates having Serial Numbers above 3000 and below 17510, (including magnetos identified with the letters "A" or "R" preceding the Serial Number), which DO NOT have the letter "B" stamped in the approximate center of the bottom line on the name plate. D-2000/D2200 magnetos having Red name plates with Serial Numbers above X2454 and below X2562 which DO NOT have the letter "B" stamped in the approximate center of the bottom line on the name plate. Remanufactured D-2000/D-2200 magnetos with Blue name plates having Serial Numbers below 806001 (including magnetos identified with the letters "A" or "R" preceding the Serial Number), which DO NOT have the letter "B" stamped in the approximate center of the bottom line on the name plate.

Part 2.

Spare Parts Affected: 10-382874 10-382505 10-382876 10-382519 10-382878 Compliance: Within the next 10 hours of magneto operating time. General Information: Field reports indicate that occasionally the magneto rear bearing, Part No. 10-353110, can become overheated. This condition may be the result of a tight bearing fit. To insure a "free" bearing fit, all affected magnetos should be checked as outlined in this bulletin. Detailed Instructions: Part 1. Determine if magneto Serial Number is listed under Equipment Affected. If magneto is within the serial numbers shown and is not identified with the letter

Same magnetos as listed in Part 1.

"B" in the approximate center of the bottom line on the name plate, proceed to Part 2 of this bulletin. Part 2. Procedure for inspection of bearings in affected magnetos to insure a "free" fit that will permit the distributor block and bearing to fall from the shaft when the magneto is turned upside down. A.

Place magneto in secure upright position with drive end down.

B.

Remove cam securing screw and breaker cam/cams.

C. Remove distributor block retaining screws.

Electrical Components Division

SERVICE BULLETIN NO. 600 Supersedes Service Bulletin N. 589 Engineering Aspects are FAA Approved Printed May 1978 Page 2 of 2 Pages

Sidney, N. Y. 13838

D. Prepare a soft surface for the distributor block to drop on or position hand to catch block when it falls from magneto shaft. Invert magneto so drive end is up (See Figure 1) and the distributor block/bearing assembly should drop from the shaft. Do not side load magneto shaft by gripping both housing and drive member. Acceptable magnetos should be reassembled in accordance with Bendix Overhaul Manual, Publication Form L-945.

G. After the new bearing is installed, repeat the block drop test described in paragraph D and reassemble magneto as noted. H. If any magneto still fails the free fall test, install a new distributor block and bearing assembly which has been tested at the factory. These assemblies have the following parts numbers: Green Blocks 10-382974 (4 cyl.) 10-382976 (6 cyl.) 10-382978 (8 cyl.)

Black Blocks 10-382970 (4 cyl.) 10-382972 (6 cyl.)

I.

Reassemble magneto in accordance with instructions in Bendix Overhaul Manual, Publication Form L-945.

J.

After compliance with this Bulletin, stamp letter "B" in the approximate center of bottom line on magneto name plate and make Engine Log Book entry.

Parts Required: As necessary. Special Tools Required: Part 1. None

Figure 1. Position of magneto for checking free fall test of bearing tolerance. E.

F.

If distributor block does not drop from shaft in step D procedure, insure that block is not sticking by moving the block approximately 1/8 inch away from housing. If block still does not drop from shaft, the bearing must be replaced. Remove distributor block from magneto and replace the bearing with a new 10-353110 part having "Bendix" identification. The 11-9998 pressing tool and 11-9999 bearing support tool must be used for this procedure.

Part 2. Special tools as required in Bendix Overhaul Manual, Publication Form L-945. Man Hours Required: Part 1.Approximately 1 1/2 hours to remove and reinstall magneto. Part 2.Approximately 1 hour to perform inspection and reassemble magneto. Weight Change: None

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 1 of 15 Pages

Sidney, New York 13838

AIRCRAFT SUBJECT:

1. Inspection of D-2000/D-2200 Series Magnetos for possible housing distortion (Ref. Section 2) 2.

Use of Coil Retention Kit, Bendix P/N 10-382939 (Ref. Section 3)

3.

Use of Bendix Cover Sealing Kit Bendix P/N 10-682007 (Ref. Section 4)

4. Method of return for magnetos found to be outside the housing distortion limits set forth in this Bulletin (Ref. Section 6)

GENERAL INFORMATION 1.

Investigation has revealed that tightening of the four center magneto cover screws can cause a dimensional change in the magneto housing distributor block pilot diameter. Should the distributor block be loosened or removed and then reinstalled, the possibility then exists that misalignment of the rotating magnet within the magneto housing may result in rotating magnet to housing interference. It has also been determined that removal of the four center magneto to harness/cover screws will eliminate the primary force that causes housing distortion. Removal of the four center attaching screws requires closing of these four holes in the cover. To accomplish this, Section 4 of this Service Bulletin describes the

procedure for installation of a Dome Head, Aluminum Closed-End, Aluminum Mandrel "POP" Rivet ("POP" Rivet is the registered trademark of the USM Corporation, Pop Rivet Division, Shelton, CT 06484) or equivalent in each of the four open screw holes. Bendix Cover Sealing Kit P/N 10-682007 is to be used for this operation if certain conditions exist as described under Section 1. Compliance. Incorporation of the latest method for coil securing has also been found to further reduce the effect on housing distortion. Installation of Coil Securing Kit, Bendix P/N 10-382939 is detailed in Section 3 of this Bulletin. The following Table of Contents will assist in locating the one or more Sections found by inspection to be applicable to the magneto or system being checked for Bulletin compliance.

*”POP” Rivet is the registered trademark of the USM Corporation, Pop Rivet Division, Shelton, CT 06484

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 2 of 15 Pages

Sidney, New York 13838

TABLE OF CONTENTS

SECTION 1

COMPLIANCE 1.1 Equipment Affected 1.2 Time Compliance 1.3 Compliance Extent 1.4 Category 1 1.5 Category 2 1.6 Category 3 TABLE

SECTION 2

HOUSING DISTORTION CHECK 2.1 General Instructions 2.2 Method 1 2.3 Method 2 2.4 Method 3 2.5 Testing

SECTION 3

INSTALLATION OF COIL SECURING KIT

SECTION 4

INSTALLATION OF COVER SEALING KIT AND COVER DECALS

SECTION 5

IDENTIFICATIN AFTER COMPLIANCE

SECTION 6

PROCEDURE FOR RETURN OF D-2000/D-2200 SERIES MAGNETOS FOR FACTORY REPAIR

SECTION 7

MAINTENANCE (SPARE) PARTS AFFECTED, WEIGHT CHANGE, TIME REQUIRED

SECTION 8

APPENDIX 1.1 Instructions for Gage Plate Fabrication

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 3 of 15 Pages

Sidney, New York 13838

SECTION 1

COMPLIANCE

1.5.3

By the presence of the letter "K" stamped after the serial number on the magneto nameplates.

1.1

Equipment Affected

1.1.1

This Service Bulletin applies to all D2000/D-2200 Series Magnetos or Ignition Systems.

1.5.4

By the presence of four "Pop" Rivets in place of the four center cover screws and the letter "K" after the Serial Number.

1.2

Time Compliance

1.5.5

1.2.1

At first opportunity, but in any case no later than 100 operating hours after receipt of this Service Bulletin.

1.3

Compliance Extent

1.3.1

The extent of compliance required shall be determined by first identifying the magneto system to be checked as being in one of the following "Categories" and then adhering to the applicable requirements as stated.

If the conditions described in 1.5.2 and 1.5.3 above exist, remove the four center screws and install a "Pop" rivet in each of the four open cover holes as described in Section 4 of the Bulletin. Magneto Systems as described in 1.5.4 above, comply with Section 4 of this Service Bulletin. Make an engine log book entry indicating compliance with Section 4 of this Service Bulletin.

1.5.6

However, at the next 100 hour inspection period, or at the next removal or loosening of the magneto distributor block, compliance with Sections 2 and 5 must be accomplished and an engine log book entry then made signifying compliance with this Bulletin 605A.

1.6

Category 3

1.6.1

All D-2000/D-2200 magnetos or systems not covered in Category 1 or 2 fall in this Category and shall first be checked for compliance with Section 2, "Housing Distortion".

1.6.2

If the magneto exceeds the specified limits of housing distortion, the magneto must be returned to Bendix for repair. Procedure for return is covered in Section 6 of this Service Bulletin.

1.6.3

If the magneto is within the specified limits, check the magneto nameplate for Code letter identification and Serial Number applicability for compliance with previously issued D-2000/D-2200 Series Service Bulletins and comply as required. Table 1 provides a step-by-step check procedure for this purpose.

1.4

Category 1

1.4.1

These magneto systems can be identified by the presence of four "POP" (Reg. TM) rivets in place of the four center screws in the magneto/harness cover. The letter "D" will also be stamped on the bottom line of the magneto nameplate.

1.4.2

The "system" as described above is in full compliance with this Service Bulletin and previously issued Bendix Service Bulletins 584B, 587, 590A, 600 and 606.

1.4.3

Make an engine log book entry signifying full compliance with Bendix Service Bulletin 605A.

1.5

Category 2

1.5.1

These magneto systems can be identified in one of the three following ways.

1.5.2

By the presence of unbroken orange TORQUE SEAL (Reg. TM of the USM Corporation, Pop Rivet Division, Shelton, CT 06484) on the four center screws of the magneto cover.

*”POP” Rivet is the registered trademark of the USM Corporation, Pop Rivet Division, Shelton, CT 06484 ** TORQUE SEAL is the registered trademark of Organic Products Inc., Irving TX 75060

Electrical Components Division Sidney, New York 13838

1.6.4

If a Category 3 magneto inspection indicates compliance with all the aspects of Section 2 and Table 1, comply with Section 4 and identify the magneto per Section 5.

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 4 of 15 Pages CAUTION Do not install a magneto/harness cover to a magneto having the letter D stamped on the nameplate without first installing the POP rivets contained in Bendix Cover Sealing Kit P/N 10-682007.

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 5 of 15 Pages

Sidney, New York 13838

TABLE 1

Step No.

* Control Code Ltr.

Acceptable Serial No. Range

1

D

Not Applicable

2

K

3

4

Magneto is identified with Control Code Ltr. Yes

No

Magneto Falls within Acceptable Serial No. Range Yes

No

If Both No

If One Yes

X

Comply with SB No. 605A in its entirety

Indicates complete compliance with SB No. 605A

Red Label – 25001 & above or Blue Label - 901001 & above or Any magneto regardless of S/N, with unbroken torque seal on 4 center cover screws

Comply with SB No. 605A in its entirety

Comply with SB No. 605A Section 4

C

Red Label – 17815 & above or Blue Label – 806001 & above

Comply with SB No. 584B (Covered in SB No. 605A Section 3)

Proceed to Step 4

B

Red Label – outside S/N range X2455 – X2561 and

Comply with SB No. 600

Proceed to Step 5

Comply with SB No. 590A

Proceed to Step 6

-outside S/N range 3001 – 17509 or Blue Label – 806001 & above 5

A R

Red Label or outside S/N range 3001 – 17509 and outside S/N range 5145-11, 744 Blue Label 701001 & above

6

None

All

Note: Compliance required to 100 operating hours and at 100 hour periods thereafter. Refer to SB No. 599

7

S

Red Label –11,744 & above

Comply with SB No. 587 Parts 1 & 2

8

S

Red Label (4 cyl) – outside S/N range 8618 – 9823 or Red Label (6 cyl) – outside S/N range 7544 - 9823

Comply with SB No. 587 Part 3

Proceed to Step 8

* Control Code Letter found stamped on magneto nameplate outside “Chg.” Block area indicates compliance with applicable reference Bendix Service Bulletin.

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 6 of 15 Pages

Sidney, New York 13838

SECTION 2 HOUSING DISTORTION CHECK 2.1

General Instructions

2.1.1

This section provides instructions to determine if the distributor block bore of the magneto housing has been distorted beyond specified limits.

2.1.2

Remove cover from the magneto and magneto from the engine.

2.2

CAUTION Do not hold magneto by clamping in a vise of by holding the drive end components. 2.1.3

Support magneto in a work stand and in an upright position, distributor block facing the operator. A suitable work stand can be constructed as shown in Figure 2-1.

2.2.2

Method 1 Using a locally fabricated gage plate as described in Section 8, Appendix, Attach it to either end of the magneto housing with two 0.50 or 0.625 inch long, fillister head 10-32 screws. The heads of the chosen screws must not project beyond the edge of the gage plate when they are at the extreme limits of the holes in the plate. Leave the two screws just loose enough so the gage plate can just slide in the 0.250 inch holes. Gage plate position as installed is shown in Figure 2-2. Loosen the two distributor block securing screws just enough to remove the spring lock washer compression.

Material 0.750 in. thick wood Hole in center top surface 3.1250 in. diameter Dimensions for Constructing Suitable Work Stand Figure 2 – 1 2.1.4 Using any one of the three following alternative methods, check the distributor block to housing clearance and center the block as instructed. Method 1. Using locally fabricated gage plate; Method 2. Using a depth micrometer; or Method 3. Using a dial indicator.

Gage Plate in Position on Housing Figure 2-2 2.2.3 Steady the magneto housing with one hand at the gage plate end. CAUTION Pressure applied in either direction should not exceed 2.50 pounds.

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 7 of 15 Pages

Sidney, New York 13838

2.2.4

With the other hand, and with finger pressure only, attempt to shift the distributor block endways in the distributor block pilot bore of the housing as shown in Figure 2-3.

Next move the gage plate toward the block as far as it will go. Then move the distributor block endways and straight back to the limit of its shift. Allow the gage plate to move with the distributor block. Make sure the gage plate is contacting both corners of the distributor block and then tighten the gage plate securing screws. After tightening the securing screws, recheck to make sure the gage plate is still in contact with both ends of the block and that it did not move when the screws were tightened. 2.2.7

With the gage plate secured, now shift the distributor block straight away from the gage plate to the full extent of the shift, again using a maximum of 2.50 pounds to accomplish the block shift.

2.2.8

While holding the block in this position, measure at points "A and B" as shown in Figure 2-4 the extent of the block shift. Using two sets of feeler gages check the clearance between both of the block corners and the gage plate at the same time. Figure 2-5 illustrates this gaging operation.

Using Finger Pressure to Check Distributor Block Shift Figure 2-3. 2.2.5

2.2.6

If there is no evident shift or block movement, remove the gage plate and proceed to paragraph 2.2.11. If a shift is present, move the distributor block with finger pressure only, first away from the gage plate.

Use Feeler Gages at Points A & B Gage Plate Position and Measuring Points Figure 2 – 4 2.2.9

If more than 0.008 inch feeler gage stock can be inserted between the block corners and the gage plate at points "A" and "B" return the magneto to the factory for correction.

Electrical Components Division Sidney, New York 13838

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 8 of 15 Pages flexible hard surface card stock such as used for computer keypunch cards is acceptable. 2.2.14 Position the rotating magnet so the "K" mark on the rotor aligns with the internal timing pointer on the data plate side of the housing. This is the No. 1 neutral position of the magnet. With the rotating magnet stabilized in this "neutral" position, center the rotating magnet in the housing using the shim stock as follows. 2.2.15 Insert one piece of the shim stock between each pole piece of the housing and the rotating magnet. Angle the shim stock so the exposed ends come out between the cover attaching holes in the magneto housing. Positioning of the 4 pieces of shim stock is shown in Figure 26.

Feeler Gage Check at Points A and B Figure 2 – 5 2.2.10 Refer to Section 6 of this Service Bulletin for procedure to follow when a magneto has been examined and found to exceed the limits as specified in 2.2.9 above. 2.2.11 If the results of the feeler gage check indicates that the distributor block shift is within the limits specified in 2.2.9 the magneto housing is suitable for continued use. 2.2.12 Before proceeding with reassembly, comply with the instructions of Section 3 of this Service Bulletin if applicable. 2.2.13 Prepare 4 pieces of shim stock 0.007 inch thick x 1 inch wide x 4.5 inch long. The shim stock to be used should be nonmagnetic. Brass, plastic or

Shim in Position Around Rotating Magnet Figure 2 – 6

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 9 of 15 Pages

Sidney, New York 13838

2.2.16 Before assembling the distributor blockgear assembly to the magneto, inspect the block itself. Remove the distributor gears and check the block for cracks in the block pilot skirt and for cracks around the rear bearing inserts. (Refer to Bendix Service Bulletin 588 for cracks and limits.) Also check for carbon tracking between electrodes and any other characteristic which might cause operational difficulties. Replace any components found to be defective. 2.2.17 Leave the shims in position as described in 2.2.15 and time the distributor gears to the rotating magnet pinion gear a described in the D-2000/D-2200 Series Magneto Overhaul Manual, Bendix Publication Form L-945. Seat the distributor block to the housing making sure none of the four shims are caught between the distributor block and the magneto housing. See Figure 2-7 for shim positioning after installation of distributor block.

2.2.18 Install the two distributor block securing screws with flat washers and lock washers. Evenly tighten the block securing screws to the recommended torque value of 25 - 30 pound inches. 2.2.19 Carefully pull, one at a time, the four shims from the assembly. Observe the shims when removed to insure that each shim was removed intact and no part of the shim stock remained inside the magneto assembly. If any piece of shim stock remains inside the magneto, it will be necessary repeat paragraphs 2.2.14. 2.2.15, 2.2.17, 2.2.18 and 2.2.19 before proceeding. 2.2.20 When the distributor block is secured to the magneto housing, the magneto assembly can be completed and retimed following the instructions contained in the D-2000/D-2200 Series Magneto Overhaul Manual, Bendix Publication Form L-945. 2.2.21 Observe all torque values specified by the Overhaul manual when tightening any and all securing screws. 2.3

Method 2

2.3.1

Checking distributor block to housing clearance and centering using a Depth Micrometer. See Figure 2-8

2.3.2

Remove the timing plug from the end of the magneto housing. This will be the work reference end.

2.3.3

Loosen the two distributor block securing screws just enough to remove the spring lock washer compression.

2.3.4

Steady the magneto housing with one hand. With the other hand, and with finger pressure only, attempt to shift the distributor block endways in the distributor block pilot bore of the housing as shown in Figure 2-3, Method 1. CAUTION

Distributor Block Secured and Centering Shims Ready to be Withdrawn Figure 2 – 7

Pressure applied in either direction should not exceed 2.50 pounds. 2.3.5

If there is no evident shift or block movement proceed to 2.3.12 of this section.

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 10 of 15 Pages

Sidney, New York 13838

2.3.11 If the result is more than 0.008 inch, return the magneto to the factory for correction using the procedure outlined in Section 6 of this Service Bulletin. 2.3.12 If the result of the depth micrometer check indicates that the distributor block shift is 0.008 inch or less, the magneto housing is suitable for continued use. 2.3.13 Before proceeding with reassembly, comply with the instructions of Section 3 of this Service Bulletin if applicable.

Depth Micrometer Positioned Against Housing Figure 2 – 8 2.3.6

If a shift is present, move the distributor block away from the working end of the housing where the timing plug was removed.

2.3.7

Position the bar of the depth micrometer against the working end, centering the depth rod against the center of the distributor block end surface as shown in Figure 2-8.

2.3.8

2.3.9

With the depth micrometer bar held against the housing set the micrometer rod so it contacts the distributor block. Record the reading obtained. Move the distributor block back toward the working end of the housing and then take another reading.

2.3.10 Subtract the reading obtained in 2.3.9 from the obtained in 2.3.8. The result is the total block shift.

2.3.14 If Section 3 compliance is not required, the distributor block may be centered at this time. Using the depth micrometer, move the distributor block back to a halfway reading and evenly tighten the distributor block screws to the recommended torque of 25-30 pound inches. 2.3.15 When the distributor block is secured to the magneto housing, the magneto assembly can be completed and retimed following the instructions contained in the D-2000/D-2200 Series Magneto Overhaul Manual, Bendix Publication, Form L-945. 2.3.16 Observe all torque values specified by the Overhaul manual when tightening any and all securing screws. 2.4

Method 3

2.4.1

Checking distributor block to housing clearance and centering using a Dial Indicator.

2.4.2

Provide a rigid flat mount for a dial indicator and attach it to the magneto housing in a manner to that showing the indicator in use in Figure 2-9.

2.4.3

Follow the same general procedures and instructions described in Method 1, paragraph 2.2.2 through 2.2.7 and applicable CAUTION note.

2.4.4

Check the block to housing clearance by observing the total indicator reading (TIR) registered when the block is moved to the extreme shift limits.

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 11 of 15 Pages

Sidney, New York 13838

2.4.9

When the distributor block is secured to the magneto housing, the magneto assembly can be completed and retimed following the instructions contained in the D-2000/D-2200 Series Magneto Overhaul Manual, Bendix Publication, Form L-945.

2.4.10 Observe all torque values specified by the Overhaul Manual when tightening any and all securing screws. 2.5 2.5.1

Testing If a test bench and slave harness with capacitors is available, perform an operational check of the magneto before reinstalling it to the engine. CAUTION

Dial Indicator Mounted on Housing Figure 2 – 9 2.4.5

If TIR is more than 0.008 inch return the magneto to the factory for correction using the procedure outlined in Section 6 of the Service Bulletin.

2.4.6

If the result of the dial indicator check indicates that the distributor block shift is 0.008 inch or less, the magneto housing is suitable for continued use.

2.4.7

Before proceeding with reassembly, comply with the instruction of Section 3 of this Service Bulletin if applicable.

2.4.8

If Section 3 compliance is not required, the distributor block may be centered at this time by moving the block to a halfway indicator reading then evenly tighten the distributor block securing screws to the recommended torque of 25 - 30 pound inches.

When installing a slave harness to a magneto on a Test Bench, use the Corner Screw Location Only. Do not exceed a tightening torque of 30 to 35 pound inches when tightening the cover attaching screws. SECTION 3 INSTALLATION OF COIL SECURING KIT 3.1

General Information

3.1.1

The coils in the D-2000/D-2200 Series Magneto, Serial Nos. 17815 and up are retained with a clamp, spring, screw and elastic stop nut. Magnetos not in this serial number range, and not already field modified, must be modified at this time to incorporate the parts in Coil Securing Kit P/N 10-382939.

3.1.2

This Service Bulletin mandates installation of the Coil Securing Kit P/N 10-382939 regardless of Magneto Serial Number unless the Kit has already been installed.

3.1.3

Looking into the magneto, after removal of the distributor block, the presence of four elastic stop nuts, one at each end of each coil core indicates that Coil Securing Kit P/N 10-382939 has already been installed. If the four stop nuts cannot be seen, the kit parts must be installed.

Electrical Components Division Sidney, New York 13838

3.1.4

The procedures for installation of Coil Securing Kit, P/N 10-3822939 are contained in Bendix Service Bulletin No. 584B, Part 3.

3.1.5

Follow the instructions of part No. 2 and part No. 3 of Service Bulletin 584B, whichever is applicable to the magneto under work.

3.2

Parts Required Per Magneto: One 10-382939 Coil Securing Kit.

3.1.1

The 10-382939 Coil Securing Kit may be obtained from Authorized Bendix Electrical Components Division Distributors and their Authorized Outlets. (Reference: Distributors Directory, Bendix Publication L-606.)

3.1.1

The kit will be supplied at no charge for those magnetos still under the Bendix Warranty of 1000 hours or one year, whichever occurs first.

3.2.3

For those magnetos outside the stated warranty period a charge will be made for the 10-382939 Coil Securing Kit.

SECTION 4

4.1

INSTALLATION OF COVER SEALING KIT AND COVER DECALS;

Detailed Instructions, Rivet Installation

4.1.1 Before attaching the magneto cover to the magneto accomplish the following: 4.1.2 Install and seat in each of the four center cover holes a Dome Head, Aluminum "Pop" (Ref. TM) rivet, Bendix P/N 10682005 or USM "Pop" rivet (USM P/N AD64AH or equivalent) as illustrated in Figure 4-1. 4.1.3 Cover Sealing Kit 10-682007 consists of 5 each Dome Head, Aluminum "Pop" Rivets, 10-682005 and Bendix publication, Form L-1163. The 5th rivet is included as a spare.

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 12 of 15 Pages

Figure 4-1 Dome Head Closed-End “Pop” Rivet 4.1.4 The location for the installation of the four specified rivets is shown in Figure 4-2.

Figure 4-2 Location of four rivets 4.1.5 Due to the depth of the alcove in which the rivet must be seated it may be necessary to make short steel adapter sleeve to be placed over the rivet mandrel next to the rivet head. The steel adapter sleeve (Figure 4-3 - should have a center hole of 0.125 (1/8 in.) diameter and a 0.3124 (5/16 in.) O.D. and length to suit riveting tool being used.

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 13 of 15 Pages

Sidney, New York 13838

Non-Pressurized Magneto (Painted Black) 30 - 35 Pounds Inches Pressurized Magnetos (Painted Gray) 40 - 45 Pounds Inches

Adapter Sleeve Figure 4-3 The adapter will move the pulling head of the riveting tool to a position where seating of the rivet and separation of the aluminum mandrel can be accomplished. To guard against loss of the adapter, it is suggested that it be securely taped to the riveting tool during seating installation of the four rivets. Use "Pop" (Reg. TM) Riveting Tool PRP26A, PRG 402 HD or PRG 111 or equivalent for seating the rivet. Cross Sectional View of “Pop” Rivet Installed in Magneto Cover (4 places) Figure 4-4

4.1.6 When seated, the underside of the rivet head should be flush with the outside of the magneto cover surface. 4.1.7 It is permissible for the mandrel portion to extend slightly above the rivet head after installation. Breakage of the mandrel below the rivet head surface or complete separation of the mandrel from the rivet is also acceptable. 4.1.8 Figure 4-4 illustrates in cross section the fully seated position of the "Pop" rivet as well as the position of the adapter and tool pulling head just before mandrel separation from the rivet proper. 4.1.9 Assemble the cover to the magneto using only the four outer corner screws. Use a torque wrench and a criss-cross pattern to squarely draw the cover down to the magneto housing. Evenly tighten the screws to the following torque values:

4.2

Detailed Instructions, Decal Installation

4.2.1 After compliance with this Service Bulletin affix a Decal as specified below to the Left magneto end of the magneto cover. Decal P/N 10-382993 must be used only on Black painted covers and Decal P/N 10282995 only on Gray painted covers as indicated by the information printed on the illustrated decals in Figure 4-5. 4.3

Parts Required per Harness Cover:

4.3.1 Cover Sealing Kit, Bendix P/N 10-682007, Cover Decal 10-382993 (Non-Pressurized Magneto) or 10-382995 (for pressurized magneto).

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 14 of 15 Pages

Sidney, New York 13838

TIGHTEN COVER SCREWS EVENLY TO 30 - 35 LB. IN. CAUTION DO NOT OVERTIGHTEN INSTALL ON BLACK COVERS ONLY

TIGHTEN COVER SCREWS EVENLY TO 40 - 45 LB. IN. CAUTION DO NOT OVERTIGHTEN INSTALL ON GRAY COVERS ONLY

10-382993 Decal 10-382995 Decal Figure 4-5 4.3.2 Cover Sealing Kit 10-682007, and decals may be procured on request to an Authorized Bendix Electrical Components Division Distributor. SECTION 5 5.1

5.2

6.1

6.1.3 Shipment should be by fastest transportation, prepaid and the package clearly addressed and identified as follows to assure rapid handling when received. SHIP TO:

When the letter "D" is on the nameplate, Section 4 (Cover Sealing Kit Installation) must be accomplished prior to the magneto/harness cover installation, if not already done. PROCEDURE FOR RETURN OF D-2000/D-2200 SERIES MAGNETOS FOR FACTORY REPAIR AND COMPENSATION POLICY

Return

6.1.1 When it is found that a magneto does not comply with the guidelines herein established by Section 2 the complete magneto with the two capacitors from the harness cover should be returned directly to the factory for repair. DO NOT RETURN THE IGNITION HARNESS. (Ref: Section 5, paragraph 5.2)

THE BENDIX CORPORATION ELECTRICAL COMPONENTS DIVISION SIDNEY, NEW YORK 13838 ATTN: Product Support Manager D-2000 Magneto Service Bulletin 605A

IDENTIFICATION AFTER COMPLIANCE

If the magneto or system has been examined and found to be in complete compliance with TABLE 1 and Section 2 (Housing Distortion Check) and is or has been altered to be in compliance with Section 3 (Coil Securing Kit inclusion) the letter "D" should be permanently stamped approximately central on the bottom line of the magneto nameplate.

SECTION 6

6.1.2 Protective packaging should be used since replacement of components damaged during shipment will not be covered by warranty repair.

6.2

Warranty Repair

6.2.1 D-2000/D-2200 Series Magnetos with 1000 hours or less of accumulated operating time and having been in service one year or less, will be repaired under full warranty coverage. 6.3

Non Warrantable Repair

6.3.1 D-2000/D-2200 Series Magnetos with over 1000 hours of accumulated operating time or having been in service for more than one calendar year will be repaired and returned on a charge basis. For repair of those magnetos in this category a Blanket Charge of $75.00 will be in effect for one calendar year after the issuance of this Service Bulletin. 6.3.2 When returning a D-2000/D-2200 Series Magneto which is out of warranty, it must be accompanied by a statement on your company letterhead providing the following information. a. b. c. d. e.

Magneto Part Number and Serial No. Time since magneto placed in Service. Make, Model and Year of Aircraft from which magneto was removed. Engine make and Model data. Aircraft Registry No. (Tail No.).

Electrical Components Division

SERVICE BULLETIN NO. 605A (Supersedes Service Bulletin No. 605) Engineering Aspects are FAA Approved Printed November 1979 Page 15 of 15 Pages

Sidney, New York 13838

f.

Repair Purchase order No. from an Authorized Bendix Electrical Components Distributor or their Authorized Branch which will be used for billing the repair charge back to the sender.

6.3.3 In those cases where the foregoing procedure is not followed, billing for the repair charge will be made through the Authorized Bendix Electrical Components Distributor serving the area from which the magneto was originally returned. 6.4

Compensation

6.4.1 Compensation for the work involved in complying with this Service Bulletin for those magnetos under warranty will be made upon the submission of a Warranty Claim submitted through a currently Authorized Bendix Electrical Components Division Distributor. Compensation will be made in accordance with established Bendix Warranty procedures. 6.4.2 Authorized Distributors are listed in Bendix Publication, Form L-606 contained in the Bendix Electrical Components Aircraft Master Manual. Form L-606 may be obtained at no charge by request to the Bendix Corporation, Electrical Components Div., Sidney, N.Y. 13838.

SECTION 8 8.1

APPENDIX

Locally Fabricated Gage Plate (ref. Section 2, paragraph 2.2.1)

8.1.1 INSTRUCTIONS FABRICATION

FOR

GAGE

8.1.2 From 0.1250 inch aluminum, brass or steel, locally fabricate gage plate as follows: 8.1.3 Cut a full size paper template per the full size template sketch and cement it to the selected material. 8.1.4 Cut the material to the form of the paper template. 8.1.5 Drill the metallic gage plate in the positions shown on the template using a 0.250 inch drill. 8.1.6 Lightly deburr all edges of the finished gage plate. 8.1.7 For those desiring to fabricate a more precise gage plate, a dimensioned sketch is shown in Figure 8-1

SECTION 7 MAINTENANCE (Spare) PARTS AFFECTED, WEIGHT CHANGE, TIME REQUIRED. 7.1

Maintenance (Spare) Parts Affected:

7.1.1 Screw P/N 10-382933 Wedge P/N 10-382930 (Replaced by Coil Securing Kit P/N 10382939) Reference Section 3.

Dimensions for Template Figure 8-1

7.1.2 Cover Screws P/N 10-382871, 10-382881, Washer 10-55501, Lockwasher 10-9287943 (Usage - 4 instead of 8 each per Magneto Cover) Reference - Section 4. 7.2

Weight Change Negligible

7.3

Man Hours Required: 2 1/2 hours maximum

PLATE

Full Size Template Cut Out

Electrical Components Division

SERVICE BULLETIN NO. 606 Engineering Aspects are FAA Approved Printed April 1979 Page 1 of 3 Pages

Sidney, New York 13838

AIRCRAFT SUBJECT: REASON FOR BULLETIN:

D-2000/D-2200 series magnetos using green distributor blocks Part 1. Part 2.

EQUIPMENT AFFECTED:

To alert users of a possible problems and provide an inspection procedure for detection. To provide instructions for distributor block replacement required.

D-2000/D-2200 Series, 6 and 8 cylinder magnetos identified as follows:

Magneto Type D6LN-2031 D6LN-2230 D8LN-2200 D6RN-2230 D6LN-2230 D6LN-2230 D6RN-2230 D8LN-2200 Maintenance (Spare) Parts Affected: Green Distributor Blocks 10-382976 (6 cyl.) 10-382978 (8 cyl.) Compliance: Part 1. Magnetos must be inspected within the next 10 hours of operating time and every 25 hours thereafter until magneto overhaul Green distributor block must be replaced with black block at time of magneto overhaul if not previously done. Part 2. If bushing is loose in green distributor block it must be replaced immediately with a black block or a serviceable green block. General Information: Field reports indicate that occasionally the bronze oilite bearings may become loose in green distributor blocks. If this condition occurs the bearings may turn and wear the block bore enough to cause the distributor gear to become mistimed and possibly result in complete ignition failure.

Magneto Part Number 10-382560-53 10-382610-53 10-382620-51 10-382910-12 10-382910-17 10-382910-53 10-382910-58 10-382920-51

Detailed Instructions: Part 1. Inspect affected D-2000/D-2200 magnetos to determine if the distributor gear bearing is loose in green distributor block as follows: NOTE Inspection of the magneto may be performed while it is on the engine, if accessibility permits, otherwise the magneto should be removed from the engine for the required inspection procedure. 1. Remove ventilator plugs, threaded bushing, and solid plug from both ends of magneto housing. 2. Remove Gear Axle Retaining Ring P/N 1092815-37, Plain Washer P/N 10-50753, and Felt Washers P/N 10-50752 from both distributor gear axle positions. 3. Fabricate a 1/4 inch round probe of nonmetallic material, preferably wood dowel rod, approximately six inches long, formed at the using end approximately 1/8 inch wide, 1/8 inch thick by 1 inch long to resemble a screw driver blade.

Electrical Components Division Sidney, New York 13838

4. Insert the formed end of the fabricated tool thru the inspection hole at one end of the magneto housing and between two teeth of the distributor gear. Gently, with moderate force, so as not to damage the gear teeth, attempt to push the gear back and forth sideways while observing the corresponding bronze bearing in the distributor block. If there is no movement detected between the bearing and the block, next insert the fabricated tool under the flat surface of the gear on its outside diameter. Exert moderate pressure on the end of the tool to lift the gear toward the distributor block. Look for movement between the bearing and the block. 5. If no bearing movement is detected by either of these two checks, repeat these procedures at the gear/bearing location at the opposite end of the magneto. 6. If no looseness is detected re-assemble the magneto per instructions listed in Bendix Publications L-928-1 and L-945 Installation Operation and Maintenance Instructions and Overhaul Instructions respectively. 7. Make Engine Log Book entry to denote first inspection of green distributor block and make additional entry at each similar 25 hours inspection thereafter.

SERVICE BULLETIN NO. 606 Engineering Aspects are FAA Approved Printed April 1979 Page 2 of 3 Pages 2. Remove cam securing screw, breakers, cams, axle retaining ring, plain washer, felt washer, distributor block retaining screws and green distributor block. 3. Replace green block, using new black block assembly P/N 10-382998 for 8 cylinder magnetos and P/N 10-382972 for 6 cylinder magnetos. NOTE If black distributor block is not available, a serviceable green block can be installed. Part 1 of this Bulletin must then be complied with at 25 hour intervals until a black block becomes available. 4. Comply with Service Bulletin No. 600. 5. Complete re-assembly of magneto in accordance with applicable instructions in D2000/D-2200 Series Magneto Overhaul publication, Bendix Form L-945 and install magneto on engine as described in Bendix publication Form L-928 Installation, Operation and Maintenance Instructions. 6. Alter magneto name plate to indicate changes in the magnetos and ignition systems as listed in table below.

8. If a loose distributor gear is detected proceed to part 2 of this Bulletin.

7. Make appropriate Engine Log Book entry.

Part 2. If a loose bearing is discovered at either end of the distributor block during compliance with part 1 of this Bulletin proceed as follows:

8. Rejected green blocks will be exchanged for black blocks through your Authorized Bendix Distributor. A labor rate allowance of 2 1/2 hours will be permitted for compliance with Part 2 of this Bulletin.

1. Remove magneto from engine, if not already accomplished. Change System P/N From (Green Block) To (Black Block) 10-385046-114 10-385046-110 10-385046-115 10-385046-109 10-385046-209 10-385046-109 10-385046-216 10-385046-116 10-385046-217 10-385046-117 10-385048-201 10-385048-101 10-385126-221 10-385126-111 10-385148-201 10-385148-101 10-385148-202 10-385148-102

Change Magneto P/N From (Green Block) To (Black Block) 10-382910-12 10-382910-18 10-382910-17 10-382910-13 10-382910-53 10-382910-13 10-382910-53 10-382910-13 10-382910-58 10-382910-18 10-382920-51 10-382920-11 10-382560-53 10-382560-13 10-382620-51 10-382620-11 10-382620-51 10-382620-11

Electrical Components Division

SERVICE BULLETIN NO. 606 Engineering Aspects are FAA Approved Printed April 1979 Page 3 of 3 Pages

Sidney, New York 13838

Parts Required: Part 1. None Part 2. Black Distributor Blocks One 10-382972 (6 Cyl.) OR One 10-382998 (8 cyl.)

B. Approximately two hours are required if it is necessary to remove the magneto from the engine to perform inspection. Two hours warranty labor will be allowed for this type of inspection. The labor allowance will be permitted for the first inspection only.

Special Tools Required: None Man Hours Required: Part 1. A. Approximately one hour is required if inspection can be performed without removing the magneto from the engine. No warranty labor will be allowed for this type of inspection.

Part 2.

Approximately two and one half hours are required to remove the magneto, replace the distributor block and reinstall the magneto on the engine. Two and one half hours maximum warranty labor will be allowed for this procedure.

Weight Change: None

Engine Products Division

SERVICE BULLETIN NO. 614 Engineering Aspects are FAA Approved Printed February 1981 Page 1 of 2 Pages

Sidney, N. Y. 13838

AIRCRAFT SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

Repair of certain starting vibrators utilizing "5" contact bushing (connector). To alert users of a possible loss of ignition and provide a procedure for corrective action. All starting vibrators with part numbers indicated below and having a date mfg. of 901 through 101, or 8010 through 8101 (see examples below) permanently stamped on the vibrator.

Vibrator Part Numbers: 10-176485-121 10-176485-122 10-176485-241

10-176485-242 10-382780-12 10-382780-24

Example of Date Mfg.: a) 901: 9 is year of manufacture = 1979; 01 is work week of manufacture = week of January 1. b) 021: 0 is year of manufacture = 1980; 21 is work week of manufacture = week of May 18. c) 101: 1 is year of manufacture = 1981; 01 is work week of manufacture = week of January 1. d) 8010: 80 is year of manufacture = 1980; 10 is work week of manufacture = week of March 2. Compliance: Procedures in this bulletin must be completed within the next 25 hours of operation. General Information: Bushing (connector), P/N 10-382943, may become loose in the vibrator plate and cause the grounding of both magnetos with possible loss of ignition. See Figure 1 (defect). Detailed Instructions: WARNING Master switch must be in the off while performing any position procedures on the engine.

Figure 1 Defect 1. Remove starting vibrator from the airframe. 2. Remove cover to expose the internal surface of the terminal bushing (connector). 3. The surface around the terminal bushing must be clean, dry, free of oil, dirt and grease. 4. Reseat the terminal bushing in the mounting plate to its full extent.

Engine Products Division

SERVICE BULLETIN NO. 614 Engineering Aspects are FAA Approved Printed February 1981 Page 2 of 2 Pages

Sidney, N. Y. 13838

5. Use RTV (Silicone rubber sealant, or equivalent, Dow corning Corp., Midland, Mich. 48640) to seal terminal bushing to the mounting plate. Apply a small bead completely around the bottom of bushing to secure the bushing to the plate as shown in figure 2 (repaired). If RTV is not available, use either Hysol, Epoxi-patch Kit (general purpose), Hysol Corp., Olean, NY or Conap, Easypoxy Kit (K20 general purpose) 1405 Buffalo St., Olean, NY, or equivalent.

7. After proper curing, reinstall the starting vibrator cover and reinstall the vibrator in the airframe. 8. When the vibrator repair has been completed as per the instructions in this bulletin, the vibrator must be permanently identified as follows: Approximately 1/4 inch to the right of the manufacture date apply a 1/16 inch dot of red dykem, or equivalent. 9. Make an appropriate entry in the airframe log book to indicate compliance with this bulletin. 10. Compensation for the work involved in complying with the Service Bulletin for those vibrators under warranty will be made upon submission of a Warranty Claim submitted through a currently Authorized Bendix Engine Products Division Distributor. Compensation will be made in accordance with established Bendix Warranty procedures, with 1/2 hour labor authorized for this bulletin procedure.

Figure 2 Repaired 6. Allow a curing time of 24 hours at room temperature of 77°F (or follow manufacturer's recommended curing instructions on the adhesive) before reinstalling the starting vibrator.

Special Tools Required: None Man Hours Required: 1/2 (.5) hour Weight Change: N/A

Engine Products Division

SERVICE BULLETIN NO. 617B Engineering Aspects are FAA Approved Printed May 1984 Page 1 of 4 Pages

AIRCRAFT SUBJECT: REASON FOR BULLETIN:

Inspection and/or replacement of distributor gears in D-2000/2200 series magnetos. 1.

2. EQUIPMENT AFFECTED:

X

To alert users of a possible loose distributor gear electrode on the subject gears. This condition could lead to rough engine operation or cylinder or engine damage. To provide users with inspection and replacement procedures.

All D-2000/2200 series magnetos below serial number 35480 (red label magnetos) and below serial number 8122106 (blue label magnetos) unless identified with an "x" in the upper left corner of the identification plate before the word "Bendix" (see figure 1). The "x" on the identification plate indicates previous compliance.

BENDIX IGNITION SYSTEM

All Gear Kits 10-682014 and 10-682016 with gears not identified in paragraph 1 of Compliance must be returned to an Authorized Bendix Engine Products Division Distributor. Compliance:

Figure 1. Location of “x” on Identification Plate Maintenance (Spare) Parts Affected:

Gear P/N Gear P/N Gear Kit P/N Gear Kit P/N

10-382894 10-382896 10-682014 10-682016

4&8 Cyl. 6 Cyl. 4&8 Cyl. 6 Cyl.

All new gears 10-382894 and 10-382896 should be returned to an Authorized Bendix Engine Products Division Distributor for credit.

1. All subject magnetos having from 0 to 500 operating hours must have the distributor gears inspected within the next 100 operating hours or at the next regularly scheduled inspection, whichever occurs first, and reinspected every 100 operating hours until the magneto has 500 operating hours. If the gears fail the inspection they must be replaced immediately with new, serviceable gears; if they pass each inspection they may remain in service until magneto overhaul, at which time they must be replaced with new serviceable gears. At

Engine Products Division

owner's option, gears that pass inspection may be replaced at any time during the compliance period with new, serviceable gears as identified in this paragraph and figure 2. Serviceable gears are identified by the presence of the letter "z" or the letters "x" and "o" appearing together, laser etched on the retaining ring end of the gear axle, or the letter "L" stamped on the electrode (see figure 2). 2. All subject magnetos having 500 or more operating hours must have the distributor gears inspected within the next 100 operating hours or at the next regularly scheduled inspection, whichever occurs first. If the gears fail this inspection they must be replaced immediately with new, serviceable gears; if they pass this inspection they may remain in service until magneto overhaul, at which time

Figure 2. Location of Identification Mark(s) on Distributor Gear they must be replaced with new serviceable gears. At owners option, gears that pass inspection may be replaced at any time during the compliance period with new, serviceable gears as identified in paragraph 1 of Compliance.

SERVICE BULLETIN NO. 617B Engineering Aspects are FAA Approved Printed May 1984 Page 2 of 4 Pages

General Information: Field reports indicate that the distributor gear electrode has been found to be loose on some D-2000/2200 series magnetos. If this condition exists, the distributor gear electrode may contact the distributor block stationary electrodes causing contamination in the distributor in the form of dusty brass particles. This contamination may cause arcing within the distributor resulting in misfiring. This could in turn cause rough engine operation or cylinder or engine damage. Detailed Instructions: The following detailed instructions apply to the inspection and/or replacement of distributor gears in D-2000/2200 series magnetos. Disassembly of D-2000/2200 series magnetos and subsequent reassembly shall be done in accordance with D-2000 installation instructions, Bendix Publication L928 and D-2000 Overhaul Instructions, Bendix Publication L-945. 1. Remove cover from magneto and inspect the retaining ring end of the distributor gear axles for the letter "z" or the letters "x" and "o". (The letter "x" may or may not be circled by the letter "o"). If the letter "z" or the letters "x" and "o" together are laser etched on the end of the axles, the gears are serviceable and the cover can be reinstalled. Identify the magneto per paragraph 6 of Detailed Instructions. 2. If the axle ends are not identified with "z" or "x" and "o", remove the magneto from the engine. Remove the block from the magneto and remove the gears from the block. 3. Inspect the block for serviceability and replace any block found to be unserviceable.

Engine Products Division

4. Clean and inspect each gear. If the gear is part of an insulated gear kit (identifiable by the presence of a nylon insulating washer on the gear axle between the gear and the block) inspect for the presence of the letter "L" on the electrode (see figure 2). If "L" is stamped on the electrode, the gear is serviceable and can be reinstalled. If "L" is not present, the gear must be replaced with serviceable gear, P/N 10-682014 for 4 or 8 cylinder magnetos or P/N 10-682016 for 6 cylinder magnetos.

SERVICE BULLETIN NO. 617B Engineering Aspects are FAA Approved Printed May 1984 Page 3 of 4 Pages

6. If new serviceable gears, identified with the "z", the "x" and "o", or the "L" are installed in the magneto, identify the magneto by stamping the letter "x" in the upper left corner of the identification plate, before the word "Bendix" (see figure 1). 7. Make an appropriate engine log book entry recording magneto serial number to indicate that the distributor gears have been inspected and comply with the requirements of this service bulletin, or that the gears have been replaced with new, serviceable gears.

5. If the gear is the uninsulated type (no nylon washer) inspect the gear for a loose electrode. Grasp the gear firmly in one hand and alternately exert clockwise and counterclockwise force against the electrode with maximum hand pressure. This should be done in a manner that would attempt to pivot the electrode around the axle (see figure 3). If any movement is detected between the electrode and the gear, the gear must be discarded and replaced with a new, serviceable gear. If gears are found to be serviceable, they may be reinstalled or replaced at owner's option. CAUTION When timing magnetos on bench or when reinstalling magneto on engine, no gear holding timing device should be used as hidden gear tooth damage may result. CAUTION If self-locking cam screw is removed or loosened at anytime, always replace with a new self-locking screw and torque to the specified value.

Figure 3. Checking for Loose Electrode Warranty Consideration: All D-2000/2200 series magnetos that are within Bendix Engine Products Division Standard Warranty period will be covered for these procedures, for one (1) inspection only.

Engine Products Division

Standard warranty period is twelve months from date of delivery to the first end user, or 1,000 operating hours, whichever occurs first. NOTE For warranty consideration, all claims must be submitted no later than June 9, 1983. Compensation: Compensation for the work and parts involved in complying with this service bulletin for those magnetos under warranty will be made upon submission of a warranty Claim submitted through a currently Authorized Bendix Engine Products Division Distributor. Compensation will be made in accordance with established Bendix Warranty procedures. Parts Required per Magneto: 2 Kits 10-682014 4&8 Cyl. Magnetos 2 Kits 10-682016 6 Cyl. Magnetos Special Tools Required: Refer to applicable manuals. Man Hours Required: 2.5 hours per engine. Weight Change: None

SERVICE BULLETIN NO. 617B Engineering Aspects are FAA Approved Printed May 1984 Page 4 of 4 Pages

Engine Products Division

SERVICE BULLETIN NO. 618 Engineering Aspects are FAA Approved Printed June 1981 Page 1 of 2 Pages

AIRCRAFT SUBJECT: REASON FOR BULLETIN:

Replacement or inspection of distributor gears in D-3200 Series pressurized (blue) magnetos 1.

2. EQUIPMENT AFFECTED:

All D-3200 Series pressurized (blue) magnetos with Serial Numbers 100 through 1422, installed on Avco Lycoming TIO, LTIO-540-J2BD engines used on the following aircraft: Piper PA31-350; STC SA1151-SO and STC SA970-SO Colemill Conversion of Piper PA31, PA31-325 and PA31350; STC SA980-NW Machen Industries Conversion of Beechcraft Bonanza B35 and A36 Series.

Maintenance (Spare) Parts Affected: None Compliance: 1. All subject magnetos with over 100 operating hours must have the distributor gears replaced or inspected prior to further flight, unless the magneto is identified by the letter "x" in the upper left corner of the identification plate (see figure 1). The "x" on the identification plate indicates previous compliance with this Service Bulletin. X

To alert users of possible loose distributor gear electrode on the subject gears. This condition could lead to rough engine operation or cylinder or engine damage. To require replacement of subject gears and provide users with inspection and replacement procedures.

BENDIX IGNITION SYSTEM

Figure 1. Location of “x” on Identification Plate 2. If gears pass inspection, and are not replaced, they must be reinspected every 50 hours of operation thereafter until they are replaced by serviceable gears. Serviceable gears are identified by the presence of the letter "z" or the letters "x" and "o" together, laser etched on the retaining ring end of the ger axle. The letter "x" may or may not be circled by the letter "o".

General Information: The distributor gear electrode has come loose in service on some D-3200 Series Magnetos. If this condition exists, the distributor gear electrode may contact the distributor block stationary electrodes causing contamination in the distributor in the form of dusty brass particles. This contamination may cause arcing within the distributor resulting in misfiring. This could in turn cause rough engine operation or cylinder or engine damage. Detailed Instructions: (Refer to D-2000 Installation Instructions, Bendix Publication L-928 and D-2000 Overhaul Instructions, Bendix Publication L-945. These are comparable to D-3000/3200 Series Magnetos and will suffice for these procedures until D-3000/3200 manuals are available.) 1. Following published procedures, remove the cover from the magneto and remove the magneto from the engine. 2. Remove the distributor block form the magneto and remove the gears from the block. 3. Inspect the block for serviceability and replace any block found to be unserviceable. 4. Return the distributor gears to any Authorized Bendix Engine Products Division Distributor to exchange for new gears under warranty.

Engine Products Division

5. Reassemble the distributor block with new serviceable gears and reassemble the magneto. 6. After installing new serviceable gears, identify the magneto by stamping the letter "x" in the upper left corner of the identification plate, before the word "Bendix" (see figure 1). 7. If for some reason the gears are not replaced immediately, they must be inspected to ensure serviceability. 8. Inspect each gear for damage such as nicked or broken gear teeth, etc. and discard any unserviceable gear. 9. Inspect each gear for a loose electrode by grasping the gear firmly in one hand and alternately exerting clockwise and counterclockwise force against the electrode with maximum hand pressure. This should be done in a manner that would attempt to pivot the electrode around the axle (see figure 2). If any movement between the electrode and gear is detected, the gear must be discarded and replaced with a serviceable gear.

SERVICE BULLETIN NO. 618 Engineering Aspects are FAA Approved Printed June 1981 Page 2 of 2 Pages 10. If gears are found to be serviceable, reassemble the block and reassemble the magneto. 11. Make an appropriate engine log book entry as follows: a. If gears have been inspected, but not replaced, reference the operating time on the magneto when inspection was performed to ensure gears are reinspected or replaced within 50 operating hours. b. If gears have been replaced, indicate that this Service Bulletin has been complied with. Warranty Consideration: All D-3200 Series Magnetos will be covered by warranty, allowing 2.5 hours for replacement of distributor gears. Compensation for work involved in complying with this Service Bulletin will be made in accordance with established warranty policy upon submission of a Warranty Claim submitted no later than September 1, 1981, through a currently Authorized Bendix Engine Products Division Distributor. Special Tools Required: Refer to applicable manuals. Man Hours Required: 2.5 hours per engine. Weight Change: None

Figure 2. Checking for Loose Electrode

Engine Products Division

SERVICE BULLETIN NO. 619 Engineering Aspects are FAA Approved Printed August 1981 Page 1 of 2 Pages

AIRCRAFT SUBJECT: REASON FOR BULLETIN:

Replacement of distributor gears in D-3000/3200 Series (blue) magnetos 1.

2.

To alert users of possible loose distributor gear electrode on the subject gears. This condition could lead to rough engine operation or cylinder or engine damage. To require replacement of subject gears and provide users with replacement procedures.

Series EQUIPMENT AFFECTED: All D-3200 pressurized (blue) magnetos with Serial Numbers 100 through 1986, not identified by the letter “x” in the upper left corner of the identification plate (see figure 1). The “x” on the identification plate indicates previous compliance.

Maintenance (Spare) Parts Affected: All distributor gear kits P/N 10-682014 and P/N 10-682016 which contain gears that are not identified by the presence of the letter "z" or the letters "x" and "o" together, laser etched on the retaining ring end of the gear axle, or the letter "L" stamped on the electrode (see figure 2).

form of dusty brass particles. This contamination may cause arcing within the distributor resulting misfiring. This could in turn cause rough engine operating or cylinder or engine damage. In order to preclude the possibility of service difficulties, the distributor gears of all affected D-3000 nd D3200 magnetos must be replaced.

Compliance: All affected magnetos with over 100 operating hours must have the distributor gears replaced within the next 100 operating hours, or at the next regularly scheduled inspection, whichever occurs first.

Detailed Instructions:

X

BENDIX IGNITION SYSTEM

(Refer to D-2000 Installation Instructions, Bendix Publication L-928 and D-2000 Overhaul Instructions, Bendix Publication L-945. these are comparable to D-3000/D3200 Series Magnetos and will suffice for these procedures until D3000/3200 manuals are available.) 1. Following published procedures, remove the cover from the magneto and remove the magneto from the engine. 2. Remove the distributor block from the magneto and remove the gears from the block.

Figure 1. Location of “x” on Identification Plate General Information: The distributor gear electrode has come loose in service on some D-3200 Series Magnetos. If this condition exists, the distributor gear electrode may contact the distributor block stationary electrodes causing contamination in the distributor in the

3. Inspect the block for serviceability and replace any block found to be unserviceable. 4. Return the distributor gears to any Authorized Bendix Engine Products Division Distributor to exchange for new gears under warranty.

Engine Products Division

5. Reassemble the distributor block with new serviceable gears. Serviceable gears are identified by the presence of the letter "z" or the letters "x" and "o" together, laser etched on the retaining ring end of the gear axle, or the letter "L" stamped on the electrode (see figure 2).

SERVICE BULLETIN NO. 619 Engineering Aspects are FAA Approved Printed August 1981 Page 2 of 2 Pages 6. Reassemble the magneto. 7. After the magneto has been reassembled with new serviceable gears, identify the magneto by stamping the letter "x" in the upper left corner of the identification plate, before the word "Bendix" (see figure 1). 8. Reinstall the magneto on the engine. 9. Make an appropriate engine log book entry indicating that this Service Bulletin has been complied with. Warranty Consideration:

Figure 2. Location of Identification Mark (s) on Distributor Gear CAUTION When timing magneto on bench or when reinstalling magneto on engine, no gear holding timing device should be used as hidden gear tooth damage may result.

All affected magnetos will be covered by warranty, allowing 2.5 hours for replacement of distributor gears. Compensation for the work involved in complying with this Service Bulletin will be made in accordance with established warranty policy upon submission of a Warranty Claim submitted no later than October 1, 1981 through a currently Authorized Bendix Engine Products Division Distributor. Special Tools Required: Refer to applicable manuals. Man Hours Required: 2.5 hours per engine. Weight Change: None

Bendix Engine Products Division Jacksonville, Fl. 32245-7880

Bendix Aerospace

SERVICE BULLETIN

JP- 00278

Engineering Aspects are FAA Approved

SUBJECT: REASON FOR BULLETIN:

EQUIPMENT AFFECTED:

Bulletin No. 623A Date 9/1982 Revised 8/1984

Inspection of impulse coupling cam assemblies. 1. 2.

To alert all users of possible impulse coupling failure. To provide an inspection procedure to preclude failure of the impulse coupling. All Bendix magnetos with type designations as follows: S4LN-21/1225/1227 S4LN-200 P/N 10-163005-7 S6RN-21/23/25/1225/1227 D-3000 all

S4RN-21/1225/1227 S6LN-21/23/25/1225/1227 D-2021/2031

(Refer to Bendix Publication L-1147 Aircraft Impulse Coupling Cross Reference Data as required.) Except Bendix Blue label magnetos above S/N 8236001 Except Bendix Red Label magnetos above serial numbers as indicated below: S-20: S-200: S-1200: D-2000: D-3000:

B-001171 or A297043 B-001732 or A297043 B-001162 or A297043 35550 B-000249 or 5806

MAINTENANCE (SPARE) PARTS AFFECTED: 1.

All impulse coupling cam assemblies.

2.

All impulse coupling assemblies.

3.

All spare magnetos incorporating an impulse coupling.

COMPLIANCE: 1.

All magnetos having impulse couplings with less than 300 operating hours must be inspected and identified as having complied with this Service Bulletin prior to the next engine start.

2.

All spare parts must be inspected and identified before being put into service.

GENERAL INFORMATION: Some improperly heat treated (soft) flyweights have been reported on impulse couplings currently in service. If this condition exists and is not detected, impulse coupling failure could occur. The flyweights must be inspected in accordance with

Bendix Engine Products Division Service Bulletin No. 623A Page 2 of 4 Pages

the instructions in this Service Bulletin and if defective (soft) the impulse coupling or cam assembly must be replaced immediately. DETAILED INSTRUCTIONS: (Refer to appropriate Bendix Magneto Overhaul Instructions for the magneto series being inspected.) NOTE The magneto should be removed from the engine only to the extent necessary to perform the inspection described herein. Depending on the engine application, it may not be necessary to remove the harness from the magneto for the inspection procedure. NOTE All magnetos with the impulse coupling recessed into the magneto flange must have the impulse coupling removed from the magneto to perform the inspection. This is a bench operation and will require the magneto to be completely removed from the engine and the harness removed from the magneto. CAUTION Whenever an impulse coupling is removed from a magneto, it must be removed following published procedures, paying strict attention to notes and cautions. Upon reassembly, the castellated nut securing the impulse coupling to the drive shaft must be torqued to 15 ft. lbs. and cotter pinned with new pin. If unable to install pin, torque nut to next castle, not to exceed 25 ft. lbs. and install pin. Removed pin must be discarded and replaced with a new cotter pin (P/N 10-90751-18). 1.

Following published procedures remove the magneto from the engine.

2.

Place the magneto in a suitable work stand with the impulse coupling facing up.

3.

Use finger pressure to push inward on the toe (see figure 1) of each flyweight so that the flyweight heel protrudes outward.

4.

Using a fine #1, double cut, 1/2 inch wide file, at least 3/32 inch thick, pass the file across the heel of the flyweight attempting to remove material. (See figure 1). If the flyweight has been properly heat treated the file will "glide" smoothly over the heel of the flyweight, removing no material. If the flyweight is not properly heat treated (soft), the file will not "glide" easily across the surface of the flyweight heel, and material will be removed.

Bendix Engine Products Division Service Bulletin No. 623A Page 3 of 4 Pages

Figure 1 Note: XXX indicates heat treated flyweight by lot number 5.

If an improperly heat treated (soft) flyweight is found, immediately remove and replace the cam assembly and/or the impulse coupling assembly following procedures in the magneto overhaul instructions, and paying strict attention to notes and cautions.

6.

Inspect the impulse coupling stop pins for wear and replace as necessary.

7.

After flyweights and stop pins have been inspected and the impulse coupling reinstalled on the magneto (if removed), identify the magneto by stamping a 1/16 inch letter "F" in the upper right corner of the identification plate to indicate this Service Bulletin has been complied with.

8.

Reinstall the magneto on the engine following published procedures.

9.

Make an appropriate engine log book entry, recording magneto serial number, to indicate that this Service Bulletin has been complied with.

10.

Inspect all spare parts assemblies, including magnetos, following the same procedures described in steps 3 and 4 of the Detailed Instructions of this Service Bulletin. If both flyweights are found acceptable, identify the cam assembly by applying yellow Dykem or yellow lacquer to the heel of each flyweight. On magneto spares, stamp a 1/16 inch letter "F" in the upper right corner of the identification plate to indicate this Service Bulletin has been complied with.

11.

Any cam assembly with an improperly heat treated (soft) flyweight should be returned to the manufacturer through a currently Authorized Bendix Engine Products Division Distributor.

Bendix Engine Products Division Service Bulletin No. 623A Page 4 of 4 Pages 12.

A new method of marking is being implemented to permanently identify heat treated cam assembly flyweights. See figure "1" for location. Pending consumption of current inventory, there will be a mixture of assemblies identified by the following methods. 1.

Original method ----- Yellow paint (Dykem or Lacquer) on the heel of each flyweight.

2.

New method ----- Stamped numbers as indicated in figure "1" on each flyweight.

WARRANTY CONSIDERATION: None applicable. SPECIAL TOOLS REQUIRED: Refer to applicable manuals. MAN HOURS REQUIRED: 1.0 hour per engine with shallow flange mag. 1.25 hours per engine with deep flange mag. WEIGHT CHANGE: None

TCM IGNITION SYSTEMS

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO.631  TELEDYNE INDUSTRIES, INC. 1989

SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

Printed September 1989 Page 1 of 1 Engineering Portions are FAA Approved

Recommended Lubricant for Tapered Drive on TCM Magnetos. Previously recommended lubricant no available.

All TCM S-20, S-200, S-1200 and D-3000 Series Magnetos.

Maintenance (Spare) Parts Affected: None Compliance: At every installation of drive member or impulse coupling. General Information: In order to avoid damage during disassembly to magneto rotor shaft and drive hardware, use of GO-JO NO-LOK #72 lubricant was previously recommended. Due to non availability of NOLOK, TCM now recommends use of TCM P/N 646943 Anti Seize Lubricant for this purpose. Detailed Instructions: 1. Apply a light coating of P/N 646943 Anti Seize Lubricant to the tapered section of the magneto drive shaft. (See Figure 1.) 2. Assemble drive device onto shaft immediately after applying lubricant. Parts Required Per Article: None Special Tools Required: None Man Hours Required: Negligible Weight Change: None

Figure 1 Apply P/N 646943 Anti Seize Lubricant to Magneto Shaft

TCM IGNITION SYSTEMS

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO.634  TELEDYNE INDUSTRIES, INC. 1990

SUBJECT:

REASON FOR BULLETIN: EQUIPMENT AFFECTED:

Printed December 1990 Page 1 of 2 Engineering Portions are FAA Approved

Replacement Of P/N 10-357173 Breaker Assemblies Exhibiting Batch Code 0690 And P/N 10-357174 Breaker Assemblies Exhibiting Batch Code 4289 Through 1790 Or Subject Breakers P/N With. To Remove From Service Breaker Assemblies Which May Experience Contact Braze Joint Failure. Magneto Models: S4RN-20, S4RN-21, S4LN-20, S4LN-21, S6RN-21, S6LN-20, S6LN-21, S6LN-22, S6RN-23, S6LN-23, S6RN-25, S6LN-25. Magneto Part Numbers: 10-51360-25, -29, -37, -40, -41, -46, -54, -55; 1051365-32, -33, -34, -35, -39, -43, -44, -45, -46, -47, -54; 10-52350-20, -22, -23; 10-79020-6, -10, -16 Having New or Factory Overhauled Magneto Manufacturing (Serial) Numbers within the Range: J168901D(R) through G319099D(R) and Magneto Part Numbers: 10-51360-26, -27, -28; 10-5136540, -48; 10-52350-19 Having New or Factory Overhauled Manufacturing (Serial) Numbers Within the Range: B059001D(R) through J199099D(R) Field Replaced Breakers: Similar Part Number Magnetos to Above Listing with P/N 10-357173 or P/N 10-357174 Breaker Assemblies Field Replaced Since October 16, 1989. NOTE...Refer to SB 633 for Manufacturing (Serial) Number Code Information.

Maintenance (Spare) Parts Affected:

Detailed Instructions:

Breaker Assembly, P/N 10-357173 - Batch Codes 0690 (sixth week of 1990) and P/N 10-357174 Batch Codes 4289 (forty-second week of 1989) through 1790 (seventeenth week of 1990) ink marked on underside of the Breaker Assembly frame.

1. Spare Breaker Assemblies. Return for warranty all P/N 10-357173 Breaker Assemblies exhibiting Batch Code 0690, and 10-357174 Breaker Assemblies exhibiting Batch Code 4289 through 1790, or either of the subject P/N Breaker Assemblies with illegible Batch Code markings.

Compliance: Spares - immediately upon receipt of Bulletin. Units in Service - only those magnetos or breaker assemblies with 150 hours or less since installation, within next 5 hours of operation. General Information: Field Reports indicated subject parts may experience failure at braze joint of stationary Tungsten contact within first 150 hours of operation, resulting in loss of ignition from affected magneto.

2. Units in Service. Following engine manufacturer's published instructions, remove magneto from engine. Following procedures in TCM Ignition Systems Form X42002, S20/S-200 Series Magneto Service Manual, remove the affected Breaker Assembly from the magneto. Inspect the underside of the Breaker for ink stamping. Refer to Figures 1 & 2. NOTE...If Batch Codes are non-existent or illegible, replace the Breaker Assembly. Replace and adjust the new or acceptable Breaker Assembly in accordance to TCM Form X42002. Reinstall magneto on engine in accordance with engine manufacturer's instructions.

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.634 Printed March 1990 Page 2 of 2 Engineering Portions are FAA Approved

Identification: Following compliance with Breaker Assembly inspection or replacement in a magneto, make an engine logbook entry indicating method of compliance. Parts Required: P/N 10-357173 or P/N 10-357174 Breaker Assembly as required. Special Tools Required:

FIGURE 1 P/N 10-357173-Batch Code 0690

Refer to S-20/S-200 Series Magneto Service Manual, Form X42002. Warranty Consideration: All affected equipment will be covered by the standard TCM Ignition Systems Warranty Policy, subject to its terms and conditions. Warranty claims may be filed through any TCM Ignition Systems Distributor. Up to 1.8 hours labor will be allowed per magneto installed on engine. Up to 1.0 hours labor will be allowed per magneto not installed on engine.

FIGURE 2 P/N 10-357174-Batch Codes 4289 through 1790

TCM IGNITION SYSTEMS

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO.635  TELEDYNE INDUSTRIES, INC. 1991

SUBJECT: REASON FOR BULLETIN:

EQUIPMENT AFFECTED:

Printed May 1991 Page 1 of 8 Engineering Portions are FAA Approved

Gold Seal Harness To Inform Users of New Part Numbers For the New TCM Gold Seal Harnesses, Leads and Spare Parts, Interchangeability With Dura-Blue Harness Hardware and New Procedures For Gold Seal Assembly Harnesses and Leads For TCM (Bendix) S-20, S-200, S-1200, D-2000, D-3000 Series Magnetos and Slick 4200 and 6200 Series Magnetos

Maintenance (Spare) Parts Affected: All TCM (Bendix) Gold Seal and Dura-Blue Ignition Harnesses and Spare Leads. Compliance: Whenever maintenance is performed on affected parts. Detailed Instructions: 1. The new Gold Seal Harnesses and Spare Leads will be supplied in lieu of the Dura-Blue Harnesses and Spare Leads previously provided. These new Gold Seal Harnesses have the following features: • • • • • •

Easy-grip spark plug Ferrules. Simplified assembly. Optional 3-way adjustable elbow clamps for both 5/8-24 and 3/4-20 spark plug terminals. Widest application coverage. Across the board ready-to-fit (Magneto and spark plug ends assembled) design. Competitively priced.

2. Publications X43001 and X42003 specify installation and repair procedures for Dura Blue Harnesses. These procedures, when used in conjunction with the interchangeability figures provided in this Bulletin, and the following assembly procedure, may be used to maintain Gold Seal Harnesses. 3. To assemble Gold Seal Braid Retaining Eyelet (P/N 10-400093) into any Gold Seal Spark Plug Outer Ferrule or Gold Seal Magneto Outlet Plate/Cover/Cap: a. Insure 3/16 inch of silicone jacket is stripped from end of shielding as shown in Figure 2. b. Insert P/N 10-400093 Eyelet under braiding to position shown in Figure 2. c. Pull cable with correctly positioned eyelet into ferrule or outlet and fully seat using a suitable pressing tool. See Figure 1) for pressing tool dimensions. FLAT FACE

Retained Features • • • • • •

Scuff resistant silicone rubber cable jacket. Individual resilient silicone outlet plate grommets. Tightly woven copper braid for minimum Radio Frequency Interference (RFI) radiation. Complete flexibility at -65°F; withstands temperature to +400°F. 5MM (inner insulation diameter) cable. Completely repairable; all components supplied as spares.

.210 - .250

FIGURE 1: EYELET PRESSING TOOL DIMENSIONS

.500 DIA MIN

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 2 of 8 Engineering Portions are FAA Approved

FIGURE 2: POSITIONING OF BRAID ON EYELET, CUTAWAY VIEW TABLE 1

TABLE 2 SPARE LEAD SUPERSEDURE

UNIVERSAL HARNESS KITS SUPERSEDURE •

Each kit contains two leads for each cylinder.

•

Leads are assembled at the spark plug end.

•

Hardware for attachment to Dura-Blue, Gold Seal and Gold Seal SK Magneto Outlet Plates is provided.

•

P/N suffix is lead length in inches

•

Hardware for attachment to Dura-Blue, Gold Seal and Gold Seal SK Magneto outlet plates is provided. SPARK PLUG 3/4-20 3/4-20 5/8-24 5/8-24 3/4-20 3/4-20

• NO. OF CYL. 6 6 4 4

SPARK PLUG 3/4-20 5/8-24 3/4-20 5/8-24

DURA-BLUE P/N 10-94460-52 10-94460-53 10-94460-54 10-94460-55

GOLD SEAL P/N 10-400416 10-400426 10-400414 10-400424

5/8-24 5/8-24 *

DURA-BLUE P/N 10-720631-48 10-720631-72, 78 10-720632-48 10-720632-72 10-720641-29, -41 10-720641-53, 65, -74 10-720642-29, -41 10-720642-53, 65, -74

GOLD SEAL P/N 10-400401-48 10-400401-78 10-400402-48 10-400402-78 10-400401-48* 10-400401-78*

10-400402-48* 10-400402-78*

Also use 10-944460-60 Kit to attach lead to Bendix Threaded Outlet Plate, Pancake Grommet Assembly, or Slick 400 and 600 Series Magnetos.

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 3 of 8 Engineering Portions are FAA Approved

TABLE 3

TABLE 3

HARNESSES FOR TCM S-20, S-200 AND S1200 MAGNETO APPLICATIONS SUPERSEDURE

(CONTINUED)

NOTE: For complete Harness-to-Engine Application Data, refer to Publication Form X44001-1.

DURA-BLUE HARNESS P/N 10-720095-5; 105, -108 10-720095-7, -107, -108 10-720095-9 10-720095-118 10-720178-104 10-720315-102 10-720320-2, -102, -104, -108, -109 10-720325-4 10-720326-2 10-720326-3 10-720365-102 10-720405-3 10-720410-3 10-720420-2, -102 10-720420-3, -103 10-720420-113 10-720435-1, -3, -4 10-720445-1 10-720465-2 10-720470-2, -3 10-720470-4 10-720470-5 10-720470-6 10-720480-1, -3 10-720505-1 10-720510-1, -2, -3 10-720510-4 10-720515-1 10-720515-3 10-720515-5 10-720515-203 10-720570-4, -5 10-720570-14 10-720580-1 10-720580-11 10-720605-3 10-720605-1, -5

SUPERSEDED BY GOLD SEAL HARNESS P/N 10-823674-1 10-823684-1 10-823671-1 10-823694-1 10-821674-22 10-821474-5 10-821674-3 10-821471-1 10-821471-2 10-821474-2 10-821674-92 10-821672-24 10-821471-2 10-823674-5 10-823684-5 10-821694-5 10-821685-8 10-821685-16 10-821685-12 10-821681-2 10-821681-2 10-821681-2 10-821671-2 10-821685-10 10-821481-2 10-821481-2 10-822482-2 10-821681-2 10-821684-2 10-821685-18 10-821695-2 10-821885-4 10-821895-4 10-821685-14 10-821695-14 10-821675-18 10-821672-18

DURA-BLUE HARNESS P/N 10-720605-4, -5 10-720640-1 10-720645-1 10-720645-2 10-720655-1 10-720690-1 10-720695-1 10-720700-1 10-720710-1 10-720710-101 10-721002-2 10-721005-2 10-721008-2 10-721009-2 10-721011-2 10-721013-2 10-721014-2 10-721015-2 10-721018-2 10-721019-2 10-721020-2 10-721021-2 10-721022-2 10-721024-2 10-721025-2 10-721026-2 10-721033-2 10-721034-2 10-721036-2 10-721040-2 10-721041-2 10-721042-2 10-724771-1 10-726714-1 10-726714-2 10-726714-3 10-726814-1

SUPERSEDED BY GOLD SEAL HARNESS P/N 10-821685-18 10-821672-9 10-821471-2 10-821474-2 10-821471-1 10-821471-3 10-821471-1 10-821471-3 10-821471-2 10-821474-2 10-821684-26 10-821471-2 10-821484-2 10-821681-2 10-821481-2 10-821675-18 10-821675-18 10-821474-2 10-821681-2 10-821484-14 10-821684-28 10-821684-30 10-821684-2 10-821671-2 10-821481-2 10-821671-2 10-821671-2 10-821671-32 10-821481-2 10-821481-2 10-821481-2 10-821481-2 10-820471-91 10-823674-1 10-823674-7 10-821674-2 10-823684-7

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 4 of 8 Engineering Portions are FAA Approved

TABLE 4

TABLE 5

D-2000 & D-3000 SERIES HARNESS SUPERSEDURE*

D-3000 SERIES MAGNETO & HARNESS SYSTEM SUPERSEDURE*

D-3000 DURA-BLUE HARNESS P/N 10-684400-303 10-684400-305 10-684405-303 10-684406-103 10-684406-303 10-684407-303 10-684408-302 10-684409-102 10-684409-106 10-684411-402 10-684412-106 10-684444-602 10-684602-303 10-684602-305 10-684602-307 10-684604-103 10-684604-109 10-684604-126 10-684607-102 10-684609-302 10-684610-126 10-684672-138 10-684800-107 10-684800-127 10-684801-107

SUPERSEDED BY GOLD SEAL HARNESS P/N 10-821414-6** 10-821444-6 10-821414-8 10-821414-4 10-821414-4 10-821414-10 10-821414-6 10-821415-12 10-821425-12 10-821414-14 10-821425-12 10-821412-93 10-821614-6 10-821644-6 10-821624-6 10-821615-4 10-821635-4 10-821625-4 10-821615-20 10-821614-6 10-821625-34 10-821635-11 10-821825-2 10-821825-2 10-821825-2

*

For complete Harness-to-Engine and System-toEngine Application Data, refer to Publication Form X44001-1.

**

For O-360-A1AD engines, use P/N 10-785124-131 System and P/N 10-820414-6.

D-3000 SYSTEM WITH DURA-BLUE P/N 10-685046-109 10-685046-110 10-685046-118 10-685046-119 10-685048-101 10-685124-106 10-685124-110 10-685124-111 10-685124-112 10-685124-113 10-685124-115 10-685124-116 10-685124-118 10-685124-121 10-685124-122 10-685124-123 10-685124-124 10-685124-129 10-685124-130 10-685124-704 10-685126-105 10-685126-107 10-685126-109 10-685126-111 10-685126-112 10-685144-112 10-685144-114 10-685146-106 10-685146-111 10-685148-101 10-685148-102 10-685164-112 10-685164-113 10-685166-107 10-685186-109 10-685286-402

SUPERSEDED BY D3000 WITH GOLD SEAL P/N 10-785046-109 10-785046-110 10-785046-118 10-785046-119 10-785048-101 10-785124-106 ** 10-785124-110 10-785124-111 10-785124-112 10-785124-113 10-785124-115 10-785124-116 10-785124-118 10-785124-121 10-785124-115 10-785124-106 10-785124-124 10-785124-129 10-785124-130 10-785124-704 10-785126-105 10-785126-107 10-785126-109 10-785126-111 10-785126-105 10-785144-114 10-785144-114 10-785146-106 10-785146-111 10-785148-102 10-785148-102 10-785164-112 10-785164-113 10-685166-107 10-785186-109 10-785286-402

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 5 of 8 Engineering Portions are FAA Approved

FIGURE 3:

3/4-20 SPARK PLUG TERMINAL PARTS INTERCHANGEABILITY

NOTES: 1) Sleeve 10-320466 cannot be used with Eyelet 10-4000097. Otherwise, indicated sleeves and spring arrangements are interchangeable. 2) May be used with 10-400112-8 or –12 Bend Clamp Kit. See Figure 7. 3) Parts may be interchanged as a pair. Dura-Blue or Gold Seal Cable may be used with either Ferrule & Eyelet arrangement.

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 6 of 8 Engineering Portions are FAA Approved

FIGURE 4:

5/8-24 SPARK PLUG TERMINAL PARTS INTERCHANGEABILITY

NOTES: 1) Parts may be interchanged as a pair. Dura-Blue or Gold seal Cable may be used with either Ferrule and Eyelet arrangement. Either outer Ferrule may be used with 10-400112-8 or –12 Bend Clamp Kit. See Figure 7.

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 7 of 8 Engineering Portions are FAA Approved

FIGURE 5:

TCM (BENDIX) MAGNETO OUTER PLATE PARTS INTERCHANGEABILITY

NOTES: 1) Current Dura-Blue Plates/Covers are marked with “ 620109 Ferrule only.

“ (older units are not marked). Use with 10-

2) Gold Seal Plates/Covers are marked with “TCM Gold Seal”. Use with 10-4000093 Retention Eyelet only. 3) Interchangeability of TCM Gold Seal Harness parts with any other brand of Harness parts is not guaranteed.

FIGURE 6: NOTE:

TCM GOLD SEAL SK TYPE MAGNETO OUTLET CAP ARRANGEMENT FOR SLICK 4200 AND 6200 SERIES MAGNETOS Interchangeability of TCM Gold Seal Harness parts with any other brand of Harness parts is not guaranteed.

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.635 Printed May 1991 Page 8 of 8 Engineering Portions are FAA Approved

FIGURE 7: ADJUSTABLE SPARK PLUG TERMINAL BEND CLAMP KIT TCM’s Gold Seal Adjustable Bend Clamp Kits are designed to replace bulky, expensive elbows on installations where positive lead location near the spark plug terminal is required. Some Gold Seal Harness assemblies are supplied with Bend Clamp Kits as bag parts. Bend clamp kits may be purchased separately for use on any TCM Gold Seal Harness, 5/8-24 or 3/4-20 terminals, as well as with Dura-Blue 5/8-24 terminals.

P/N:

10-400112-8 10-400112-12

IGNITION CABLE

110o

(8 ASSY’S FOR 4 CYL HARNESSES) (12 ASSY’S FOR 6 CYL HARNESSES)

90o

70o

CLAMP SECONDARY 10-400107

CLAMP SECONDARY CLAMP PRIMARY

FERRULE

CLAMP PRIMARY 10-400105

SCREW 10-35936-6

NUT 10-90404-4

RETENTION SCREW & NUT TCM GOLD SEAL 3/4-20 SPARK PLUG TERMINAL SHOWN FOR REFERENCE

INSTRUCTIONS FOR ASSEMBLY: 1. For proper orientation of finished assembly, harness should be assembled onto magneto, engine and spark plugs. 2. Install primary clamp over Ferrule oriented as shown in illustration; pinch closed. 3. Align toothed leg of secondary clamp with notched side of primary clamp. Install secondary clamp onto cable; pinch partially closed. (Clamp should still slide on cable.) 4. While holding primary clamp closed, position tooth of secondary clamp into desired angular position slot of primary clamp (see illustration); squeeze both clamps closed and align screw holes. CAUTION:

Insure that positioning tooth of secondary clamp is in one of the slots of primary clamp, otherwise tooth can be bent or broken, rendering secondary clamp unusable.

5. Insert retention screw through aligned holes of both clamps. 6. Install retention nut onto screw and, while insuring that both clamps are correctly positioned, tighten nut onto screw using torque of 15 to 20 LB-IN.

TELEDYNE CONTINENTAL IGNITION SYSTEMS

service bulletin

No. 636 Technical Portions Are FAA Approved

August 1992 SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

Bendix/TCM Ignition Switch Inspection To provide inspection procedures and to promote continual switch integrity. All Key Type Ignition Switches and Spare Keys

Compliance: 1. Immediate - At pre-flight run up PRIOR TO THE NEXT FLIGHT after receipt of this service bulletin for all affected equipment. 2. As an additional safety measure, it is recommended that the switch be tested as described in this bulletin at all subsequent pre-flight or pre-maintenance engine run-ups for all affected equipment. General Information: Field reports indicate that it is possible that some switches might allow removal of the key between the "R" and "Off" detent positions in such a manner that the Right Magneto is not grounded when the key is removed. This can cause a hazardous "Hot Magneto" condition. NOTE 1 If this condition is discovered, immediate switch replacement is recommended. Until switch can be replaced, magneto grounding circuit may be secured following engine shut down by insuring that the switch is in the full counterclockwise "Off" position detent before removing the key. NOTE 2

Detailed Instructions: 1. With engine running at idle, slowly rotate ignition switch counterclockwise from "R" position while gently pulling outward on the key. If the key can be removed and the engine continues to run, the switch should immediately be replaced. 2. Optional test with switch removed or disconnected from the magnetos: Connect a continuity lamp or ohmmeter across terminals marked "R" and "GND" on switch support. Slowly rotate ignition switch from "R" position counterclockwise while gently pulling outward on the key. If the key can be removed without continuity between "R" terminal and "GND" terminal, switch should immediately be replaced. 3. Upon compliance with this immediate inspection requirement, make an Airframe Logbook entry indicating compliance method and inspection results. Warranty: Up to 1.0 hour labor will be allowed for each installed switch replaced under warranty.

Test must be repeated for each existing spare key and for all field-duplicated keys.

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

Printed August 1992 Page 1 of 1

TCM IGNITION SYSTEMS

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO.638  TELEDYNE INDUSTRIES, INC. 1993

SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

Printed February 1993 Page 1 of 1 Engineering Portions are FAA Approved

Revised Assembly Procedure for Impulse Coupling Spring P/N 10-400042

Change to spring dimension renders previous assembly procedure obsolete.

Magneto Models: Magneto Part Numbers:

Spare Parts Affected: Spring P/N 10-400042 in package marked with Code 192 (Format: MYY) or later, or marked with two letter code (example: JC). Compliance: At assembly of affected part. Detailed Instructions: Refer to TCM D-3000 Series High Tension Ignition Systems Manual X42003, dated July 1989, Paragraph 9.2.12, Step 1, involving turning impulse coupling cam an additional one-half turn following assembly of cam to spring is impossible and unnecessary when using Spring 10-400042 with package code as detailed above. Therefore, when using an affected spring, Step 1 must not be performed.

D6LN-2031 and 10-382560-11 10-382560-13

D6LN-3000 10-682560-11 10-682560-13 10-682560-131

TCM IGNITION SYSTEMS

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO.639  TELEDYNE INDUSTRIES, INC. 1993

SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

COMPLIANCE:

Printed March 1993 Page 1 of 2 Engineering Portions are FAA Approved

Proper installation of impulse couplings To modify, confirm and stress the importance of proper installation procedures of impulse coupling assemblies

All TCM & Bendix S-20, S-1200, D-2000 and D-3000 series magnetos with impulse couplings as installed on TCM, Lycoming, Franklin and other manufacturer’s engines.

MANDATORY AT TIME OF INSTALLATION OF ANY BENDIX/TCM IMPULSE COUPLING ASSEMBLY

General Information:

WARNING...Use of unapproved hardware and/or lubrication of threads will produce inaccurate torque values and increased stress on the impulse coupling during assembly.

Field reports indicate that there have been instances in which the impulse coupling cam assemblies have cracked upon installation. See Figure 1. Cracking can be caused by improper installation procedures which may result in coupling assembly damage or potential engine failure.

4. Using a CALIBRATED torque wrench, tighten nut to 180 in-lbs. Install and secure new cotter pin. If unable to install pin, increase torque gradually to align the first available slot in the castellated nut.

Detailed Instructions: The following instructions pertain to installation of new impulse coupling assemblies as well as those that are being reinstalled after scheduled magneto maintenance. 1. Clean impulse coupling assembly and magneto drive shaft using standard cleaning solvent. 2. Apply a light coating of TCM P/N 646943 anti-seize lubricant to the tapered section of the magneto drive shaft. This prevents seizure of the cam assembly to the shaft and avoids damage during disassembly. Do not apply lubricant to shaft or nut threads. See Figure 2.

WARNING...Under no circumstances should you exceed 300 in-lbs. torque. Any impulse coupling that is damaged in any way during installation must be replaced. The preceding information will be incorporated into the next revision of the TCM Master Service Manual form No. X40000.

3. Install woodruff key in tapered portion of the shaft. Install coupling assembly, washer(s) and thread nut onto shaft. Use approved hardware specified in the appropriate TCM Ignition Systems parts manual. (continued)

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.639 Printed March 1993 Page 2 of 2 Engineering Portions are FAA Approved

FIGURE1

FIGURE 2 Apply P/N 646943 Anti Seize Lubricant to Magneto Shaft

CONTINENTAL ® AIRCRAFT ENGINE

service bulletin

M64-18 FAA-DER Approved

October 7, 1968 TO:

Owners and Operators of Continental Aircraft Engines

SUBJECT:

Field Conversion to Turbocharging of Continental Aircraft Engines.

Gentlemen: In the design and construction of our naturally aspirated engines, it has been our policy to rate the engine at the maximum possible power to permit normal leanout at cruise without detonation for the particular grade of fuel to be used. At full power, the engines are set to mixture strengths necessary to properly cool and be detonation free. Service experience is abundant with such engines and reliability is quite predictable. Engines altered in the field by addition of any type of supercharger will impart to the engine a new group of characteristics which are not predictable as to reliability. The danger of detonation and preignition is very real and can result in failure of basic engine components. Even without these abnormal stresses from detonation and preignition, the higher combustion chamber pressures and stresses which can result from supercharging with engines not designed for this characteristic may result in short engine life or failure. Also, these conversions are not always equipped with automatic controls which are all important to prevent the possibility of over-boosting which results in over-stressing of engine components. Later engines of 8.5 - 8.6 compression ratio, as previously stated, are rated to the highest power that can be tolerated with the use of high octane fuel. The engine is designed and qualified for the resulting peak cylinder pressures and stresses for all engine components. Under hot day leanout conditions at cruise the engine will not tolerate advanced magneto timing, substandard fuel, or other factors which increase pressure or temperature above that for which it was qualified. Therefore, any effort to supercharge these engines would be risky, even with the socalled "normalizing" only. This is because sea level manifold pressures would be utilized at high altitude with resulting high manifold air temperatures that are above the maximums for detonation-free operation. We are, therefore, not in a position to continue engine warranty on engines which were not originally designed for turbocharging but which have been converted to turbocharging in the field  TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL ® AIRCRAFT ENGINE

service bulletin

M67-12 FAA-DER Approved

May 31, 1967 TO:

Owners and Operators of Continental Aircraft Engines

SUBJECT:

Overboost of Turbocharged Engines

Gentlemen: All turbocharged engine installations which are equipped with controller systems automatically control the engine power within prescribed manifold pressure limits. Although these automatic controller systems are very reliable and eliminate the need for manual control through constant throttle manipulation, they are not infallible. For instance, such things as rapid throttle manipulation (especially with cold oil), momentary waste gate sticking, air in the oil system of the controller, etc., can cause overboost. Consequently, it is still necessary that the pilot observe and be prepared to control the manifold pressure, particularly during take-off and power changes in flight. The type of momentary manifold pressure overshoot which normally occurs with cold oil on initial take-off or during a change to full throttle operation in flight is considered an occasional occurrence and must be monitored by the pilot on each and every take-off to keep it from happening. It is generally in the area of 2" to 3" and can usually be controlled by slower throttle movement, however, if slower throttle movement fails to control it and overshooting of this nature persists or if the amount of overboost is from 3" to 6" the system should be checked immediately for necessary adjustments or replacement of the malfunctioning component. Severe overboost over 6" generally results from extreme malfunction of controls which causes a very rapid and instantaneous rise in manifold pressure very often to the maximum instrument limits if it is not caught immediately. Such overboost can cause engine damage. If it occurs it should immediately be reported to the Continental Motors Branch Regional Service Manager so he can assist you in determining what action needs to be taken. It is imperative that the time interval and degree of overboost be reported to the best of the pilot's ability.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

service bulletin

M67-5 FAA-DER Approved

May 2, 1967 TO:

Owners and Operators of Continental Aircraft Engines

SUBJECT:

Lagging Engine Breather Line on GTSIO-520 Engines.

Gentlemen: Normal breathing of the GTSIO520 Engine produces some condensation which can cause sludging in the breather system, especially in colder climates and operation in cold temperatures at altitude. Heaviest sludging generally accumulates in the area from the breather elbow, on the prop gear reduction section, back to the connection at the oil filler neck. Condensation can also collect in the breather separator causing blockage of the return suction line from the breather separator to the scavenge pump. Partial blockage of the breather system causes an increase in internal crankcase pressure and can cause oil to be thrown overboard, showing up as a sudden increase in oil consumption. Lagging of all metal portions of the breather line (refer to sketch page 2 ) for the entire length from the breather elbow back to the diaphragm baffle at the rear of the engine will significantly reduce the amount of condensation build up and retard sludging. (Rubber hose connectors need not be lagged.) Lagging the line with regular plumbers fibre glass insulation (or equivalent) covered with tape has proved effective. The system should be checked for blockage at every 100 hour periodic thereafter or as often as experience dictates is necessary consistent with the type of operation and geographic location.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Page – 2 –

M67-5

May2, 1967

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M70-11 FAA-DER Approved

June 22, 1970 TO: SUBJECT:

Owners and Operators of Teledyne Continental Aircraft Engines Slick Electron Bulletin 1-70

Gentlemen: The subject bulletin is attached for your information.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Designers and Manufacturers of Magnetos-Ignition Parts and Precision Equipment . . . 530 BLACKHAWK PARK AVENUE, ROCKFORD, ILLINOIS 61101 PHONE 815 965-7704

26 March 1970

SERVICE BULLETIN NO. 1-70 SUBJECT: CONTACT POINT BURNING AND CAM WEAR ON 400 AND 600 SERIES SLICK MAGNETOS Burned spots and pits on contact points are normal, but have caused premature removal from magnetos. Before internal inspection of magneto follow these steps: 1. Check the timing of the magneto to the engine. 2. Adjust the magneto to a maximum of plus or minus 5-degrees, to specified engine timing. If more than ± 5-degrees, REMOVE the magneto and check internally. 3. MAGNTEO SHOULD NEVER BE SERVICED ON THE ENGINE. It is necessary for contact points to burn and the cam to wear a comparable amount so the magneto will remain time with itself. In some cases the contact points do not get a good starting area, and after a short time there will be a build-up on one point which is metal transfer from the opposite point. The magneto generates alternating current sot the reverse current will cause transfer of metal to return. When the build-up is too great, this could cause a miss. A small dent will appear on the nylon insulator between the cam follower and the breaker bar. This is normal and does not require replacement. The pictures show good and bad conditions.

These Contacts Are OK To Use.

These Contacts Need Replacement.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M70-17 Technical Portions Are FAA Approved

April 1, 1971

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

SUBJECT:

Checking for gasket deformation and/or fuel leaks at the fuel injector pump variable orifice housing.

ENGINE MODELS AFFECTED: NEW TSIO-360-A engine serials 184001 thru 184379, 184381 thru184393, 184397 thru 184409, 184411, 184415, 184416, 184418, 184419, 184420, 184421, 184423, 184424, 184425, 184427, 184429, 184430, 184431, 184445, 184433 thru 184443, 184447 thru 184453, 184455 thru 184466, 184468, 184469, 184472, 184474, 184475, 184477, 184478, 184479, 184480, 184482, 184483, 184485, 184490 thru 184491 Remanufactured TSIO360A serials 197001 thru 197010 NEW TSIO-520-B engine serials 145001 thru 145779, 145781, 145782, 145783, 145784, 145785, 145787, 145788, 145789, 145790, 145793, 145796, 145798, 145799, 145800, 145802, 145806, 145808, 145809, 145810, 145812, 145815, 145816, 145817, 145818, 145819, 145820, 145823, 145824, 145825, 145827, 145828, 145829, 145831 thru145837, 145840 thru 145846, 145848 thru 145875 plus 145880 and 145881. Remanufactured TSIO-520-B serials 176001 thru 176105 NEW TSIO-520-D engine serials 156001 thru 156146 Remanufactured TSIO520D serials 180001 thru 180012 NEW TSIO-520-E engine serials 165001 thru 166099, 206001 thru206256, 206258 thru 206270, 206272, 206273, 206275, 206277thru 206291, 206293 thru 206306, 206309, 206310, 206311, 206313, 206314, 206315, 206317 thru 206343, 206345, 206346, 206347, 206349 thru 206359, 206361, 206364, 206365, 206366, 206367, 206368, 206369, 206371, 206373, 206374, 206375, 206376, 206380, 206385, 206388, 206389, 206391, 206392, 206396, 206397, 206398, 206399, 206404, 206405, 206406, 206407, 206408, 206413, 206415, 206420, 206426 and 206429. Remanufactured TSIO-520-E serials 182001 thru 182148 NEW TSIO-520-J engine serials 208001 thru 208114, 208116, 208118, 208119, 208120, 208121, 208122, 208123, 208124, 208126 thru 208140, 208142 thru 208157, 208159 thru 208163, 298165 thru 208197, 208199 thru 208203, 208205, 208206, 208207, 208209, 208214, 208217, 208230, 208234, 208235, 208238, 208239 and 208240 Some of the engines in the above serial affected group, both new and remanufactured, had the new gasket installed prior to shipment. These pumps are identified by white paint stripe around the aneroid housing. Those pumps so identified do not require inspection.

 TELEDYNE INDUSTRIES, INC. 1974

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

April 1, 1971

M70-17 WHEN TO BE ACCOMPLISHED:

Page 2

Inspect within the next 25 hours of engine operation and at each subsequent one hundred hour inspection until such time as the new P/N 638223 gasket is installed.

Gentlemen: Injector fuel pump fuel leaks at the variable orifice housing cover, due to possible flow of the gasket material under compression, have been reported. Therefore, the following action is recommended. Inspect the subject housing for gasket flow and fuel leaks. To simplify inspection and gain access to the critical area, snip the cooling shroud inboard of the elbow fitting approximately 3/8 inch vertically so as to allow bending of the bottom edge of the shroud upwards (illustrated in figure 1) in order to expose the area to be inspected. First, check for an extruded gasket condition such as is illustrated in figure 1. Figure 2 shows a normal condition with the edges of the gasket flush with the edge of the cover. Then place mixture control in idle cut-off and turn the boost pump on high position and inspect for fuel leaks.

FIGURE 1

FIGURE 2

If a fuel leak is observed, tighten the four slotted variable orifice housing screws and repeat the check. If the leak persists or if the gasket is extruded in the manner illustrated in figure 1, remove the pump from the engine and install a new P/N 638223 gasket in place of the P/N 632647 gasket in accordance with the following recommended procedure: 1.

Mount the pump in a suitable fixture.

2.

Cut safety wire on through bolts.

3.

Turn air bleed fitting sufficiently to get at hex head through bolt.

4.

Remove slotted screws on variable orifice housing.

5.

Remove the four hex head through bolts.

6.

Break the gasket joint on the variable orifice housing with a sharp instrument.

7.

Lift the aneroid housing and variable orifice housing, as an assembly, straight up. CAUTION: Make sure that the ball check valve and spring remain in the pump housing. Also, be sure not to lose the one inch pin locking the

April 1, 1971

M70-17

Page 3

aneroid metering pin in the variable orifice housing. (Some of the early pumps do not have this one inch pin.) Remove relief valve spring and its two retaining cups and set aside. 8.

Measure length of aneroid adjusting screw from housing to end of screw (Record).

9.

Remove the lock nut on the aneroid adjusting screw and turn the screw in half way. Then gently pull the aneroid housing away from the variable orifice housing to break the "O" ring joint. Then turn the screw in al the way and remove the aneroid housing. CAUTION: Do not stretch or compress the aneroid excessively during this operation.

REASSEMBLY 1.

Install a new "O" ring, P/N 630979-2 on the variable orifice housing and lubricate lightly with engine oil.

2.

Insert the four slotted screws in the variable orifice housing and position a new gasket P/N 638223 on the screws.

3.

Assemble the variable orifice housing to the pump body and only snug up the screws. CAUTION: Make sure the ball check valve spring is not displaced during this operation.

4.

Place relief valve spring and cups back in position on top of the diaphragm.

5.

Assemble the aneroid housing by turning the adjusting screw about a half inch, counterclockwise, out thru the housing, making sure the relief valve spring and cups stay in position. NOTE: TSIO360A pump, P/N 634263, has a mixture control assembly incorporated in the aneroid housing. Care must be taken to keep the mixture control shaft in a mid-open position and also not to damage the shaft "O" ring.

6.

Press the aneroid housing down over the "O" ring.

7.

Install the four hex head through bolts with new belleville washers P/N 628357-1 (two per bolt). CAUTION: Belleville washers are special and must be installed with concave surfaces facing each other.

8.

Torque the through bolts evenly to 30 inch lbs. Pump should be rotated to insure the pump is free. If the pump is not free, it will be necessary to loosen the through bolts, and realign the pump segment. A driving torque of ten inch lbs. maximum is permissible.

9.

If the driving torque is excessive, loosen the through bolts, realign the elements and retorque.

10.

If the driving torque remains excessive after step 9, the following procedure should be followed. Now hold the pump in a vertical position (drive end down) and remove the four through bolts.

11.

Lift the aneroid housing and vapor separator body intact from the pump body and adapter exposing the pump end plate and seal. Index mark shroud to pump adapter before lifting it off.

12.

Lift out the end plate and seal.

April 1, 1971

M70-17

Page 4

13.

Press the drive shaft up even with the shaft seal to expose the pump blades. Lift out blades.

14.

Wipe blades against 500 grit emery cloth placed on a hard flat surface as per illustration. See figure 3. (Three or four wipes on each side should be sufficient.)

FIGURE 3 15.

Clean blades thoroughly and reinstall in place and depress pump drive shaft into position.

16.

Put four or five drops of light lubricating oil on top of rotor assembly and reinstall end plate and seal.

17.

Reposition aneroid housing and vapor separator body assembly matching index marks.

18.

Install the four through bolts and torque to 30 inch lbs.

19.

If the drive torque still exceeds 10 inch lbs., repeat steps 10 through 18.

20.

Remove the four slotted variable orifice housing screws, clean with Loctite grade T primer, then apply Loctite Screw Lock, reinstall screws and tighten.

21.

Reset the aneroid adjusting screw to the recorded height and install the lock nut.

22.

Safety wire the four through bolts.

23.

Reposition the air bleed fitting.

24.

Install pump on engine.

25.

Prior to running engine, operate the aircraft boost pump with the mixture control in the idle cutoff position and inspect for possible leaks.

26.

Recheck full throttle static high end metered pressure and adjust as necessary.

If the gasket is not replaced, it must be reinspected at each subsequent 100 hour periodic until such time as the new P/N 638223 gasket is installed. The cooling shroud may be left in the bent up position as this does not affect cooling efficiency. The new gasket must be installed at any time that the pump is removed and at the next pump overhaul. Also, spare pumps in stock must have the new gasket installed before being put in service. Stock of P/N 632647 gaskets are to be scrapped. Affected fuel pumps by basic P/N 632637, 632818 and 634263.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M70-3 FAA–DER Approved

February 3, 1970 TO:

Distributors, Dealers, Engine Overhaul Facilities and Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

Crankcase Modification Recommended at Next Engine Major Overhaul.

PURPOSE:

To provide additional oil drainage behind the propeller shaft oil seal and reduce the possibility of oil seal leakage

EENGINE MODELS AFFECTED:

GTSIO-520-C Serial 150001 thru 150869: GTSIO-520-D Serial 188001 thru 188754

Gentlemen: The subject crankcase modification can be accomplished accurately with a new template and grooving tool recently developed by Borrough's Tool Figure 1. The following procedures are recommended with the use of this tool. This is to be accomplished on both crankcase halves. See Figures 2 and 3. 1. With the fixture bolted to the crankcase half, chuck the cutting bit in a power tool, either electrically or air driven, which has a full load speed of 2000 R.P.M. minimum. See Figure 4. 2. Start the cutting at the counterbore with moderate pressure on the tool handle, backing off frequently to clear chips. After cutting through the counterbore, move the cutting tool and cut from the inside of the crankcase. Apply moderate pressure on the tool handle, backing off frequently to clear chips. 3. Use a find India stone to deburr the parting line faces of each crankcase half after completing the grooving. The tool is Borrough's P/N 5208 and can be procured directly from Borrough's Tool and Equipment Corporation, 2429 North Burdick Street, Kalamazoo, Michigan 49007.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

February 3, 1970

M70-3

Page -2-

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M70-7 FAA-DER Approved

March 17, 1970 TO:

Distributors, Dealers, Overhaul Facilities, Teledyne Continental Motors Aircraft Engine Owners and Operators.

SUBJECT:

Increasing Size of Oil Feed Holes to Starter Adapter Shaftgear.

PURPOSE:

To reduce Possibility of Oil Feed Hole Plugging and Cutting Off Lubrications to Starter Adapter Clutch Spring.

ENGINE MODELS AFFECTED:

All O-470, IO-470,IO-520 and TSIO-520

Gentlemen: On engines with sand cast crankcases, the oil feed hole to the starter adapter shaftgear comes off the rear main bearing boss of the 1-3-5 crankcase half and enters the needle bearing counterbore near the top of the holes (at 10 to 11 o'clock position). This hole can be enlarged only at major overhaul or at any time the crankcase is disassembled. This should be accomplished per the illustration on page 2.

On Permold crankcases, the oil feed hole comes off the rear cam bearing of the 1-3-5 crankcase half and intersects a very short hole in the center of the needle bearing counterbore. This can be enlarged at any time with the starter adapter removed. Using a greased drill will help trap the chips. The oil system should then be pressurized to flow oil thru the enlarged hole before the starter adapter is replaced.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

March 17, 1970

M70-7

Page -2-

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M71-14 FAA-DER Approved

June 21, 1971

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

Slick Service Bulletin No. 1-71

MODELS AFFECTED:

All engines equipped with Slick Model 400 and 600 Series Magnetos.

Gentlemen: We recommend that the inspection procedures outlined in the attached Slick Bulletin No. 1-71 be closely followed at any time that the magneto is removed from the engine for any reason.

 TELEDYNE INDUSTRIES, INC. 1974

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO. 1-71

SUBJECT: IMPULSE COUPLING INSPECTION ON SLICK MODEL 400 & 600 SERIES MAGNETOS

We have had some reports of the rivets coming loose which support the impulse coupling pawls on the hub of our impulse couplings. These pawls could eventually break and damage the frame of the Magneto. At your next inspection, remove the impulse coupling hub from the shaft and inspect the pawl rivets for looseness. Use a pair of pliers on the head of the rivet, and use caution with the pliers so as not to damage the head of the rivet. If the rivet turns in the plate, the hub assembly should be replaced. For proper spring tension in reassembly, refer to instructions on page 25 of Slick green service manual (Form #1012), or page 27 in our yellow service manual (Form #1020).

4-30-81

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M71-20 Supersedes M70-12 FAA-DER Approved

August 20, 1971 TO: SUBJECT: MODELS AFFECTED:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motor Aircraft Engines . Installation Instruction for the compressor Sheave to the Starter Adapter (637778). GTSIO-520-C, D, F, G and H

Gentlemen: When installing air-conditioning, the compressor drive hub P/N 637775, attaches to the starter adapter shaftgear on top of the viscous damper. Remove the starter adapter assembly from the engine and proceed as follows: 1.

Remove the P/N 502171 snap ring and discard it. (Ref. Page 19 in Parts Catalog, Form X-30046, dated January 1968.)

2.

Remove the P/N 632980 key, the P/N 628311 spring and the P/N 632979 Marsden nut.

3.

Remove the P/N 631922 washer and discard it. IMPORTANT: This washer is NOT used with the compressor sheave.

4.

Install the P/N 637775 hub over the shaft end with the nut inside the cone.

5.

Install the Marsden nut and torque to 195-235 ft./lbs. while shaftgear is held in a fixture locating on at least four gear teeth. A special fixture designed to locate on all the gear teeth is available from Borrough's Tool and Equipment Corporation, 2429 N. Burdick Street, Kalamazoo, Michigan 49007, under their Tool No. 5211. This tool will also accommodate starter adapters for IO520 and TSIO520 models.

6.

Install the P/N 628311 spring. Use a new spring if the original is deformed or compressed.

7.

Install the P/N 632980 key and secure with a new P/N 502171 snap ring.

8.

For installation instructions for the 637774 sheave see Cessna 421 Service Manual, Section 13, Page 13 - 64T or Weston Air Products Air-Conditioning Overhaul Manual, OM-421-1, as applicable.

 TELEDYNE INDUSTRIES, INC. 1977 Member of GAMA

General Aviation Manufacturer’s Association

TELEDYNE CONTINENTAL MOTORS Aircraft Products Division PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M71-21 FAA-DER Approved

November 22, 1971

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engine.

SUBJECT:

PROCEDURE FOR FREEING TURBOCHARGER TURBINE SHAFTS WHICH ARE DRAGGING OR FROZEN BY RUST DEPOSITS

MODELS AFFECTED: All turbocharged engine models Gentlemen: New or low time turbochargers which have been subjected to short intervals of engine operation prior to engine shut down, will sometimes form rust deposits in the area of turbine shaft piston ring seal as a result of water vapor accumulation. These deposits, while they do restrict or even stop shaft rotation, are not harmful to subsequent turbocharger operation once they are removed sufficiently to again give free shaft movement. If the turbine shaft is binding or frozen, a power loss will be noted and possibly some oil leakage past the turbocharger seal will be apparent. When this condition is noted, remove the exhaust discharge stack and apply an approved penetrating oil liberally to the area behind the wheel around the turbine shaft seal. A list of approved oils is given below. After a few minutes attempt to turn the shaft. A light rap on the shaft end with a soft mallet will often assist in freeing the shaft. Once the shaft is free the engine can be started and a power check made to confirm turbocharger outputs either on the ground or in flight. This condition occurs only when the unit is new or low time and combustion deposits have not formed a protective barrier on the seal surfaces. Units which are binding after long time service are coked internally and must be removed for cleaning or replacement.

NOTE Do not return any turbochargers for warranty consideration for the above condition unless the procedure recommended in this bulletin fails to correct the problem.

(Continued)

 TELEDYNE INDUSTRIES, INC. 1977 Member of GAMA

General Aviation Manufacturer’s Association

TELEDYNE CONTINENTAL MOTORS

Aircraft Products Division PO Box 90 Mobile Alabama 36601

Page -2-

November 22, 1971

M71-21

It should be noted that oil leakage past the turbocharger seal can also be caused by one of the following: 1.

Inadequate scavenging caused by air ingestion or leaks in the suction line.

2.

Erratic check valve in the oil inlet line to the turbocharger (when applicable) APPROVED PENETRATING OILS

Kano Aerokroil - Kano Laboratories, 1000 S. Thompson Lane, Nashville, Tennessee 37211 Mouse Milk Penetrating Oil - Worldwide Aircraft Filter Corporation, 1685 Abram Court, San Leandro, California 94577 WD-40 - Rocket Chemical Company, 5390 Napa Street, San Diego, California Crown Penetrating and Cleaning Oil - Crown Industrial Products Company, 100 State Line Road, Hebron, Illinois 60034 Sprayon No. 203 Penetrating Oil - Sprayon Products, Industrial Supply Division, 26300 Fargo Avenue, Bedford Heights, Ohio 44146

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M72-17, Rev. 1 Supersedes M72-17

5 October 1973

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engine.

SUBJECT:

New Maximum Weight Difference Allowance Between Connecting Rods and Pistons in the Same Engine

MODELS AFFECTED:

All Models

Gentlemen: The allowable variation in weight between the connecting rods and pistons in the same engine no longer relates to the entire set. Instead, the difference relates to connecting rods or pistons opposite each other only. The new allowable variation is one-half ounce (1/2 ounce) between opposite connecting rods and one-half ounce (1/2 ounce) between opposite pistons These new tolerances will be included in the various overhaul manuals as they are revised. In the meantime, please amend your publications accordingly. The removal of metal from connecting rods, crankshafts and pistons, for the purposes of balancing, is not an approved procedure. Indiscriminate work of this type, accomplished without the benefits of renitriding, shot peening and/or heat treatment can seriously compromise the structural integrity of the engine.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M72-8 FAA Approved

June 21, 1972 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engine.

SUBJECT:

New Design Splined Drive Scavenge Pump Shaft and Gear Assembly

MODELS AFFECTED:

TSIO520B, D, E, J and K

Gentlemen: An improved scavenge pump assembly, which eliminates the Woodruff key type of drive, is now available for the TSIO-520 permold crankcase engines. Conversion to this configuration must be accomplished at the next engine overhaul or the next starter adapter and scavenge pump assembly overhaul. Observe the following instructions and procedures when converting to the new assembly configuration. 1.

Disassemble P/N 635061A1, A2 or A3 starter adapter and scavenge pump assembly as outlined in the TSIO-520 Overhaul Manual, pages 4-9 and 4-10.

2.

Rework P/N 632659 cover assembly by opening up the shaft gear hold to .672/.682 diameter. (See Figure 1.) After rework, this becomes P/N 639405.

3.

Rework P/N 636322 scavenge pump body assembly by adding a .088/.093 diameter oil passage. (See figures 2 and 3.) A special fixture and stop-drill, P/N 497801, accomplishes this simply and accurately and is available from Borrough's Tool and Equipment Corporation, 2429 North Burdick Street, Kalamazoo, Michigan 49007. After rework, this body assembly becomes P/N 639407.

4.

Replace P/N 635335 starter shaftgear assembly with P/N 639406 splined shaftgear assembly.

5.

Replace P/N 635330 scavenge pump driver gear and MS35756-3 Woodruff key with P/N 639388 splined scavenge pump driver gear.

6.

Reassemble starter adapter and scavenge pump assembly as outlined in Overhaul Manual Page 7-2. Insure that the shaftgear spline is free sliding fit with mating driver gear.

(Continued)

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Page - 2 -

7.

May 8, 1972

M72-8

After conversion the starter adapter and scavenge pump assembly becomes P/N 635061A5. Identify the assembly by ink stamping this P/N on the starter adapter housing in some convenient location.

This new P/N 635061A5 assembly went into production on the following new engines beginning with the serial numbers indicated. TSIO520B

Serial 145920 and on.

TSIO520D

Serial 156147 and on.

TSIO520E

Serial 206592 and on

TSIO520J

Serial 208290 and on

TSIO520K

Serial 217655 and on

FIGURE 1. ENLARGED SHAFT HOLE DIMENSION.

Page - 3 -

May 8, 1972

FIGURE 2. DRILLING NEW OIL PASSAGE

FIGURE 3. SETTING DRILL DEPTH

M72-8

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M73-12 FAA-DER Approved

8 June 1973 TO:

SUBJECT: MODELS AFFECTED:

Distributors, Dealers, Aircraft Engine Overhaul Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines Marvel-Schebler Carburetor Bulletin A1-73 All Teledyne Continental Aircraft Engines Equipped with a Marvel-Schebler Carburetor Model MA-3SPA, MA-4-5, or MA-3PA

Gentlemen: Attached is a copy of the subject bulletin. As pointed out by Marvel-Schebler, the major change is the improved throttle shaft and lever arrangement. This change is both FAA and TCM approved. Teledyne Continental Motors recommends that these components be replaced at the next engine or carburetor overhaul. This is an approved equivalent procedure for compliance with FAA Airworthiness Directive 72-6-5

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Februray 15, 1973

NO. A1-73 To:

All Registered Manual Holders

Subject:

Updated parts Lists and Exploded Views

Enclosed please find your new Aircraft Manual parts Lists and Exploded views. Remove the Continental, Franklin and Lycoming sections and replace with these new updated sections. Keep the old sheets in your files, as you have need to refer to obsoleted models. Or better still order a new Manual and retire the old to your library. The major change you will notice is the improved throttle shaft and lever arrangement. (Forged steel levers and stops with extended thread shafts and retaining nuts). A minor change is the elimination of “Rubber Cure” by the use of non deteriorating rubber components. New Repair Kits have been assigned to all models, they include the new throttle shaft and lever parts. Order the new numbers when your present kits are sold. We still have available a few of the old Blue Manuals complete with all the Service Bulletins. A must if your are servicing Aircraft built in the 1940 – 1950 period. New Manuals updated to 1973 and the old Blue style are available from your Marvel-Schebler/Tillotson Distributor.

MARVEL-SCHEBLER / TILLOTSON

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M73-13 FAA-DER Approved

10 July 1973 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

SUBJECT:

Reaming and Bushing Rocker Shaft Bosses

MODELS AFFECTED:

A65, A75, C75, C85, C90 O-200, O-300 and GO- 300.

Gentlemen: The following diagram is incorporated in our overhaul manual covering the subject engine models.

This method of repairing worn rocker shaft bosses on subject engine cylinder assemblies, is possible and recommended providing there is adequate stock in the wall at the center boss.

(continued)

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

10 July 1973

Page 2

M73-13 FAA-DER Approved

The following must be taken into consideration before proceeding with such repairs: 1.

The minimum boss wall thickness measured at the edge of the center boss prior to any reaming and bushing must be .240 inch to be acceptable.

2.

If the thickness of the center boss falls within this dimension, the bosses may be reamed. The center boss wall thickness must again be measured after reaming. If it is below .18 inch in any area, the cylinder must not be bushed and should be retired from service.

3.

We cannot overstress the importance of producing a smooth finish on the inside diameter of the cylinder bosses when reaming prior to installation of the bushings. Too rough a surface bore finish can contribute to boss breakage. The bore surface roughness should not exceed 60 RMS.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M73-2 FAA-DER Approved

17 January 1973 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engine.

SUBJECT:

FAA Airworthiness Directive No. 72-20-2

MODELS AFFECTED:

IO470D, E, F, H, L, M, N, S, U and V TSIO470B, C and D

Gentlemen: Since the publication of the subject Airworthiness Directive, it has been brought to our attention that identification of Part Number 626820 "non-H" and "H" cylinder assemblies, by means of the date of manufacture steel stamped at the base of a rocker shaft support, is unreliable because, in many instances, the numerals are illegible due to overstamping or have been partially or wholly removed by remachining. The purpose of this bulletin is to provide other visual physical characteristics as a means of identification. If the date of manufacture is not legible, inspect for the following: 1.

Observe the first full length cylinder head cooling fin (cylinder in vertical position) below the top spark plug port. If the thickness of the exposed portion between the two partial fins is approximately .040 inches thicker than the outboard ends (ref. illustration no. I), then the cylinder was manufactured subsequent to April, 1963, and conforms to the "H" configuration.

2.

If the cooling fin described in (1) does not have the thickened section, inspect the exposed (as installed on an engine) or top side of the cylinder base flange. If the cylinder hold down nut seats are circular spotfaces, the cylinder was manufactured or remanufactured subsequent to April, 1963, and is of the "H" type. If the base flange is contour milled for nut seats, then the cylinder is of the "non-H" type and must be retired from service. (Ref. illustrations no. II).

 TELEDYNE INDUSTRIES, INC. 19xx

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

17 January 1973

Page 2 M73-2

3.

In the event the cylinder cannot be identified by either of the two (2) described characteristics, then radiographic inspection can be used. The X-ray exposure must be made at precisely a 90 degree angle to the threaded joint between the cylinder head and cylinder barrel so that the thread form is accurately projected on the film. The thread of the "non-H" cylinder barrel will have a sharp "V" root profile while the "H" type will have a full fillet root radius. (Ref. illustration III).

It has been brought to our attention that certain engine overhaul agencies advertise and sell overhauled Teledyne Continental Motors aircraft engines and cylinder assemblies as being remanufactured. Thus, it becomes necessary to point out that reference to remanufactured engines and cylinder assemblies in A.D. 72-20-2 was intended to mean "Factory Remanufactured" after April, 1963.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M73-6, Revision 1 FAA-DER Approved

11 June 1973 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

Prestolite Alternator Cooling Fan Maintenance and Inspection

MODELS AFFECTED:

O-470, IO-470,IO-520, and TSIO-520 Models Equipped With Prestolite Belt Driven Alternators

Gentlemen: A new alternator cooling fan and sheave assembly is now FAA approved and released as a replacement for cooling fan Part Number PU1605, PU1605A and 90-2241 on Prestolite alternators installed on the above listed TCM engine models. The complete assembly is identified as Eq. 6494 and consists of P/N 640261 Sheave, P/N 640399 - Fan and P/N 640420 - Backing Plate. Teledyne Continental Motors recommends that this combination be installed on their engines in complying with FAA Airworthiness Directive 72-15-2. All other assemblies tested displayed vibration characteristics which would lead to limited service life. The difference between TCM Eq. 6494 and Prestolite Package No. 90-2241 is the concave backing plate - the ventilating fans are identical. The backing plate approved for use on TCM engines has the same material thickness as the ventilating fan (.064"). Also, P/N 640261 Sheave is included and MUST be used with P/N 640420 - Backing Plate to provide vibration dampening and correct belt alignment. The new sheave can be distinguished from the old by the fact that, when installed, it has contact with the backing plate for its full diameter. If Prestolite Package No. 90-2241 has been installed in place of fan P/N PU1605 or PU1605A, then only the correct backing plate and sheave need be procured to bring the assembly into conformity with the TCM approved design. Reference Prestolite Aircraft Service Bulletin No. ASM-8 for installation instructions.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Prestolite has designed and released a new venti-lating fan assembly that we recommend be used whenever replacement is necessary. The new, two piece unwelded construction ventilating fan shown in Figure 1 consists of a thick gauge aluminum material ventilating fan and a thin gauge aluminum material backing plate. The backing plate is dished to provide vibration dampening when the fan and backing plate are properly assembled on the shaft and the retaining unit is torqued to the proper specification.

Figure 1

The new far and backing plate being aluminum, are easily identified by their appearance The new ventilating fan and backing plate are contained in parts package number DO-2241.

Figure 2

Figure 3 Installation

Correct assembly of the fan and backing plate is shown in Figure 2. Make certain the outside edge of the backing plate contacts the outside edge of the fan. Install the pulley, lockwasher, and retaining nut then torque the retaining nut to 35ft. lbs. Minimum to 40 ft. Lbs. Maximum. Use a strap wrench or a pulley gripping tool, similar to the type shown in Figure 3, to hold the pulley while torquing the retaining nut. NOTE: Proper tightening of the pulley retaining nut and proper belt tension are extremely important as these have been the two major contributing factors to the ventilating fan problems.

Make certain the torque wrench is accurate and DO NOT undertorque or overtorque the retaining nut. After installing the alternator on the engine, use one of the two following methods to adjust the fan belt tension. 1.

SLIP TORQUE METHOD: This method consists of installing a torque wrench on the pulley retaining nut and measuring the amount of torque required to make the pulley slip. Turn the torque wrench in a clockwise direction, as viewed from the pulley end, and adjust belt tension accordingly.

BELT WIDTH

SLIP TORQUE NEW BELT

SLIP TORQUE USED BELT

3/8 Inch

11 to 13 Ft. Lbs.

7 to 9 Ft. Lbs.

1/2 Inch

13 to 15 Ft. Lbs.

9 to 11 Ft. Lbs.

If a new belt is being installed the slip torque should be checked to the used belt specification after 1 hour operation, at 25 hours, and each 100 hours thereafter. See Aircraft Manual or call Aircraft Manufacturer. NOTE:

2.

The higher the torque value for the new belts is to compensate for the initial stretch of the belt that occurs as soon as it is operated. Do not use the higher torque value for a belt that has been previously used. BELT TENSION METHOD: This method consists of installing a belt tension meter on the fan belt at mid point of the longest unsupported section of the belt and adjusting the alternator to obtain the specifications listed below.

TYPE ALE ALH, ALT, ALZ ALY, ANG ALU, ALX

OUTPUT 40 Amp 50 Amp 60 Amp 70 Amp

BELT LOAD 50 Lbs. 75 Lbs. 75 Lbs 75 Lbs.

The meter used for these specifications was a Borroughs Belt Tension Meter Model # BT-33-73F. The above specifications are for a used belt, or a new belt after 1 hour inspection. Prestolite Technical Service Toledo, Ohio 43601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M74-15 FAA-DER Approved

20 August 1974 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

SUBJECT:

Carburetor Calibration

MODELS AFFECTED:

O-470-R

Gentlemen: Under certain conditions, a little richer calibration of the carburetor is desirable in the part throttle range on the subject model engine. This will provide a slightly richer flow during the part throttle climb out period as well as during part throttle cruise operation. This should help reduce cylinder head temperatures where higher than normal temperatures have been observed. It will also give you a greater latitude for leaning during cruise conditions. Carburetors which incorporate this change in part throttle calibration were installed on O-470-R, engine serial numbers 459542, 459601, 459601, 459607, 459608,45609, 459633, 459634, 459641, 459642, 459644, through 459705, 459708, 459709, 459710, 459712, 459713, 459714, 459716, 459718, 459720 through459741, 459743 and all subsequent. The Teledyne Continental Motors’ part number is 641139 (Marvel-Schebler P/N A10-4893-1). Carburetors not incorporating the latest change to increase part throttle fuel flows can be modified using Teledyne Continental Motors’ kit part number A666-814. Installation of this kit converts model MA4-5 part number A104893 in A10-4893-1 and part number A10- 3965-12 into A10-3965-12-1. The kit part number A666-814 consists of: 1 –173-159 Metering Pin 1-24-A30 Metering Pin Return Spring 1-16-A56 Gasket Metering Plug Kits can be ordered from any Teledyne Continental Motors’ distributor.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

20 August 1974

Page 2

M74-15

Instructions for setting the mechanical economizer jet without the use of the M-94 series tools:

I.

II.

With Throttle Closed A.

Remove lockwire and metering plug. Discard gasket.

B.

Remove air metering pin jet assembly from carburetor casting.

C.

Install new metering pin and return spring in air metering pin jet.

D.

Re-install air metering pin jet assembly in carburetor casting to an approximate setting of ½” from the face of casting A to face C of the air metering pin jet assembly.

With Throttle in Wide Open Position A.

III.

Measure distance from the face of casting A to tip of air metering pin B using a suitable depth gage. See diagram.

Return The Throttle Valve To A Fully Closed Position A.

Adjust the air metering pin jet assembly in or out so that the distance from A to C is the sum total of A to B (measured in II-1) plus .480. In making the setting, make certain that the end of the depth gage is seating on face C of air metering pin jet assembly.

B.

Install New gasket on metering plug. Re-install plug and re-safety.

C.

Stamp a (-1) after part number on nameplate.

OR

20 August 1974

Page 3

M74-15

If you have tool M-94, reset the economize flush plus 2-1/2 turns with the throttle wide open.

M-94 Flush Pin Gage Tool

NOTE: Re-safety the plug and stamp a (-1) after part number on nameplate.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

74-16 SUPERSEDES M49-15 FAA-DER APPROVED

17 JUNE 1974

TO:

DISTRIBUTORS, DEALERS, AIRCRAFT ENGINE OVERHAUL FACILITIES, OWNERS AND OPERATORS OF TELEDYNE CONTINENTAL MOTORS’ AIRCRAFT ENGINES

SUBJECT:

USAGE AND IDENTIFICATION OF VALVE SPRINGS

MODELS AFFECTED:

ALL “A” SERIES, “C” SERIES, AND “E’ SERIES ENGINES

OBJECT:

TO INSURE CORRECT USAGE AND IDENTIFICATION OF VALVE SPRINGS

Gentlemen: Because there have been several spring combination changes in various engines in the past years, this bulletin is written to summarize these changes and consolidate the information presented in previous releases. Table 1 shows approved spring combinations and the color code for identification of stock. INNER SPRING

INTERM. SPRING

ENGINE MODEL

PART NO

COLOR

PART NO

A65

21365

C75,C85

24029

C90

24031

White or Orange

*C90 Optional

24031

White or Orange

C125

24031

White or Orange

24029

C145

24031

White or Orange

24029

*C145 Optional

24031

White or Orange

E165,E185

637836

*E165,E185 Optional

520106

**E165,E185 Optional

35988

OUTERSPRING PART NO.

COLOR

Yellow

21366

Yellow

White or Orange

24030

White or Orange

24030

White or Orange

24669

Black

White or Orange

24030

White or Orange

White or Orange

24030

White or Orange

530302

Green

Aluminum

520105

Blue

Blue

520105

Blue

Plain

35989

Plain

24029

COLOR

White or Orange

* Permissible with cast iron camshaft, three spring combination preferred and must be used with later type steel camshafts. ** Use aluminum spacer part number 520023 with number 35988 and number 35989 spring combination. Do not use spacer with spring combination consisting of part numbers 530106 or 637836 and 520105.

It is recommended that all springs be striped for identification immediately after disassembly of any engine and thorough cleaning. Also all springs in stockrooms should be color striped immediately according to the code. In order to assure proper marking, springs on hand should be checked against data shown in Table 2. Use only a good grade enamel. The stripe should be approximately 1/4" wide and should touch only the outside of each coil. Do not apply enough to cause runs or drops.

(continued)

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

17 JUNE 1974

M74-16,R1

PAGE 2

SPRING IDENTIFICATION PART NO

COLOR Yellow

COILS WOUND L.H.

FREE LENGTH(APPROX) 1.922”

21365 21366

Yellow

R.H.

2.203”

24029

White or Orange

L.H.

24030

White or Orange

R.H.

24031

White or Orange

24669

INSIDE DIA.(MIN) .870”

WIRE DIA. .105”

1.167”

.135”

2.312”

.880”

.111”

2.125”

1.165”

.142”

R.H.

1.781”

.630”

.091”

Black

R.H.

2.125”

1.165”

.148”

35988

Plain

R.H.

2.156”

.912”

.142”

35989

Plain

L.H.

2.187.”

1.287”

.177”

520105

Blue

L.H.

2.562”

1.287”

.177”

520106

Blue

R.H.

2.406”

.912”

.142”

*530301

Red

L.H.

2”

.880”

.125”

530302

Green

R.H.

2.094”

1.170”

.162”

637836

Aluminum

R.H.

2.406”

.912”

.142”

TEST DATA

SPRING LOADS PART NO.

COMPRESS TO

LOAD (LBS)

COMPRESS TO

LOAD (LBS)

21365

1.25”

20-22

21366

1.344”

32.5-35-5

24029

1.528”

25-28

24030

1.559”

33-37

1.168”

58 - 63

24031

1.466”

10-13

1.075”

27 - 30

246669

1.559”

43-47

1.168”

71 - 76

35988

1.809”

28-34

1.329”

71 - 81

35989

1.840”

41-47

1.360”

100 - 113

520105

1.840”

65-71

1.360”

107 - 120

520106

1.809”

43-49

1.329

78 - 88

*530301

1.528”

25-29

1.137”

55 - 61

530302

1.559”

47-53

1.168”

93 - 101

637836

1.809”

43-49

1.329”

78 - 88

.860”

34.5 - 37.5

.953”

52 - 56

1.137”

40 - 44

* Destroy all number 530301 valve springs to prevent their use in any engine. These springs are different from any other type now in production and must not be used as replacements.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M74-18 FAA Approved

16 September 1974 TO:

Distributors, Dealers, Aircraft Engine Overhaul Facilities Owners and Operators of Teledyne Continental Aircraft Engines

SUBJECT:

Compliance with Slick Bulletin 1-74

Gentlemen: We recommend that the attached Slick Service Bulletin No. 1-74 be complied with as indicated.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

1-74

SUBJECT: AD74-08-05 This airworthiness directive is being revised and will be published within the next two (2) weeks. The new AD will give relief regarding inspection and replacement of slick impulse couplings on the 400 and 600 series magnetos. When removal of impulse coupling is necessary on Slick 400 and 600 series magnetos, the proper puller MUST be used.

THE THREE (3) COUPLING PULLERS ARE: M-1764, 12-CMTA AND 021-CMT, As found in Slick catalog and service manual form-1020 which supersedes form-1012. Improper pulling of the coupling hubs will result in damage,

CAUTION: DO NOT pry off the hub. This will damage the frame.

530 BLACKHAWK PARK AVENUE, ROCKFORD, ILLINOIS 61101

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M75-14 FAA-DER Approved

30 June 1975

TO:

Distributors, Dealers, Aircraft Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

SUBJECT:

635014 AIR THROTTLE BRACKET ASSEMBLIES

MODELS AFFECTED: IO-470-D, U, V; IO-520-E

Gentlemen: It has been called to our attention that air throttle body bracket assemblies (P/N 635014) used on the subject engine models have cracked under certain conditions. Therefore, it is highly recommended that these brackets be inspected at each 100-hour inspection and replaced during major overhaul with an improved bracket (P/N 641638) which is now available. These new brackets went into production on the following engine serial numbers: NEW

REMANUFACTURED

IO470D

456008

105462

IO470U

457006

118368

IO470V

55699

170506

IO520E

556196

215509

* * * * * *

 TELEDYNE INDUSTRIES, INC. 1974

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M75-15 FAA-DER Approved

14 July 1975 TO: SUBJECT: MODELS AFFECTED:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. NEW CARBURETOR AIRBOX O-200-A

Gentlemen: A new, improved carburetor airbox (P/N 641534) is now available and is currently being supplied with new production O200A engines. Wear, due to vibration, has been greatly reduced by incorporating replaceable teflon bushings at each end of the valve shaft. In the event it becomes necessary to replace the teflon bushings due to operation in an area where there is a high concentration of dirt, it can easily be accomplished on the air boxes (P/N 641534). Simply remove the cotter pin (P/N MS24665-132) and washer (P/N 2472) from one end of the shaft, remove the bushing and install a new one (P/N 641527). On the opposite end of the shaft, remove the lock nut (P/N MS21044N4), washer (P/N 2742), lever (P/N 641523), and washer (P/N AN960-516L). Remove the bushing, install a new bushing and re-install removed parts. A repair kit (P/N 641689) is also available to repair older style airboxes (P/N 628122). This kit comes complete with all necessary parts including an instruction drawing. The new airbox, the repair kit and the teflon bushings can be purchased from any Teledyne Continental Motors' distributor.

* * * * *

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M75-17 FAA-DER Approved

17 July 1975 TO: SUBJECT: MODELS AFFECTED:

All Teledyne Continental Motors' Aircraft Parts Distributors, Dealers, Repair Facilities and Engine Owners and Operators CYLINDER HEAD AND ROCKER PIVOT PIN CHANGE 6-285B, C - Tiara

Gentlemen: The original cylinder head (P/N 638095) on the 6-285B engine along with its rocker pivot pin (P/N 635856) was redesigned late in 1973. The new cylinder head (P/N 640589) differs from the original only in that the depth of the pivot pin slot was increased from 1/16" to approximately 5/16". See diagram below.

Because of this depth change, the rocker arm pivot pin had to be increased in height. The original pivot pin (P/N 635856 - approximately .738 in height) was, therefore, replaced in the new head with P/N 640532 - approximately .988 in height. NOTE:

When changing cylinder heads on the 6-285B engine, it will be necessary to identify whether they are old or new style so that the correct pivot pin can be ordered and/or installed. The heads are interchangeable and can be mixed on the same engine providing you use the correct pivot pin. All 6-285C engines built incorporated the new cylinder head P/N 640589.

 TELEDYNE INDUSTRIES, INC. 1974

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M75-30 FAA-DER Approved

19 December 1975 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

PRESTOLITE ALTERNATORS

MODELS AFFECTED:

IO-520-B, BA, C, M; TSIO-520-B, D, E, J, K, L, N; GTSIO-520-C, D, H, L

Gentlemen: We recommend that the attached Prestolite Aircraft Service Bulletin No. ASM-10 be complied with.

 TELEDYNE INDUSTRIES, INC. 1975

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

It is recommended that the subject bearing be inspected and, if necessary, relubricated at each 100 hour engine inspection. The subject bearing is accessible by removing the bearing cover as shown in Figure 1. Use a small sharp chisel, knife blade, or screwdriver to pry the cover out the end head. Care must be taken not to damage the end head. If the bearing cover is damaged during removal, a new cover must be installed. Without further disassembly visually inspect the bearing and shaft end for discoloration or any sign of overheating or wear. Pay particular attention to the bearing inner and outer race. See Figure 2. If there is any sign of overheating or an indication that the rotor shaft has been turning in the inner race or the outer race has been turning in the end head, the alternator must be removed and repaired. If the rotor shaft has been turning in the bearing inner race, the rotor and bearing must be replaced. If the bearing outer race has been turning in the end head, the bearing and end head must be replaced. Check the bearing grease for any sign of overheating or contamination such as dirt, or metal filings. If the grease is a dark brown or black color, or is so contaminated, the alternator must be removed and the bearing replaced. If the bearing shows no sign of discoloration, overheating, wear, or contamination, fill the bearing only (not the entire cavity) with Chevron BRB #2 or Chevron SRI #2 grease, see figure 2, and replace the bearing cover. Do not use a substitute lubricant. Refer to Prestolite Form No. L664 for disassembly and assembly procedures when repairing the alternator.

Figure 1

Figure 2

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M75-6, Rev. 1 Supersedes M75-6 FAA-DER Approved

4 June 1975

TO:

All Teledyne Continental Motors’ Aircraft Distributors, Dealers Maintenanceand Overhaul Facilities, Engine Owners and Operators

SUBJECT:

CONVERSION OF ENGINES FROM ONE MODEL TO ANOTHER

MODELS AFFECTED:

All Models

Gentlemen: Although we have never recommended conversion of engines from one model to another, we have had over the years, many inquiries on whether or not it is permissible to convert from one model to another. As a result, in order to maintain a good relationship with owners who desire to convert their engines, we have issued previous bulletins granting that certain conversions can be accomplished, such as: 1.

Within a basic engine family, it is permissible to convert from one dash number (or letter) to another as long as it is accomplished with parts currently approved for the model to which the engine is being converted.

2.

In the case of the "E" series engines, any conversion of an E-185 to an E-225 will require a new serial number, which can only be issued by Teledyne Continental Motors. For information on how to procure a new nameplate, see our bulletin M75-5.

3.

On other models, impression stamp the letter "C" after the existing model letter (or number) and then impression stamp the new designation letter per the following example: IO-470-U to IO-470-V = IO-470-UCV

4.

Do not alter serial number or suffixes.

It should be pointed out that obviously TCM cannot accept the same degree of responsibility on engines which are altered or converted by persons over which it has no control, as it does engines which are built and shipped as complete units for installation in specific aircraft. For this reason, TCM feels that any owner or service facility involved in any conversion, should fully understand that when such conversions are completed, TCM's warranty does not apply in any manner, including new parts which may have been installed.

 TELEDYNE INDUSTRIES, INC. 1974

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M75-7,Rev. 1 Supersedes M75-7 FAA-DER Approved

4 April 1975 TO:

Distributors, Dealers, Aircraft Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

SUBJECT:

OIL FILTER CHANGE

MODELS AFFECTED:

IO-360, TSIO-360,LTSIO-360

Gentlemen: As a product improvement feature, the subject engines, beginning with serial numbers listed below, will incorporate an oil filter which has a by-pass valve assembled in it. NEW ENGINES TSIO360C TSIO360D TSIO360E LTSIO360E IO360

300320, 300348, 300349, 300352 and on 302024 and on 303154 and on (except 303193, 303194 and 303195) 304155 and on (except 304193, 304194 and 304195) Serial Numbers not available; this is an airframe option

REMANUFACTURED ENGINES TSIO360C 224316 and on IO360 Serial Numbers not available; this is an airframe option. At the same time, the by-pass valve in the oil filter adapter is being eliminated as it is no longer necessary when used in conjunction with the new oil filter. The new oil filter P/N 641583 replaces P/N 637584. It can be installed in place of P/N 637584; however, 637584 (without by-pass valve) must not be installed in place of 641583 on adapters which do not incorporate a by-pass valve. By relocating the by-pass valve from the adapter to the oil filter, the desirable feature of having a new bypass valve every time the oil filter is changed is accomplished. If you wish to incorporate this product improvement, the valve assembly can be removed from adapters and the opening sealed by the installation of plug P/N 641614 as per the sketch shown

 TELEDYNE INDUSTRIES, INC. 1974

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

4 April 1975

M75-7, Rev. 1

Page 2

STAKE SECURELY IN FOUR (4) PLACES EQUALLY SPACED

641614 PLUG

After the plug has been installed and securely staked, re-identify the adapter with a permanent type ink. OLD P/N 640835 640836 641012 633324 or 640927

OIL FILTER ADAPTER

NEW P/N

Becomes " " "

641575 641574 641576 641734

The new adapters (without by-pass) can be identified on production engines by the new P/N's shown above. The new oil filters are easily identified because of their gold color.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-12 FAA-DER Approved

24 May 1976 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

Chrome Plating of Cylinders

MODELS AFFECTED:

All GTSIO-520 Series

Gentlemen: According to the field service experience accumulated by Teledyne Continental Motors and FAA Malfunction and Defect Reports, the practice of chroming the subject model engine cylinders definitely affects their reliability. As a result, Teledyne Continental Motors has no alternative but to strongly recommend that the practice of installing such cylinders on GTSIO-520 engines be discontinued.

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-15 FAA-DER Approved

17 June 1976 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

FUEL PUMPS

MODELS AFFECTED

O-200-A

Gentlemen: When installing an AC fuel pump on the subject engine, care must be taken to install the correct pump, depending on the camshaft in the engine. The correct camshaft and pump combinations are: 1. Camshaft part number 626608 to which part number 630403 gear and eccentric has been assembled, uses fuel pump TCM part number 631391. 2. Camshaft part number 628421 uses fuel pump TCM part number 40585. Installation of the incorrect pump can cause excessive fuel pressures and/or lever fracture.

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-20 Supersedes M75-27, R. 1

FAA-DER Approved

19 July 1976 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

OIL FILTERS

MODELS AFFECTED:

IO-520-B, BA, C, M; TSIO-520-B, D, E, J, K, L, N; IO-346-A; 6-285-B and C (TIARA – See page 2)

Gentlemen: In April of 1975, the subject engines were manufactured with an oil filter which has a by-pass valve designed into it. At the same time, the by-pass valve in the oil filter adapter was eliminated as it was no longer necessary when used in conjunction with the new oil filter. The new oil filters (P/N 641583 and P/N 641584) can easily be identified because of their gold color. The earlier filters (P/N 632399 and P/N 637584) are black. CAUTION: While oil filters P/N 632399 and P/N 637584 can still be used on the earlier adapter (P/N 632881), the individual installing either of these must make absolutely certain that the adapter involved incorporates a by-pass valve as illustrated. (Figure 1) It should be pointed out that there are other oil filters not supplied or approved by Teledyne Continental Motors which will fit adapter P/N 641639. Here again, you must make certain that such oil filters incorporate a by-pass valve before installation. If neither the adapter nor the oil filter has a by-pass valve, there obviously will be no by-pass capabilities in the system. The new gold oil filters can be installed on either the new or the old adapter without any modifications to the system.

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

19 July 1976

Page 2

M76-20

NOTE: During production, some of the old adapters P/N 632881 were reworked by having the by-pass valve removed. After its removal, a plate was installed which was then staked into place. The part number was not changed but the new oil filter must be used on these reworked adapters as they no longer have by-pass capability. There are two ways to identify the old, the reworked and the new oil filter adapter. One is by the part number ink-stamped on the side of the casting. The other is by checking visually to determine if it has a by-pass valve. This can easily be seen with the oil filter removed. By applying pressure to the valve location, you can determine if is has been removed and replaced with a staked plate. See Figure 1 showing the location of the by-pass valve in the original adapter, the staked plate in the reworked adapter and the new adapter which has no by-pass valve. Tiara Engine Models The method of identifying the oil filter adapter on these engines is the same as Figure 1. The part number of the new Tiara oil filter is also 641584 which supersedes P/N 632399. The original oil filter adapter P/N 637609 (with by-pass valve) has now been superseded by P/N 641629 (without by-pass valve). Care must be taken that the correct filter is installed on the correct adapter. The important thing is that at least one by-pass valve is in the system.

FIGURE 1

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-22 FAA-DER Approved

30 August, 1976 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

Compliance With Rajay Bulletin #21A

MODELS AFFECTED:

TSIO-360-E & LTSIO-360-E

Gentlemen: We recommend that the attached Rajay Bulletin be complied with as specified.

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

PAGE 1 OF 2

A Subsidiary of The Texstar Corporation NO. 21A FAA APPROVED

DATE:

SERVICE LETTER

(SUPERSEDES SERVICE LETTER NO. 21 DATED MAY 15, 1976)

AUGUST 9, 1976

SUBJECT:

INSPECTION OF TURBOCHARGER TURBINE (EXHAUST) HOUSINGS

EQUIPMENT AFFECTED:

ALL AIRCRAFT ENGINES EQUIPPED WITH RAJAY TURBOCHARGERS

DISTRIBUTION TO:

AIRCRAFT AND ENGINE MANUFACTURERS – AIRCRAFT OPERATORS AND AIRCRAFT MODIFICATION AND MAINTENANCE BASES

TIME OF COMPLIANCE:

AT THE NEXT ENGINE MAJOR OR TURBOCHARGER OVERHAUL, WHICHEVER COMES FIRST.

REASON: HAIRLINE CRACKS HAVE BEEN DISCOVERED IN THE TONGUE AREA OF THE TURBINE HOUSING INLET IN RAJAY TURBOCHARGER MODELS 301E10, 315F10, 325E10, AND 325EF10. THESE TURBOCHARGERS ARE FITTED WITH TURBINE HOUSING PART NUBMERS TC 59-11, TC 60-11, AND TC 82-11 AS APPLICABLE. INVESTIGATION INDICATES THIS CRACK DOES NOT PROPAGATE RAPIDLY THEREFORE DOES NOT APPEAR TO BE A PRESSING AIRWORTHINESS ITEM. EXAMPLES IN HAND INDICATE NO EXTERNAL DISTRESS APPARENT IN UNITS THAT HAVE BEEN IN SERVICE UPWARDS TO 10 YEARS.

PURPOSE: INSPECTION FOR HAIRLINE CRACKS IN THE TURBINE HOUSING INLET IN RAJAY TURBOCHARGER MODELS 301E10, 315F10, 325E10, AND 325EF10. THESE TURBOCHARGERS ARE FITTED WITH TURBINE HOUSING PART NUMBERS TC 59-11, TC 60-11, AND TC 82-11 AS APPLICABLE. INSTRUCTIONS: IT IS RECOMMENDED THAT THE INSPECTION SCHEDULE OF THIS LETTER BE PUT INTO EFFECT AND CONTINUED UNTIL THE UNIT IS REPLACED WITH PART NO. TC 59-11 “E” CHANGE OR LATER, TC 60-11 “D” CHANGE OR LATER OR THE TC 82-11 “A” CHANGE OR LATER, APPROPRIATE TO THE TURBOCHARGER MODEL. REPLACEMENT OF THE SUBJECT UNIT SHOULD BE MADE AT ANY TIME THE CRACK IS OBSERVED TO EXTEND BEYOND ¾ INCH IN LENGTH IN TYPE A CRACKS AND OVER 2 INCHES IN TYPE B CRACKS. (SEE SKETCHES BELOW)

CAUTION NOT MISINTERPRET THE PARTING LINE OF THE CASTING IN THIS AREA TO BE A CRACK. DO

EXHAUST GAS INLET

POSSIBLE CRACKS IN THEIS AREA ALLOWABLE TO ¾ INCH.

2600 EAST WARDLOW ROAD P.O. BOX 207 / LONG BEACH, CALIFORNIA 90801 / (213) 426-0346

PAGE 2 OF 2

POSSIBLE CRACKS IN THIS AREA ALLOWABLE TO 2 INCHES

VIEW OF TURBINE HOUSING WITH TURBO CENTER SECTION REMOVED.

ENLARGED VIEW OF CRACKED AREA TYPE B

IT IS RECOMMENDED TO REPORT THE INSPECTION FINDINGS BY COMPLETING THE MALFUNCTION OR DEFECT REPORT, FAA FORM 8330-2, AND TO SUBMIT IT TO THE LOCAL FAA GENERAL AVIATION DISTRICT OFFICE.

2600 EAST WARDLOW ROAD P.O. BOX 207 / LONG BEACH, CALIFORNIA 90801 / (213) 426-0346

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-4 FAA-DER Approved

12 March 1976 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

INSTALLATION INSTRUCTIONS FOR PROPELLER SHAFT OR CRANKSHAFT OIL SEALS

MODELS AFFECTED:

ALL MODELS

Gentlemen: The following procedures should be followed to eliminate propeller shaft or crankshaft oil leaks on the subject model engines: I.

II.

STRETCH OVER TYPE A.

Remove propeller and oil seal assembly.

B.

Clean surfaces thoroughly making certain that no foreign material remains on the shaft or in the seal counterbore. Wash seal area with solvent.

C.

Inspect the propeller mounting flange carefully to insure that no nicks, burrs or sharp edges are present which could damage the oil seal surface during installation.

D.

Remove any plating in the 1" area pointed out in Figure 1 by holding a piece of very fine emery cloth around the shaft and rotating the engine with the starter. This should blend the finish uniformly without leaving any lines (scratches). Top spark plugs should be removed to allow smooth, even rotation during the polishing operation.

E.

Apply helix as indicated in Figure 1 using a strip of 180 grit emery cloth approximately 1/2" wide. Do approximately 1/4 of the surface indicated in Figure 1 at a time, stroking the cloth outward toward the propeller flange in the direction of rotation (CCW towards you using maximum hand pressure) which should result in a 30 degree pattern similar to that illustrated in Figure 1. After doing the first portion, engage the starter just long enough so that the next portion is visible. Apply the same pattern again and continue completely around the crank or prop shaft in this manner.

F.

Repeat cleaning operation.

INSTALLATION A.

Use only oil seal assembly P/N 641250 which consists of an oil seal, retainer ring and spring P/N 641306. Check the spring length. It should be 7 53/64" +0 in length. See Figure 2. -1/32”

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

12 March 1976

-2-

M76-4

B.

Remove spring and reinforcing ring from new oil seal. Unhook the spring ends using an unwinding motion. Wrap spring around shaft in seal area, turn spring ends in unwinding direction, then join and allow one end to wind into the other end.

C.

Oil propeller flange, shaft and I.D. of seal liberally with SAE 50 engine oil. The seal is to be stretched over the propeller mounting flange. DO NOT SPLIT THE SEAL.

D.

Squeeze oil seal until egg-shaped and start seal over bottom of propeller flange, groove side up. Work seal carefully to prevent damage to lip, upward over flange. Placing a lightly oiled plastic bag over the prop flange will help protect the seal lip. Also, a special tool for stretching the seal over the prop flange is available from Borrough's Tool and Equipment Co., 2429 North Burdick St., Kalamazoo, Michigan.

E.

Install reinforcing ring, working O.D. of seal over ring to insure snug fit. Install spring in cavity in seal.

F.

Apply a thin coat of Permatex to O.D. of seal.

G.

USING THUMB PRESSURE, force seal into counterbore.

H.

After seal is in place, wipe oil from seal and shaft.

I.

Spray exposed portion, from which plating has been removed, with aluminum primer.

12 March 1976 -3III. SPLIT TYPE OIL SEALS - INSPECTION AND INSTRUCTIONS PRIOR TO SEAL INSTALLATION A.

M76-4

Follow same procedures as listed for stretch type oil seals except it is not necessary to remove the propeller. With the propeller installed, any removal of plating or blending of the 1" area referred to in I, Part D will have to be done around the shaft manually without engine rotation. NOTE:

On left hand rotating engines (LTSIO360E) the helix must be applied in the opposite direction as shown in Figure 1. Stroke the strip of emery cloth outward toward the flange in the direction of rotation...(CW toward you using maximum hand pressure.)

IV. INSTALLATION A.

Use applicable split type seal depending on engine model.

B.

Remove spring from oil seal assembly and unhook its ends. Coat the lip of the seal liberally with SAE 50 engine oil or a molyshield grease. Twist the seal and slide it over the crankshaft with the felt side toward the flange. (If the seal does not incorporate a felt, just place the seal on the shaft with its recessed side toward the rear.) Bring the ends of the seal back together. Wrap the spring around the crankshaft in the seal areas. Turn the spring ends in an unwinding direction then join and allow one end to wind into the other end. With hooked ends opposite the seal split, lift the spring into the seal recess. Work the remainder in by moving the fingers in both directions from the starting point. Make sure the spring is in the deepest part of the recess all around.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-5, Rev. 1 Supersedes M76-5 FAA-DER Approved

25 May 1976 TO:

Distributors, Dealers, Aircraft Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

REMOTE MOUNTED OIL COOLERS

MODELS AFFECTED:

All Teledyne Continental Motors' Models Where Applicable

Gentlemen: The majority of Teledyne Continental Motors produced aircraft engines are equipped with engine mounted oil coolers; however, new aircraft installations are being designed utilizing remote mounted oil coolers. Trapped air in the oil system can cause oil aeration which in turn can cause poor valve train dynamics that could result in internal engine damage. At the factory, all engines are pre-oiled with a pressurized bowser system whereby oil aeration is an impossibility. If a remote mounted oil cooler system is utilized, then any time the oil cooler or the oil lines are drained or removed for flushing or replacement, the following procedure is recommended to make certain any trapped air is eliminated from the system: 1.

2.

Pre-Start Procedures: a.

Remove the lower spark plugs from the cylinders.

b.

With the mixture in idle cut-off and the magneto switches on "off", rotate the engine with the starter.

c.

Rotate the engine for a 30-second period. Stop for at least one (1) minute. Repeat this procedure at least four (4) times until the oil pressure gauge indicates a stabilized oil pressure reading during rotation. Continue to rotate the engine for at least ten (10) seconds after the oil pressure has stabilized.

d.

Reinstall the lower spark plugs.

Start engine and run at 900-1000 RPM for four to five minutes. Shut engine down, check the oil quantity and add oil as necessary to bring to full mark and safety wire the oil filter.

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-7 FAA-DER Approved

25 March 1976 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

P/N 634021 ALTERNATOR FACE DRIVE GEAR LOCKPLATES

MODELS AND SERIAL NUMBERS AFFECTED: MODEL

NEW

REMANUFACTURED

OVERHAULED

IO520M

560355 thru 560743

None

None

IO520BA

551743 thru 551999 562000 thru 562211

122414 thru 122417 122423 thru 122439 122441 thru 122446 122449 122451 thru 122455

901004 901142

IO520C

555942 thru 555999 561000 thru 561237

172647, 172658, 172659 172661, 172662, 172664 172666, 172667 thru 172719, 172723 thru 172735, 172738 thru 172741, 172743 thru 172745

901045 901046

TSIO520B

500216 thru 500349

176196, 176198, 176204 thru 176206, 76209, 176210, 176213

None

TSIO520J

503352 thru 503521

218549 thru 218550 218553 thru 218555 218556 thru 218560 218578 thru 218583

901011

TSIO520K

504284 thru 504306

224509 thru 224516

None

TSIO520L

508029 thru 508129

None

None

TSIO520E

502645 thru 502896

182495, 182508, 182509, 182535, 182536, 182558, 182559, 182560 thru 182606, 182608 thru 182609

901006 901123 901136

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

25 March 1976

M76-7

Page 2

MODEL

NEW

REMANUFACTURED

OVERHAULED

GTSIO520C

602009 thru 602011

155380, 155383, 155390 155399, 155400 thru 155403

None

GTSIO520D

601021 thru 601029 601031 thru 601032

219200, 219210 thru 219222, 219225 thru 219229

None

GTSIO520H

600445, 600693 thru 600702, 600704 thru 600732, 600734 thru 600805, 600807 thru 600812, 600814 thru 600875

218142 thru 218157 218159 thru 218189 218191

None

Gentlemen:

There have been instances of lockplate breakage reported from the field on the above enigine models. Both our testing experience and a close survey pf engines in the field indicate that if the lockplate cracks and /or breaks, it will so so prior to the first 100 hours of engine operation. Also, if either does occur, it has no effect on the integrity of the cap screws. Inasmuch as this condition could exist on any of the engine model serial numbers listed above, it is recommended that the following inspection be performed at the next 100-hour inspection or when the alternator is removed for any reason: (On some engines, the alternator drive gear cap screws may be secured with lockwire. In this case, the following instructions can be ignored and the alternator can be reinstalled.) 1. Remove the alternator from the crankcase. 2. Rotate the crankshaft so that one lockplate is visible through the port. 3. Inspect to see if the lockplate is visible through the port. 4. If it is found to be cracked or broken adjacent to either of the two attaching screws, the portion between the attaching screws should be removed without disturbing the cap screws. 5. Verify that the cap screws are tight. 6. Rotate the crankshaft until the other lockplate is visible and proceed as in 4 and 5. 7. Replace the alternator.

(continued)

25 March 1976

NOTE:

M76-7

Page 3

If the inspection reveals any portion of the lockplate between the cap screws has completely broken away and dropped into the oil sump, proceed to locate and remove it by using either of the two following methods: 1. Insert a magnet on a fairly long flexible shaft through the alternator port down along the bottom of the sump. Sweep this area with the magnet until it picks up the broken piece and remove it. OR 1. Locate the broken piece by applying the largest surface area of a thin section of a ceramic (ferrite) permanent magnet directly to the outside of the sump. 2. Sweep the bottom of the sump slowly until the magnet locates the section of plate. When it does, it will clamp itself to the sump. Because of clearance problems on some installations, it may be necessary to attach the magnet with one layer of masking tape to the end of something flexible such as the looped end of a wire coat hangar. 3. Slowly move the magnet towards wither the crankcase alternator port or the oil drain hole. This procedure will drag the broken section to either of these points. 4. Remove the piece.

NOTE:

An ordinary steel magnet will generally not work because its weight will not allow it to stick to the outside of the sump. The ceramic magnet referred to is the type used in radio speakers. It should be rectangular in shape and approximately 1-7/8” long, 7/8”wide, and 3/8” thick. These can be procured from Edmund Scientific Company, located in Barrington, New Jersey (phone 609-547-3488). A similar size piece of radio speaker magnet will work as well.

A labor allowance of 1.5 manhours at posted shop rates will be allowed to complete the above inspection procedure. The claim should be submitted through our distributor organization on our standard claim form.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M76-8 FAA-DER Approved

13 April 1976

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

INTAKE VALVE CHANGE

MODELS AFFECTED:

C75, C85, C90, O-200, O-300, AND GO-300

Gentlemen: Engine testing, both in the laboratory and in the field, has shown that with the use of higher leaded fuels, service life of the intake valves can be significantly improved by introducing the following changes: 1.

New valve and seat angle for improved sealing.

2.

New valve seat material to minimize erosion.

P/N 641792, Intake Valve, and P/N 641793, Intake Valve Seat Insert, are being incorporated into all engines manufactured by Teledyne Continental Motors. The valves may now be procured through TCM distributors. The valve seat inserts will be installed in production engines beginning approximately May 19, 1976, and will be available from distributors for installation in cylinders approximately May 28, 1976. It is permissible to install the new valve on the old 45°seat insert after first grinding it to the correct angle as shown in Figure 1. However, installation of the new insert (P/N 641793) is highly desirable and both the new intake valves which supersede P/N 531608 and the new inserts which supersede P/N 3912, should be installed at the next top overhaul or major overhaul, whichever comes first. Initially, some 531608 valves were reworked to the 30°angle face configuration and were identified by etching the letter "M" after the part number either on the top or the underside of the valve head. This was done as an interim measure and such rework is definitely not authorized in the field. These valves must also be replaced at the next top or major overhaul, whichever comes first. The 30° intake valves were first installed at TCM on the following model and serial numbers. MODEL

NEW S/N

REMF'D S/N

OVERHAULED S/N

O200A O300A O300C O300D C90

254178*

6645-R 16092-R 23223-R 25560-R

901140-0 901146-0

901169-0

(continued)

 TELEDYNE INDUSTRIES, INC. 1976

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

13 April 1976

M76-8

Page 2

*NOTE:.......It is possible that a few O-200-A new engines prior to S/N 254178 were built incorporating 30° face intake valves. Therefore, when servicing any cylinders, check the cylinder part number which is stamped on the base flange before installing the valves. If you install these new intake valves in cylinders which incorporated valve P/N 531608 (see cylinder part numbers listed under - "old") it is necessary to regrind the intake valve seat insert to 60°, +30' -0', to the valve guide axis to obtain a 0.060" (approx.) seat width. The seat O.D. must be kept within the O.D. of the valve face as per Figure 1. If reducing the O.D. is required, it can be accomplished with a second grind of 75°, +/- 1°as indicated. It should be pointed out here that this valve design is commonly referred to as a "30° angle valve"; however, the standard design practice is to dimension the valve face angle off of the valve stem centerline and the valve seat insert off of the valve guide centerline; thus, the 60° shown in the sketch. Reidentify the cylinder assemblies by "X-ing" out the old part number on the base flange and restamping as follows: "OLD"

"NEW"

P/N A50222

becomes

P/N 641916

P/N 639702

becomes

P/N 641916

P/N 626710

becomes

P/N 641917

P/N 639703

becomes

P/N 641917

Make an entry in the engine log book that this Service Bulletin has been complied with.

FIGURE 1.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M77-19 FAA-DER Approved

August 12, 1977 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

Intake and Exhaust Rocker Arm Identification and Application

MODELS AFFECTED:

C-75, C-85, C-90, C-125, C-145, O-200 and O-300 Series Engines

Gentlemen: It has been brought to the attention of Teledyne Continental Motors Aircraft Service Department that on occasion intake and exhaust rocker arms are not being installed in their proper respective positions during servicing of the above mentioned model engines. We wish to point out that intake rocker arms, Teledyne Continental Motors part number 639614, do not have an oil orifice drilled in the valve stem end of the rocker arm as does the exhaust rocker arm, Teledyne Continental Motors part number 639615. The oil orifice as evident in Figure 1 provides needed lubrication to the exhaust valve stem during engine operation. Caution notes regarding this subject should be placed in your Teledyne Continental Motors Overhaul Manuals Form Number X-30013 dated July, 1970, or earlier and Form Number X-30010 dated April, 1973 or earlier.

FIGURE 1 Teledyne Continental Motors part number 639615 exhaust rocker arm.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M77-3 FAA-DER Approved

11 January 1977 TO:

Distributors , Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines

SUBJECT:

USE OF ALTERNATE AVIATION GRADE FUELS IN ENGINES ORIGINALLY CERTIFICATED ON 80/87, 91/96, AND 100/130 GRADE FUELS

Gentlemen: Numerous customer inquiries have been received regarding the use of alternate fuels in TCM engines. The limited availability of 80/87 octane fuel has demanded increased utilization of higher grade fuels. The American Society for Testing and Materials (ASTM) has recently revised ASTM D910-70, the Standard Specification for Aviation Fuels. The new specification, D910-75, re-identifies the three current grades of aviation fuel as Grade 80, Grade 100, and Grade 100LL (low lead). The three grades replace those fuels commonly known as Grade 80/87 and Grade 100/130. Although Grade 100 and 100LL have the same anti-knock qualities, they differ in the maximum allowable tetraethyl lead content. The following table provides a comparison of the current and previous fuel specifications: SPECIFICATIONS ASTM D910-70 GRADE

ASTM D910-75

MAX TEL ML/US GAL

COLOR

GRADE

0.50

Red

80/87

0.50

Red

100LL

2.00

Blue

100

3.00

Green

100/130

3.00

Green

115/145

4.60

Purple

Red

80

91/96

2.00

Blue

Discontinued

Green

115/145

4.60

Purple

MAX.TEL ML/US GAL

GRADE

0.50

3.00

MAX TEL ML/US GAL

COLOR

80/87

100/130

MIL-G-5572E AMEND. 3 COLOR

The amount of tetraethyl lead in these higher grade fuels has increased the lead build up and fouling of spark plugs along with valve erosion incidents reported on some lower compression engines.

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Page 2

11 January 1977

M77-3

Those TCM engines most affected include the A65, A75, C75, C85, C90, C125, C145, O200, O300 and GO300 series. The following list of replacement components, by engine series, improves engine reliability when operating on the higher grade alternate fuels. Refer to Service Bulletin M76-8. ENGINE MODEL A65 and A75

GO-300

C75,C85,C90,O-200 O-300,C-125,C-145

COMPONENT

PART NUMBER

Intake Valve

639661

Exhaust Valve

639662

Exhaust Valve

631639

Intake Valve

641792

Intake Valve Seat

641793

Intake Valve

641792

Intake Valve Seat

641793

The valves and valve seat inserts installed in TCM engines E-165, E-185, E-225, O-470, IO-470-J and IO-470-K series engines are compatible with higher grade fuels. These engines were originally certificated on 80/87 octane fuel; however, field service history indicates that operation on Grade 100LL does not adversely affect intake or exhaust valve longevity. SPARK PLUG LEAD FOULING Spark plug lead fouling increases when higher leaded fuels are used in engines originally certificated on 80/87 octane fuel. Such fouling can be reduced by more frequent spark plug cleaning and spark plug rotation. Fine wire spark plugs that are FAA approved for use in those TCM engines listed may further alleviate fouling problems. In any case, the rotation of plugs every 50 hours of operation and cleaning/rotation every 100 hours is recommended. A ground run at 800 to 1000 RPM of 60 to 90 seconds duration just prior to shutdown will allow temperature stabilization and burnoff of deposits accumulated during letdown and taxiing. Mixture cutoff should be accomplished at this RPM without returning to idle. EXHAUST VALVE STICKING Exhaust valve sticking can result from lead salt (sulfated ash) accumulation in the lubricating oil. It is recommended that regular 50 hour oil changes be implemented to reduce such accumulation. A few stuck exhaust valves have been reported where examination of the cylinder assembly revealed an exhaust leak between the exhaust elbow flange and the exhaust port face. This condition created localized cylinder head overheating and subsequent exhaust valve and guide distress. The exhaust system should be inspected every 100 hours and leaks corrected prior to continued engine operational service.

11 January 1977

Page 3

M77-3

RECOMMENDED MIXTURE LEANING PROCEDURES The TCM Engine Operator's Manual or the Aircraft Manufacturer's Owners Manual should be consulted for the proper leaning procedures applicable to each model engine. Leaning as specified will reduce spark plug fouling. The following chart identifies the fuels considered acceptable for use in TCM engines provided the foregoing recommendations are implemented. SERIES

SPECIFIED FUEL

ALTERNATE FUELS

A65, A75, C75, C85, C90, C125 & C145

80/87

+100LL

E165, E185 & E225

80/87

+100LL

O-200, O-300, GO-300

80/87

+100LL

IO-360, TSIO-360 LTSIO-360

100/130

100, 100LL, 115/145

IO-346 O-470-4, -11, -13, -15; O-470-A, F, J, K, L, R, & S

91/96 80/87

100, 100LL, 115/145 +100LL

O470-B, G, H, M, N, & P O470-T, & U

91/96 100LL

100, 100LL, 115/145 100, 115/145

LIO-470, IO-470-A, C, G, P&T

91/96

100, 100LL, 115/145

IO470-D, E, F, H, L, M, N, S, U, V & VO; GIO470; TSIO470

100/130

100, 100LL, 115/145

IO520, TSIO520, GTSIO520, Tiara 6-285, 6-320 & T6-320

100/130

100, 100LL, 115/145

NOTE:

+ The use of Grade 100LL is highly recommended when the specified fuel is not available; however, Grade 100 may be used for limited operation when Grade 80 or 100LL is not available.

All TCM engines which were certificated on 91/96 octane or grade 100/130 aviation gasoline will operate satisfactorily on Grade 100LL or military Grade 115/145. It is recommended that Grade 100LL be used in these engines because of the reduction in combustion chamber deposits realized with the lower TEL content.

11 January 1977

Page 4

M77-3

USE OF AUTOMOTIVE FUEL IN TCM AIRCRAFT ENGINES TCM does not recommend or authorize the use of automotive fuels in any of their aircraft engines. The engine warranty and pro rata policy will be voided if such fuels are utilized. Fuels must conform to ASTM-D910 or MIL-G-5572E, if satisfactory engine service life is anticipated. Automotive fuels can contain additives that act as corrosive agents, formulate gum deposits and, therefore, increase combustion chamber deposits. Continued operation on automotive fuel can lead to detonation, pre-ignition and sticking or eroded valves. The vapor pressure of automotive fuels exceeds that allowable for aviation fuels. This increased vapor pressure increases the tendency to vapor lock at higher altitudes. A vapor lock condition can cause complete power loss. The use of any fuel that does not conform to the above specifications may cause cylinder assembly, valve, piston and/or piston ring damage/failure.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M77-9 FAA-DER Approved

16 March 1977 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines

SUBJECT:

THRU-BOLT-CHANGE

MODELS AFFECTED:

IO-TSIO-LTSIO-360, IO-346, IO-TSIO-520 and GTSIO-520 Series Engines

Gentlemen: Teledyne Continental Motors has recently incorporated a product improvement change to crankcase thru-bolts installed in the above mentioned engines. The new thru bolts incorporate two (2) "O" ring seals on the center dowel section to prevent external oil leakage. Thru bolts of the new design can be installed at the next top or major engine overhaul period or whenever a persistent oil leak develops in the thru bolt area. Crankcase modification consisting of chamfering of the thru bolt dowel bores must be accomplished prior to thru bolt installation. Tools to perform the chamfering operation are available through: Borroughs Tool and Equipment Corporation 2429 N. Burdick Street Kalamazoo, Michigan 49007 Tool Part Number 8065 8064

Diameter Thru Bolt .500 .4375

Page 1

 TELEDYNE INDUSTRIES, INC. 1977

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

New

Old

Nomenclature

Inches Diameter

641930

539050

Thru Bolt

.500

641931

634504

Thru Bolt

.500

641941-1

641546-1

Thru Bolt

.500

641944

531205

Thru Bolt

.4375

642041

635934

Thru Bolt

.4375

NOTE- All new thru bolts utilize 2 each "O" ring seals part number MS29513-010. Refer to the appropriate Overhaul Manual and Service Bulletin M75-3 for specific thru bolt torque applications. Refer to the appropriate parts catalog for specific thru bolt part number and length required.

Page 2

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M78-16 FAA-DER APPROVED

29 November 1978 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

NUMBER TWO CYLINDER INTAKE ELBOW TUBE, TCM PART NO. 629138

MODELS AFFECTED:

TSIO-520-N, Spec 5, 6 and 8

Gentlemen: An improved cylinder intake elbow tube has been incorporated to TSIO520N, Spec 5, 6, and 8 engines to provide an expanded clamping interface with the flexible induction elbow. For serial number effectivity of engines incorporating the 642590 intake elbow tube, refer to TCM Service Bulletin M78-5 Revision 3. Teledyne Continental Motors part number 642590 is now available through your local Teledyne Continental Motors distributor.

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M78-2 FAA-DER Approved

January 10, 1978 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

TURBOCHARGER OIL SUPPLY LINE AND FITTING CHANGE: TCM SERVICE KIT EQ6536

MODELS AFFECTED:

TSIO/LTSIO-360-E Engines as Installed in Piper PA34-200T Seneca II Aircraft

Gentlemen: The Teledyne Continental Motors Aircraft Service Department has received reports of "low" oil pressure indications on older Seneca II aircraft. In most instances investigation reveals the engines to be operating normally. We wish to advise that it is not unusual and is quite acceptable for operators to see cruise (2300-2575 RPM) oil pressures of 30 to 40 psi at oil temperatures of 180° F to 240° F. Reports of low oil pressure indications (below 30 psi at 2300-2575 RPM) should be verified and investigated starting with a remote pressure gauge connected at the turbocharger oil supply line tee fitting at the same position the cockpit oil pressure gauge line is attached. NOTE: Minimum idle oil pressure is 10 psig. TSIO360E and LTSIO360E engines currently in production incorporate a larger diameter turbocharger oil supply line and fittings, a single high load oil pressure relief valve spring, and an improved (low pressure drop) oil cooler Teledyne Continental Motors part number 642063. Teledyne Continental Motors Service Kit EQ6536 as illustrated on Page 2 (Press F7 to see Page 2) provides the necessary component parts (less oil cooler) and instructions for those operators requesting installation of subject parts on early production TSIO360E and LTSIO360E engines. An average cockpit oil pressure indication increase of 10 psi, in the cruise RPM ranges, is normally seen after installation of this kit. Installation of Teledyne Continental Motors part number 642063 oil cooler is recommended whenever service replacement of the original cooler becomes necessary. Inspection for prior installation of the spring and hose assembly should always be conducted before ordering the kit from your local Teledyne Continental Motors Distributor. CAUTION: Cruise oil pressures below 30 psi are not normal and should be thoroughly investigated prior to kit installation.

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

January 10. 1978

Page Two

INSTRUCTION DRAWING EQ6536 OIL SUPPLY LINE AND FITTING – TURBO TO CRANKCASE SEQUENCE OF INSTALLATION 1) Remove MS20822-4 90° Elbow from CRKC, 635218-4-36.00 Hose Assy, MS21919G12 Clamp and 641961 Check Valve. 2) Install MS20822-6-2 90° Elbow in CRKC, 635218-6-36.00 Hose Assy, MS21919G16 Clamp and 642211 Check Valve. 3) Remove 635002 and 539619 Oil Pressure Relief Springs. 4) Install 627548 Oil Pressure Relief Spring.

M78-2

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M78-3 Supersedes M70-18, Rev. 3 FAA-DER Approved

January 11, 1978 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

GOVERNOR OIL TRANSFER COLLAR SLEEVES, RETAINING CLIPS AND CLEARANCES

MODELS AFFECTED:

O-470, IO-470, TSIO-470, IO-520 and TSIO-520 Engines which incorporate Oil Transfer Collar Assembly TCM Part Number 626739

Gentlemen: The Teledyne Continental Motors Aircraft Service Department is pleased to announce the availability of an improved governor oil transfer sleeve TCM part number 642249 to be used with two (2) each MS9021-011 "O" rings (as shown in Figure 1) in all of the above mentioned model engines which incorporate TCM part number 626739 governor oil transfer collar assembly. These parts replace transfer sleeve part number 626890 and "O" ring part number AN123695. Installation of the new sleeve and "O" ring assembly is recommended at the next overhaul period to reduce the possibility of governor oil leakage between the crankcase and transfer collar assembly.

FIGURE 1 On those engines which incorporate the flat governor oil transfer clip, it is recommended that TCM part number 642250 clip be used in place of the earlier clip TCM part number 637678. Both flat clips are similar in overall dimensions except for thickness. TCM part number 642250 clip is .0269" to .0329" thick. TCM part number 637678 clip is .036" to .040" thick.

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

January 11, 1978

Page 2

M78-3

CAUTION: Early design crankcases which incorporate the 90 degree transfer collar spring clip TCM part number 626900 as shown in Figure 2 must continue to use that clip with the following caution: If the transfer collar spring clip is assembled to the crankcase in an excessively raised position, it can cause loading of the transfer collar into the crankshaft resulting in collar scoring and loss of governor control. To provide a means of assuring flatness of this clip to the crankcase at assembly, inspect and maintain the tolerance as shown in Figure 2. If the required tolerance cannot be attained by tapping the clip with a plastic hammer, discard the clip and select another.

TO PROVIDE MEANS OF ASSURING FLATNESS OF CLIP TO CRANKCASE AT ASSEMBLY ALL ENGINES USING SPRING CLIP TCM P.N626990 MUST BE ASSEMBLED AND INSPECED AS SHOWN.

SECTION A-A CRANKCASE 1-3-5 SIDE

TOP OF CLIP (626990) MUST BE FLAT WITHIN .002 T.I.R. WITH PARTING LINE SURFACE OF CRANKCASE FIGURE 2

Care must also be taken in assembling the collar to the crankshaft because of the close running fit involved. Pre-lubricate the collar and adjacent portion of the crankshaft liberally with grade 30 Aviation Lubricating Oil during assembly. Tighten nuts alternately in 20" lbs. increments to 75-85" lbs.

January 11, 1978

M78-3

Page 3

It should rotate freely as any binding or loading can result in "localized frictional heating and pickup" leading to more serious consequences. The collar to crankshaft clearances are as follows: SERVICE

NEW PARTS

LIMIT

MIN.

MAX.

.0018

.0006L

.0013L

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M78-5 Rev.3 Supersedes M78-5 Rev. 2 FAA-DER Approved

23 October 1978

TO:

Teledyne Continental Motors Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FLEXIBLE ELBOW TCM PART NUMBER 635930

MODELS AFFECTED:

TSIO-520-J and TSIO-520-N Series Engines as Applicable

Gentlemen: We have received reports of TCM part number 635930 flexible elbows having partially or totally separated from the intake manifold elbows at number 1 and/or number 2 cylinder locations on the above mentioned engine models. In addition, regular inspection of the flexible elbows occasionally reveals cracks, abraded areas or other damage. We must emphasize the need for inspecting the flexible elbows at 100 hour intervals for cracks or abrasions extending through the outer ply and for security and proper positioning of the clamps at both ends. Therefore, within the next 25 hours of operation and at each 100 hour time in service interval thereafter, perform the following inspection of each flexible elbow TCM part number 635930. Conduct an external inspection of the flexible elbows (2 each per engine). Inspect for cracks, abrasions, or other signs of distress which penetrate through the outer material ply. Refer to Figure 1 for critical inspection points. If cracks, abrasions, or other signs of distress are noted, replace the flexible elbow(s). All parts must be thoroughly clean and free from oil prior to installation. Install the flexible elbows with the ends extending beyond the intercooler neck bead and the intake elbow bead 5/8" minimum 3/4 maximum. Position clamps so as not to interfere with any baffles or other surrounding structure and assure they do not extend over or beyond the end of the flexible ducts. Cessna clamps part number B35A-21P, U84-260-SH and U84-270-SH are to be torqued 30 to 35 inch pounds. See Figure 2. Re-inspect the flexible elbows and check clamp torque at each 100 hour time in service interval. If no cracks, abrasions, or other signs of distress are noted, inspect the flexible elbow ends for proper engagement over the intake elbow and intercooler neck. See Figure 1. Inspect clamps for interference with baffles or other surrounding structure and assure they do not extend over or beyond the end of the flexible ducts. Check the clamps for security. Cessna clamps part number B35A-21P, U84-260-SH and U84-270-SH are to be torqued 30 to 35 inch pounds. See Figure 2. Re-inspect the flexible elbows and check clamp torque at each 100 hour time in service interval. Replacement elbows, TCM part number 635930, are available through your local TCM distributor.

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

23 October 1978

Page 2

INSPECT OUTER PERIMETER OF FLEXIBLE ELBOW AT THESE POINTS FOR CRACKS, ABRASIONS OR OTHER DETERIORATION EXTENDING THROUGH OUTER PLY.

FIGURE 1

FIGURE 2

M78-3 Rev. 3

23 October 1978

Page 3

M78-3 Rev. 3

FIGURE 3 A new intake elbow tube, P/N 642590, is now available to replace intake elbow tube, P/N 629138, on #2 cylinder only. (See Figure 3) If this intake elbow tube is installed, the repetitive inspections outlined in this bulletin are no longer necessary. The new intake elbow tube incorporates an extended runner. This improvement will provide a wider clamping area to assure full clamp seating similar to the condition occurring on the #1 cylinder intake elbow tube which has not reported to have been a problem when properly installed. The replacement intake elbow tubes, TCM P/N 642590, are now available through your local TCM distributor.

23 October 1978

Page 4

M78-3 Rev. 3

The new intake elbow tube, part number 642590, has been installed on the following new engines at Teledyne Continental Motors: TSIO520J, Serial Numbers 503598, 503604 and on. TSIO520N, Serial Numbers 514272 - 514275, 514277 - 514285, 514303, 514313 - 514318, 514327, 514330 - 514345, 514347 - 514350, 514352 - 514371, 514373 - 514424, 514435 514447, 514458 - 514470, 514487 - 514504, 514523 - 514540, 514543 and on. The new intake elbow tube, part number 642590, has been installed on rebuilt engines at Teledyne Continental Motors beginning with the following serial numbers: TSIO520J, Serial Number 21874 and on. TSIO520N, Serial Number 228091 and on.

CONTINENTAL AIRCRAFT ENGINE

M78-6 Supersedes M71-17 and M71-17 Supplement FAA-DER APPROVED

service bulletin March 3, 1978 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

REMOVAL AND RE-INSTALLATION OF SPECIAL ROSAN EXHAUST PORT STUDS

MODELS AFFECTED:

6-285, 6-320, TSIO-520, GTSIO-520, Series as Applicable

Gentlemen: Some of the models in the above mentioned engine series are equipped with cylinders which have a special Rosan ring-locked stud installed in the exhaust ports. These studs are either "size on size" or "step" type and require certain precautions be taken during removal to prevent cylinder head damage. Removal of "Size on Size" Studs The "size on size" captive lockring studs were designed with a small external diameter lockring to allow usage in locations where edge distance is a problem. The lockring is so small in diameter that the use of a typical Rosan "SM" or "BT" series milling tool is impractical and could cause unwanted removal of cylinder head material in the lockring area. Therefore, the following removal method is suggested: 1.

Cut the stud off approximately flush with the surface of the cylinder head.

2.

Center punch the remaining stud.

3.

Locate the noted drill (#1) directly over the center of the stud and drill into the stud to the depth noted.

4.

Center the second larger drill (#2) over the small hole and drill to the depth noted. This should cut the engagement between the stud serrations and the internal serrations of the lockring. BASIC

#1 REMOVAL DRILL

#2 REMOVAL DRILL

(INCHES)

(INCHES)

STUD NO.

DIAMETER

MIN. DEPTH

DIAMETER

(+.015) DEPTH

(.164 dia) SFC164

1/16 (.062)

.250

3/16 (.188)

.080

(.190 dia) SFC190

1/16 (.062)

.250

7/32 (.219)

.090

(.250 dia) SFC250

3/32 (.093)

.250

19/64 (.297)

.105

(.312 dia) SFC312

1/8 (.125)

.312

R

(.339)

.120

(.375 dia) SFC375

1/8 (.125)

.375

13/32 (.406)

.120

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

March 3, 1978 M78-6 Page 2 5. The remaining lockring will have a very thin wall. A sharp punch will easily break it away from the cylinder head.

6.

Drive an "ezy out" into the small hole in the stud and apply removal torque.

7.

Clean the hole.

Removal of "Step" Studs The "step" type captive lockring studs have a larger lockring than the "size on size" type and therefore can be removed any one of two ways. Method 1. Using the appropriate Rosan removal tool as pictured below, mill the lockring away to the appropriate depth and, by any suitable means, apply removal torque to the stud. The remaining portion of the lockring should lift out as the stud is being removed or can be broken away from the cylinder head using a sharp punch.

REMOVAL TOOL FIGURE 1

FIGURE 2 Method 2. Using the same procedure as for "size on size" stud removal, select the appropriate removal drill sizes with regard to the stud end dimension: Example: To remove a "step" stud with a .250" dia. nut end and a .312" dia. stud end use the appropriate removal drills for a .312" dia. "size on size" stud.

March 3, 1978 Stud Reinstallation

Page 3

M78-6

1.

With applicable wrench, install stud to depth shown. Note: Location of flange is important so that the lockring drive tool will not make contact with surface "A". Any impact or pressure on this surface may cause damage to threads in cylinder head resulting in a loose fit.

2.

With applicable drive tool install lockring to depth shown.

FIGURE 3 All special tools for installation and removal of Rosan Lockring Studs including tool kits and prices can be obtained from: Rosan, Inc., 2901 West Coast Highway, Newport Beach, California 92663, Phone (714/584-5533).

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M78-8

25 August 1978

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

IGNITION SYSTEM MAINTENANCE

MODELS AFFECTED:

L/TSIO-360-E, EB, and TSIO-360-F, FB Series Engines as Installed in Piper Turbo-Arrow and Seneca II Aircraft.

Gentlemen: The Aircraft Service Department is continuing to received reports of intermittent roughness during high altitude operation (above 12,000 feet) on these engines. In most instances, the problem(s) is determined to be an ignition system component(s) requiring routine maintenance. The Piper Service Manuals for the Seneca II and Turbo-Arrow Aircraft include the statement: "For operation above 12,000 feet more frequent ignition system maintenance is required". It is not uncommon to have to perform complete routine servicing at 100 hour intervals or less when the aircraft is being operated consistently at high altitude. We, at TCM, would like to point out some of the areas commonly overlooked during routine servicing of the ignition system and recommend that efforts be made to determine the cause of the problem(s) rather than immediately changing spark plugs or reducing plug gaps below minimum when occasional ignition system roughness occurs. The Spark Plug Manufacturer's Service Manual and the Bendix Electrical Components Division Master Service Manual should always be referred to for the particular details of each cleaning and servicing operation. Required items to check during troubleshooting and performance of routine ignition system maintenance are: 1) Spark Plugs a. Cleanliness should be equivalent of a new spark plug at both the firing and terminal barrel ends after servicing. The firing end should be cleaned using the proper vibrator cleaner or "Abrasive Blast" cleaner. The preferred method of cleaning the terminal well end is with the "Abrasive Blast" cleaner and the proper terminal well cleaner adapter. Terminal well cleaning is often overlooked and shows up as "terminal well flashover" during operation causing intermittent engine roughness.

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

January 11, 1978 M78-3 Page 2 b. Ceramic should not be chipped or cracked in the firing end or terminal well end.

c. Electrodes for wear beyond 50% of their original thickness. Electrodes gaps should be set at .016" for both fine wire and massive electrode plugs. A.015" go and .017" no go gauge should be used to check plug gaps. d. Threads for cleanliness and deterioration. Threads on the shell and shielding barrel should be cleaned with a wire hand brush or power driven brush with wire size not exceeding .005" diameter. e. After cleaning and visual inspection of spark plugs, test for satisfactory plug operation using an approved compression chamber test unit. The test pressure should be 135 psi at an electrode gap setting of .016". 2) Ignition Harness a. Using a High Tension Lead Tester, check ignition leads for high voltage leakage and resistance. b. Check sleeves and ferrules on spark plug end of harness for cleanliness and cracks. Terminal sleeves should be handled only with clean dry hands. Clean with a lint-free cloth moistened in methylethyl-ketone or clean unleaded gasoline. c. Check contact springs for corrosion or other signs of deterioration and replace as necessary. 3. Distributor Block and Cover Plate a. Check for signs of carbon tracking or arc-over to surrounding magneto structure. Check grommets for cleanliness and security. 4. Magneto Condition a. Check for internal cleanliness noting any signs of oil seal leakage. b. Check contact point gap .018" ± .006" and "E" gap 6° to 14°. Bendix Timing Kit 118150 should be used for this operation. Breaker points should always be inspected for signs of severe erosion or deterioration prior to checking point gap and "E" gap and replaced as required. 5. Magneto to Engine Timing Adjust magneto to engine timing to 20° BTC using the procedures in section 8 of the TCM Overhaul Manual publication number X-30030A. Please remember that timing marks for the LTSIO-360 are on the outer edge of the crankshaft propeller flange. If propeller device equipment is installed on this engine, a universal propeller tip timing disc can be used similar to that sold by Borroughs Tool and Equipment Corporation, Kalamazoo, Michigan. The preferred method of engine timing is to use the positive stop method of determining T.D.C. and the propeller tip timing disc. The Spark Plug Manufacturer's Service Manual is available through you local Spark Plug Distributor. The Bendix Master Service Manual is available through your local Bendix Electrical Components Distributor or from: Bendix Electrical Components Division Sidney, New York 13838

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M78-9 Supersedes M66-4 FAA-DER Approved

23 August 1978 TO: Distributors, Dealers, Aircraft Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. SUBJECT: CRANKCASE, CRANKSHAFT AND BEARING APPLICATIONS MODELS AFFECTED:

All O-470, IO-470, IO-520, TSIO-470 and TSIO-520 Engines Referenced in this Bulletin.

Over the years, there have been several changes to the crankcase, crankshaft and bearing combinations used with various engine models. The following charts have been compiled to assist the customer in identifying the proper combination for his engine. SPECIAL NOTE: ALTHOUGH THE STUDDING ASSEMBLY PART NUMBER ON THE PHASE 2 STYLE CRANKCASES REMAINS, IN MOST INSTANCES, THE SAME AS THE PHASE 1 STYLE, THE ACTUAL MACHINING OF THE CRANKCASE IS DIFFERENT. FOR THIS REASON, IT IS IMPERATIVE TO MAKE ABSOLUTELY CERTAIN WHICH CRANKCASE YOU ARE WORKING WITH. PHASE 1 Crankcases were machined for flanged type thrust bearings for O-470 and IO-470 engines. PHASE 2 Crankcases for above listed models are machined to accommodate four thrust washers at the front mains. In addition, the rear main bearing was moved back .060 because of new crankshaft on 0-470 and IO-470 engines as listed in Service Bulletin M74-12. Many of the new crankshafts have narrower rod bearings, smaller lightner holes and thicker cheeks. Because of the narrower crankpin bearings, it is necessary to use different connecting rods and rod bearings. PHASE 3 Main bearing journals have been narrowed, which required relocation of bearing tangs. Identification can be made by way of new casting part number CA642360 and CA642361. CAUTION: BECAUSE OF THE CHANGE IN THE NEWER CRANKSHAFT, YOU MUST BE CERTAIN THAT WHEN INSTALLING THIS CRANKSHAFT IN THE PHASE 1 STYLE CRANKCASE, YOU INSERT TWO PIECES OF SERVICE BEARING, PART NO. 633334, AT THE REAR MAIN CRANKCASE LOCATION.

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

23 August 1978

Page 2

M78-9

This bearing is for service use only. When installing the new crankshaft in an old Phase 1 style crankcase, simply substitute the 633334 bearings for the two rear main bearings listed. The different location of the tang in this bearing moves it back enough to allow proper installation of the crankshaft. After the crankshaft is installed, you must check for clearance between the forward side of the rear main bearing boss and the crankshaft cheek. This must be .020 to .030. Provide necessary clearance by burring if required. When installing either an old style crankshaft in a new style crankcase or a new style crankshaft in Phase 2 or 3 new style crankcase, there will be no clearance problem and you simply install the applicable thrust washers and bearings in new style crankcase and old style bearings per chart when using Phase 1 style crankcases. You will also note that on this chart we have listed Phase 1, 2, and 3 new style and old (optional) crankshafts, crankcases, applicable bearings and bearing sets. For information on connecting rods and rod bearings, please refer to Bulletin M74-12.

Page 3

23 August 1978

O-470 – Phase 3

Engine Model G F, J1, 8 J11, R14 J14 R3, 5, 7, 11, 15, 16 20, 23, 25, 37 R6 R13, 17, 35 R32 S1 S2 K1 K17 L1, 9, 10 L16 M22 M23, 26 U1, 3 U2, 4 G F F, J1, 8

O-470 – Phase 2

J11, R14 J14 R3, 5, 7, 11, 15, 16 20, 23, 25, 37

Crankcase Studding & Machining Assembly 642178 642183 642162 642191 642159

Crankshaft & Damper Assembly

Forward

633256

642270(2)

642164 642161 642163 642194 642194 642183 642162 642182 642162 642192 642193 642194 642195

633225

641213 626762 539734 641186 539500 641215 628239 641271

S1 S2

641212 632309 641435 640540 641185 641187 635635 641398 641373

B N

539501 629548

R6 R13, 17, 35 R32

Front Main Bearings Rear Full Length 642270(2)

633136(2)

M78-9 Thrust Washers At Front Main Bearings 637579(4)

Intermediate Main Bearings Standard Option

Rear Main Bearings Standard Option

Complete Bearing Sets

642720(4)

642720(2)

642720A1

637579(4)

642720(4)

642720(2)

633136A3

637579(4)

630464(4)

633219

641905

632256

530386(2)

630464(2)

633225

633136(2)

637579(4)

530386(4)

633227

633136(2)

637579(4)

630464(4)

537848(4)

630464(2)

537848(2)

530386(2)

537848(4)

630464(2)

630464A5

633136A1

537848(2)

633136A2

Page 4

23 August 1978 Engine Model P

O-470 – Phase 2 (cont.)

K1 K17, L16 L1, 9, 10 M22 M23, 26

O-470 – Phase 1

U1, 3 U2, 4

Crankcase Studding & Machining Assembly 641213 626762 641186 539500 641215 628239 641226 625193 641225 636433 641270 625168 641398 641373

A

537498

C

537498

E

539734

F

539500

J

539500

R

632309

B

539501

N

629548

G

626762

K

539500

L

625193

M

625168

P

626762

Crankshaft & Damper Assembly

Forward

633258

530386(2)

M78-9 Thrust Washers At Front Main Bearings

Intermediate Main Bearings Standard Option

Rear Main Bearings Standard Option

Complete Bearing Sets

637579(4)

630464(4)

630464(2)

630464A5

633136(2)

637579(4)

530386(4)

633136(2)

637579(4)

630464(4)

633136(2)

637579(4)

530386(4)

Front Main Bearings Rear Full Length 630464(2)

537848(4)

537848(2)

530386(2)

633136A1

633129

641905

537848(4)

630464(2)

537848(2)

530386(2)

633136A2

633136A1

37401A1 537920

537401(2)

530386(4)

539576

538879(2)

630464(4)

537848(4)

630464(2)

537848(2)

538879A1

630464(4)

537848(4)

630464(2)

538897(2)

627795A1

627576

530386(2)

626740(1) 626741(1)

627795(2) 537401(2)

530386(2)

530386(4)

530386(2)

537401A1

539665 538879(2) 627587

530386(2)

627795(2)

626740(1) 626741(1)

630464(4)

537848(4)

630464(2)

537848(2)

538879A1

630464(4)

537848(4)

630464(2)

538897(2)

627795A1

Page 5

23 August 1978

IO-470 – Phase 3

Engine Model D D42 E, S1, 3 F1 F3, 4, 5, 19 F7, 18, 23, 26 G M S2, 8 C J K L L H U V1, 2 V6, 8, 9, 10 D D42 E, S1, 3

IO-470 – Phase 2

F1 F3, 4, 5, 19 F7, 18, 23, 26 G M S2, 8 C

Crankcase Studding & Machining Assembly 642172 642196 642167 642173 642175 642174 642178 642166 642168 642178 642189 642178 642177 642176 642179 642169 642170 642171 541193 627490 641227 641192 628137 641191 627856 641195 629398 641194 632545 641213 628137 641197 628858 641210 636611 641213 626762

Crankshaft & Damper Assembly

Front Main Bearings Forward Rear Full Length

M78-9 Thrust Washers At Front Main Bearings

Intermediate Main Bearings Standard Option

Rear Main Bearings Standard Option

Complete Bearing Sets

630927

642720(2)

642720(2)

637579(4)

642720(4)

642720(2)

642720A1

530386(2)

630464(2)

637579(4)

630464(4)

630464(2)

630464A5

633258 633246 630886 630977 632195

630927

633258

530386(2)

630464(2)

637579(4)

630464(4)

537848 (4)

538897 (4)

IO-470-G Only

IO-470-G Only

537848(4)

630464(2)

538897(2)

630464A5

Page 6

23 August 1978 Engine Model J K L

IO-470 P Phase 2 (cont.)

L N1, 7, 10, 11

N3 N12 H

U1, 3 V1, 2 V6, 8, 9, 10

IO-470 – Phase 1

D

Crankcase Studding & Machining Assembly 641214 628509 641213 632285 641189 628500 641188 629300 641273 641072 633363A1 641274 641211 640881 641273 641072 633363A1 642276 641190 633170 641206 635006

M78-9 Thrust Washers At Front Main Bearings

Crankshaft & Damper Assembly

Forward

633246

530386(2)

630464(2)

637579(4)

633246

530386(2)

630464(2)

637579(4)

630464(4)

530386(2)

630464(2)

637579(4)

630464(4)

Front Main Bearings Rear Full Length

Intermediate Main Bearings Standard Option 630464(4)

537848(4) 537848(4)

Rear Main Bearings Standard Option 630464(2) 630464(2)

538848(2) 538848(2)

Complete Bearing Sets 630464A5 630464A5

630886

630932

630464(2)

630464A5

630977

632195

627490

E

628137

F

627586

G

628137

M

628858

S

628137

627530

537848(4)

538897(2)

626740(1)

C

626762

626784

J

628509

628358

K

632285

L

628500

628694

H

627816A2

627348

R

628137

629366

N

627816A2

629309

530386(2)

627795(2)

and 626741(1)

630464(4)

630464(2)

627795A1

537848(4)

538897(2)

537848(4)

538897(2)

Page 7

23 August 1978

TSIO-470 PHASE 2

Engine Model B B2, 3 C D

IO-520 – Phase 3

IO-70 – Phase 1

B B2, 3 C D A, D, F2, 3, 4, 5 7, 9, J, L D10, 15, F6, K E A, D, F2, 3, 4, 5 7, 9, J, L D10, 15, F6, K

IO-520 – Phase 2

E B, BA

BA12 C2, 3, 6

C5, 7

Crankcase Studding & Machining Assembly 642155 642190 642157 642157 641207 629254 641208 629288 641209 631977 641209 631977 631716 642186 642158 641200 631596 641199 634685 641201 635133 642088 641315 640471 630969 642089 641501 642090 641316 640472 631096 642091 641318 640474 638101

Crankshaft & Damper Assembly

628995

Front Main Bearings Forward Rear Full Length

M78-9 Thrust Washers At Front Main Bearings

Intermediate Main Bearings Standard Option

Rear Main Bearings Standard Option

Complete Bearing Sets

642720(2)

642720(2)

637579(4)

642720(4)

642720(2)

642720A1

530862(2)

630464(2)

637579(4)

630464(4)

630464(2)

630464A5

631716

642720(2)

642720(2)

637579(4)

642720(4)

642720(2)

642720A1

631716

630464(2)

630464(2)

637579(4)

630464(4)

630464(2)

630464A1

635439(2)

635439(2)

637579(4)

630464(4)

635439(2)

635439A2

632494

628995

632494

639243

633620

Page 8

23 August 1978 Crankcase Studding & Machining Assembly

TSIO-520 – Phase 2

TSIO-520 Phase 3

IO-520 – Phase 2 (cont.)

Engine Model M

642092 641202 641048

Crankshaft & Damper Assembly

Front Main Bearings Forward Rear Full Length

M78-9 Thrust Washers At Front Main Bearings

Intermediate Main Bearings Standard Option

Rear Main Bearings Standard Option

Complete Bearing Sets

633620

635439(2)

635439(2)

637579(4)

635439(4)

635439(2)

635439A2

631716

642720(2)

642720(2)

637579(4)

642720(4)

642720(2)

642720A1

631716

630464(2)

630464(2)

637579(4)

630464(4)

630464(2)

630464A1

635439(2)

635439(2)

637579(4)

635439(4)

635439(2)

635439A2

635439(2)

635439(2)

637579(4)

635439(2)

635439(2)

635439A1

635439(2)

635439(2)

637579(4)

635439(4)

635439(2)

635439A2

A, C, G, H 642165 M, P, R

642185

A, C, G, H

641198 632775 642035 642094 641317 640473 632778 642093 641314 640470 633249 642096 641326 640739

M, P, R B, E, J, K, N

D

L

633620

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M79-12 FAA-DER Approved

1 August 1979 TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

STARTER ADAPTER SHEAVE

MODELS AFFECTED:

TSIO520-E, EB, TSIO-520-J, JB and TSIO-520-K, KB

Gentlemen: The affected engine models, as installed in certain Cessna twin engine aircraft, may have an optional starter adapter with a power take-off provision and sheave to drive an air conditioning compressor. Early versions of the starter adapter utilized a keyed shaft (.4380 to .4375 in. diameter) to attach a double groove sheave, TCM P/N 637811. This system used two belts to drive the air conditioning compressor. Later, a change was made by Cessna to a single belt drive with a new single groove sheave supplied by Cessna, P.N 5690511-1 (refer to Cessna Service Letter ME73-19, "Operation Cool"). TCM has since made a revision to the starter adapter shaft which eliminated the key and increased the shaft diameter to .562 to .560 in. Therefore, the old small shaft hole diameter sheaves, both single (Cessna) and double grooves, (TCM) will no longer fit. A new double groove sheave is available, TCM P/N 641907 and should be ordered when the latest starter adapter, TCM P/N 642087A7, is ordered. This sheave may be used with the single belt drive air conditioning compressor if the groove closest to the starter adapter housing or forward groove is used. When installing sheave P/N 641907 to the larger non-keyed shaft use washer P/N MS 9320-15 and nut P/N AN-320-9. Torque nut to 700-850 in-lb. Do not over torque - change nut and/or washer if required to install cotter pin. If sheave P/N 641907 is currently installed with nut P/N MS9358-15, remove this nut and replace with washer P/N MS9320-15 and nut AN320-9 within the next 50 hours of operation. Torque nut to 700-850 in-lb per instructions outlined above.

TCM P/N 637811

CESSNA P/N 5690511-1

 TELEDYNE INDUSTRIES, INC. 1976

TCM P/N 641907

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M79-15 FAA-DER Approved

4 September 1979

TO:

Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FREON COMPRESSOR BRACKET ALIGNMENT

MODELS AFFECTED:

TSIO-360-E, EB, and F, FB

Gentlemen: On engines equipped with a freon compressor it is important that the brackets supporting the freon compressor be properly aligned. A fixture for this alignment procedure may be manufactured locally in accordance with the dimensions shown in Figure 1. When installing the air pump between the compressor mount brackets, a special tool is also required to tighten and torque the lower hold down nuts. Instructions for construction of this tool are shown in Figure 2. NOTE: If the engine is equipped with the large air pump required for aircraft de-ice equipment (Airborne model 441CC-7), it will be necessary to remove the rear freon compressor bracket prior to pump replacement. A complete freon compressor bracket alignment will be necessary upon replacement of this air pump. ALIGNMENT PROCEDURES 1)

Install forward freon compressor bracket in place on starter adapter. Insure special spacer washers are behind bracket as shown in Figure 3, Detail B & C. Tighten fasteners finger tight.

2)

Remove compressor driving pully from freon compressor drive assembly.

CAUTION: Left hand thread. 3)

Install rear freon compressor bracket with (4) 1/4 - 28 nuts. Tighten nuts finger tight. See Figure 3. Section A-A for arrangement of hardware.

4)

Install alignment fixture in freon compressor location. Secure with 3/8 inch bolts, washers and nuts two (2) places. Tighten nuts.

NOTE: 5)

Move brackets in position until all misalignment and strain is eliminated. Torque front freon compressor bracket nuts to 180-220 inch pounds. Torque rear freon compressor bracket to 90-110 inch pounds. Install lockwire as required.

 TELEDYNE INDUSTRIES, INC. 1979

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

4 September 1979

Page 2

M79-15

6)

Remove alignment fixture.

7)

Install air pump using tool as shown on Figure 2 for torquing lower hold down nuts. Torque to 90-110 inch pounds.

NOTE:

Large air pump, Airborne model number 441CC-7 used with de-ice equipment will have to be installed with the rear freon compressor bracket off. Proceed as directed in Steps 1-6, except only snugging down rear bracket. Remove rear freon compressor bracket, install air pump and torque pump to 90-110 inch pounds. Install rear freon compressor bracket and alignment fixture. Torque rear freon compressor bracket to 90-110 inch pounds. Secure with lockwire.

8)

Install freon compressor using eight (8) plain washers, four (4) lock-washers, four (4) 3/8-24 nuts and four (4) 3/8-24 bolts 1.50 inches long. Tighten hardware finger tight.

9)

Install freon compressor driving pulley with drive belt to drive shaft. Install bolt and washer. Torque to 600-650 inch pounds.

CAUTION:

Left hand threads.

10)

Tension belt to 45-50 pounds.

11)

Torque compressor 3/8-24 bolts to 240-260 inch pounds.

12)

After minimum of twenty (20) minutes and a maximum of two (2) hours run-in with compressor loaded, re-tension the drive belt to 45-50 pounds. Refer to the appropriate airframe manufacturer's service manual for specific details regarding the freon compressor installation and servicing.

4 September 1979

Page 3

FIGURE 1

FIGURE 2

M79-15

4 September 1979 Page 4

FIGURE 3

M79-15

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M79-4 Supersedes M75-23, Rev. 1 FAA-DER Approved

February 14, 1979 TO:

All Teledyne Continental Motors’ Aircraft Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FUEL INJECTION ADJUSTMENT AND FLIGHT TESTING PROCEDURES OF TIARA 6-285 SERIES ENGINE

Gentlemen: Engine performance and service life can be greatly improved through proper adjustment of the fuel injection system. Such full rich manual adjustments affect engine idle speed, idle unmetered fuel pump pressure, idle mixture setting, and the maximum/mid range metered fuel pressure and/or flow values. The following step by step adjustment and flight testing procedures should be followed: I

Ground Adjustment 1. Install a tee fitting in the fuel pump outlet line at the fuel pump outlet fitting or the metering unit inlet fitting. This tee fitting must have the same inside diameter as the fuel pump/metering unit line fittings. Connect a 0-50 psi calibrated gauge to the fitting using a line of sufficient length that the gauge can be monitored in the aircraft cockpit. 2. Start and warm up the engine until the cylinder head temperature and oil temperature are in the green arc. 3. Back out the idle speed adjustment screw A such that the engine speed can be controlled by the throttle and maintained at 500 RPM propeller/tachometer speed. 4. While maintaining 500 RPM, adjust the fuel pump idle pressure adjustment screw B as required until the external pressure gauge reads 6.0 to 7.5 psig. CW increases pressure and CCW decreases pressure. 5. Starting with 500 RPM full rich, check the idle mixture adjustment by slowly moving the mixture control lever toward the idle cut-off position. Optimum idle mixture adjustment exists if the propeller RPM increases 25 to 50 RPM prior to the engine running rough. Cylinder head and oil temperature should be in the upper half of the green arc when accomplishing this check. Move the mixture control lever back to the full rich position prior to the engine running rough. If adjustment is required, turn the idle mixture adjusting screw F CW to lean the mixture (decrease RPM rise) and CCW to enrichen the mixture (increase RPM rise).

 TELEDYNE INDUSTRIES, INC. 1978

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

February 14, 1979

M79-4 Page 2 Note: If the idle mixture required adjustment, the fuel pump idle pressure should be rechecked and readjusted if required. Cross check and readjust idle mixture and fuel pump idle pressure until both are within specified limits. Always set low unmetered fuel pressure and mixture prior to any adjustment of max power adjustments.

6. Turn the max power fuel pump adjustment screw D CW until it is bottomed, then turn it CCW 1/6th of a turn. 7. Now increase power to full throttle, maximum 2000 RPM with the mixture full rich. The aircraft fuel flow gauge should indicate within the limits illustrated on Curve No. 77041 for the manifold pressure observed during this maximum power check. Example:

29 Inches MAP Fuel Flow Min. 25.4 gph Fuel Flow Max. 26.4 gph

8. If adjustment is required, turn the aneroid adjustment screw E CCW to increase fuel flow and CW to decrease it. Note: If the maximum specified fuel flow cannot be obtained using the aneroid adjustment screw E, the fuel pump return line swivel tee fitting P/N 639111 (red color identification) should be replaced with P/N 642756 (blue color identification). This fitting has a smaller fuel return orifice, therefore, more fuel down stream. After replacement of fitting, readjust max fuel flow. 9. After the maximum power fuel flow has been adjusted, check and assure that the idle speed, mixture and fuel pump pressure has remained within specified limits. Cross check and adjust as required until idle mixture, idle fuel pump pressure and maximum power fuel flow values are within limits. 10. Now, adjust the idle speed adjustment screw A such that the engine idles at 600 to 650 RPM. (Throttle idle position). II

FLIGHT CHECK 1. Disconnect the external fuel pump pressure gauge, check for fuel leaks, and make the aircraft ready for flight. Note: The flight check must be accomplished to assure that the fuel system is properly adjusted and compensating fuel flows to specified values at various altitudes. This flight check will also assure that the mid range fuel flows are as specified regardless of the operational altitude. 2. Take off and climb at full open throttle fuel rich mixture and maximum RPM (2000 RPM propeller speed). Continue to climb to a least 4000 feet above the take off field elevation. Record manifold pressure at each one inch drop and corresponding fuel flow. Record at least 4 points. 3. Plot these points on Curve No. 77041. If the points fall above (Rich) of the curve line, the fuel pump swivel tee fitting should be replaced with P/N 642756 (blue

February 14, 1979

M79-4 Page 3 color identification) prior to further adjustments. Readjust max fuel flow with aneroid on ground prior to flight to limits.

4. If the plotted points fall below the curve lines, the fuel pump aneroid adjustment screw E (Figure 2) will require readjustment. Turn the adjustment screw E CCW to increase maximum fuel flow approximately 2 turns for each GPH increase. Now, readjust screw D to achieve the specified fuel flow illustrated on Curve No. 77041 ; CW to increase and CCW to decrease fuel flow. 5. If the max power adjustment screws D or E are adjusted, re-verify that the idle speed, idle fuel pump pressure and idle mixture settings have remained within specified limits. Readjust as required. III

FUEL SYSTEM ADJUSTMENT TROUBLE SHOOTING PROCEDURES A. Cockpit Fuel Flow Gauge Check 1. The accuracy of the cockpit fuel flow gauge can be checked using the external fuel pressure gauge used to adjust the idle fuel pump pressure. 2. Tee the external gauge into the fuel line that is connected to the cockpit fuel flow gauge. Operate the engine at maximum power (Step 7 Ground Adjustment Procedures). The external gauge should indicate the metered fuel pressure (psi) corresponding to the flow values indicated on Curve No. 71-52. 3. If the cockpit gauge is not within limits, it should be repaired or replaced as required. B. Maximum Power Fuel Flow Adjustment Note: The aneroid control feature is intended to automatically control fuel flow values within specified limits relative to various engine manifold pressures. 1. The aneroid adjustment screw E is used to adjust the maximum power fuel flows such that the fuel injection system will provide the specified full rich flow rates as the engine ascends to altitude at all power settings. 2. The maximum power adjustment screw D is used to obtain the desired maximum fuel flow rates once the aneroid adjustment screw is positioned properly. 3. Both maximum power adjustment screws D & E must be adjusted properly in order for the fuel injection system to operate within specifications. 4. The maximum power adjustment screw D should not be bottomed out. It must have 1/16th of a turn or more remaining in order to provide adjustment capability.

February 14, 1979

Page 4

AIR THROTTLE AND METERING ASSY.

FIGURE 1

FUEL PUMP

FIGURE 2

M79-4

February 14, 1979

Page 5

FIGURE 3

M79-4

February 14, 1979

Page 6

FIGURE 4

M79-4

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-10 FAA Approved

28 March 1980 TO: SUBJECT: MODELS AFFECTED:

All Teledyne Continental Motors’ Aircraft Engine Distributors, Dealers, Maintenance and Overhaul Facilities, Engine Owners and Operators.

REPLACEMENT OF SOME P/N 642232 FLEXIBLE ELBOWS TSIO-520-N, Spec. 5, 6, & 8 Used on Cessna 414A

Gentlemen:

Flexible elbow P/N 642232 was supplied to TCM by two different vendors and can be identified by color as shown in figure 1. Those which are colored black, purple and orange have been found to exhibit incidences of fabric and rubber ply separation and must be replaced. Those which are all orange (P/N 642232) and green (P/N 643019) may exhibit splits in the outer layer of silicone rubber in the areas around the convolutions. This outer layer is a heat barrier. As long as the splits do not extend into the fabric and rubber plys beneath the outer layer of silicone rubber, these may be continued in service. A new flexible elbow, P/N 643019, (green in color) supersedes P/N 642232 on all current production engines. A labor rate of 1.0 hours per elbow will be paid for replacement of the black, purple and orange duct. Only those engines listed are affected by this bulletin. Service Bulletin M78-5, Rev. 3 still applies to other TSIO-520-N, NB and TSIO-520-J, JB engines.

FIGURE 1

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-11

14 April 1980

TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. INTAKE MANIFOLD TUBE DRAIN BOSSES IO-520-M, MB

Gentlemen: Additional drain bosses have been added to the aft intake manifold tubes of the IO-520-M, MB engines. This change increases the intake manifold drain system flow capability and therefore improves the system's ability to handle inadvertent overpriming. The additional drain bosses will be effective on all rebuilt engines built on or after September 23, 1979 and on new engines commencing with serial numbers 565873, 565878, 565880 thru 565893 and thereafter. Overpriming can lead to cylinder hydrostatic lock. It is therefore suggested that the Pilot's Operating Handbook be reviewed for proper engine ground starting and inflight restarting techniques to prevent inadvertent overpriming. The new intake manifold tubes, P/N 643380 (1-3-5 side) and P/N 643379 (2-4-6 side) replace intake manifold tube P/N 641163. Each tube will be shipped with a 1/4-18 plug, P/N 6295182H. Upon installation, the inboard drain is to be connected to a new aircraft drain system while the outboard drain boss should remain plugged. (See Cessna Service Information Letter ME8013 for specific information concerning additional aircraft plumbing required to complete the new drain system installation.)

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-14 FAA-DER Approved

28 April 1980 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. FREON COMPRESSOR BRACKET IO-520-L, TSIO-520-P, R, T when Freon Compressor is Installed

Gentlemen: Reports of wear in the P/N 642885 freon compressor bracket forward mounting bolt hole wear determined to have been caused by an improper torquing sequence. The proper sequence is to tighten the forward bolt to the proper torque (275-325 in lbs.) first, then tighten the aft bolt to the proper torque (275-325 in lbs.). In this manner, the application of torque will seat the flanged bushing in the compressor mounting bracket, providing a tight joint at both mounting bracket bosses. Brackets with front holes elongated may be repaired in the following manner: 1.

Ream the elongated hole to a diameter of 0.485 - 0.4395. (Scrap any bracket with a hole that will not clean up at these dimensions.)

2.

Install bushing P/N 630455 flush to 0.010 below the surface.

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-18 FAA-DER Approved

2 September 1980 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. MODIFIED BREATHER SYSTEM IO-360 and TSIO-360 Series built prior to Nov. 1978.

Gentlemen: A modified breather tube in the crankcase is now being installed in new and rebuilt IO-360 and TSIO-360 engines. This breather tube, P/N 537505, is also available for field installation in engines in service to improve oil consumption due to a lower loss through the breather. It should be noted that breather tube P/N 537505 is included in EQ6554 as detailed in Service Bulletin M79-19. The old breather tube can be removed by jamming a long screw driver through the tube and prying up with a claw hammer or pry bar. Before installing the new breather tube clean all dirt and oil from the area. Make sure the hole is clean and dry. It is not necessary to remove all loctite residue from the old installation. For a tight installation the following steps are to be taken: 1.

Apply Loquick Primer, Grade N to both surfaces and allow to dry completely.

2.

Apply Loctite, Grade 271 to both surfaces.

3.

Install breather tube to an extended height of 2.19 inches and with the 3/4 inch diameter tube pointed toward the 2-4-6 side and forward 12-1/2 degrees or across the second back bone bolt from the front (See figure 1).

4.

Wipe excess Loctite from crankcase surface.

5.

Allow installation to cure at least 2 hours before attaching breather hose.

FIGURE 1

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-24 Technical Portions are FAA-DER Approved

18 September, 1980 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. EXHAUST TAILPIPE MODIFICATION TSIO-360-GB in Mooney 231

Gentlemen: As a result of reports of exhaust stains on the nose gear door and underside of the fuselage, the tailpipe has been redesigned. The new tailpipe, part number 642220-107, has the tip bend rotated 15 degrees to the outboard side to allow the exhaust gases to exit away from the gear door. This change can be incorporated in the earlier airplanes by either purchasing the new exhaust tailpipe from your local Teledyne Continental Motors Distributor or by having a certified welder modify your current tailpipe. To modify the existing tailpipe, it will be necessary to remove the tailpipe by disconnecting the clamp, part number 633358, tailpipe to turbo, and the wastegate bypass assembly part number 642220-108. The tailpipe should then be taken to an FAA certified repair station and modified per the following: 1. Scribe a line at the approximate center line of the tailpipe as shown. 2. In the straight section and 1" up from the bend at the exit end of the pipe, cut the pipe. 3. Looking at the exit end of the pipe, rotate it counterclockwise .378" from the scribe mark (15 degrees). 4. Weld the pipe completely around. 5. Using the appropriate inspection methods, make sure there are no leaks or cracks in the welded area. 6. Reinstall the pipe on the engine.

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-25 Technical Portions are FAA-DER Approved

24 October 1980 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. INSTALLATION INSTRUCTIONS FOR AIR CONDITIONING KITS IO-520-BA, BB, TSIO-520-L, LB, WB

Gentlemen: The following instructions should be followed anytime an air conditioning kit is installed in the field on the listed models. Anytime a component is replaced in the field, that portion of the instructions that apply should be adhered to. Proper belt tension and alignment of bracket assembly with driver sheave must be maintained. INSTALLATION PROCEDURE 1.

Remove outer spacer from end of starter shaft gear. Install driver sheave with nut and torque to 700-850 in. lbs. Do not over torque the nut to install the cotter pin. Change the nut and/or washer as required for cotter pin alignment. (Permissible to use AN960-C916L washers or equivalent as required).

2.

Remove spacer from thru bolt. Inspect AN123862 "O" ring for damage and replace if necessary. Install freon compressor bracket assembly and align idler sheave with driver sheave. Idler should be tightened snug within track. Install the existing nut and washer on thru bolt and the two (2) .375 x 2.00 lg bolts with washers and tighten finger tight; then torque in sequence counterclockwise beginning with thru bolt to 220-260 in. lbs.

3.

Install freon compressor (Airframe Supplied) utilizing bolts, washers, and self-locking nuts that are supplied with bracket Eq. Kit. Torque nuts to 275-325 in. lbs. Check alignment with driver sheave using Burroughts alignment bar No. 8082 and reposition bracket assy. if necessary.

4.

Loosen jam nut on adjusting bolt and self locking nut on idler arm. Install V-Belt with lap step facing away from direction of rotation. Adjust idler assy. outward by rotating adjusting bolt inward to obtain proper belt tension. New belts should be installed with a static tension of 65-80 pounds. After charging procedure and engine run-in is complete. The belt should be retensioned and maintained in a static tension range of 50-65 pounds. Properly tensioned new belts will require a 4.1-5.0 pound deflection force for a 1.140 inch mid-spacn deflection. After run-in properly tensioned belts will require a 3.3-4.1 pound deflection force for the same 0.140 inch mid-span deflection.

5.

Torque jam nut to 275-325 in. lbs. and self-locking nut to 300-350 in. lbs.

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M80-9 Rev. 1 Supersedes M80-9 FAA-DER Approved

30 June 1980 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FUEL METERING SHAFT

MODELS AFFECTED:

GTSIO-520-M

Gentlemen: TCM has received reports of some GTSIO-520-M engines experiencing rough operation because of an overrich fuel/air mixture during certain approach to landing conditions (high rpm, low manifold pressure). A new "lean" fuel metering shaft intended to correct this situation is now in production on new engines with serial number 606426 and after and rebuilt engines with serial number 227959 and after. The new fuel metering shaft is P/N 625221-10 and may be ordered separately or as part of control assembly P/N 633573-10A1. Compliance with this bulletin should be as soon as practical if the conditions described are evident, but no later than the next overhaul.

 TELEDYNE INDUSTRIES, INC. 1980

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-10 Technical Portions Are FAA-DER Approved

9 March 1981 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. REPLACE DIPSTICK P/N 632062-2 WITH P/N 632062-29 O470R, S & U engines used in Cessna 182 series aircraft above S/W 182-55059

Gentlemen: To prevent possible overfilling of the lubrication system a more accurate dipstick is in current production on the affected engines. Existing dipsticks may be reworked in accordance with the following instructions. Re-identify with P/N 632062-29. 1.

Remove existing markings from the dipstick using #320 grit sandpaper or equivalent.

2.

With an electric marking pencil re-mark the dipstick as shown.

CAUTION . . . Etch marks should only be deep enough to be distinct.

6

8

10

12

2.30 3.30 4.10 5.00

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-12 Technical Portions Are FAA-DER Approved

11 May 1981 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

INSTALLATION INSTRUCTIONS AND REWORK INSTRUCTIONS FOR THE PART NO'S 642266 & 643935 ALTERNATOR BRACKETS

MODELS AFFECTED:

O470U, IO520D, F, L, TSIO520M, P, R, T

Gentlemen: Several alternator brackets have been returned with elongated mounting holes because of a lack of torque on the 7/16-20 bolt and nut used to hold the alternator. The proper torque for this nut is 400 to 450 in. lbs. when using a plain nut. If a self locking type nut is used then the running torque of this nut must be added to the tightening torque of 400 to 450 in. lbs. to provide the proper clamped joint between the bracket and alternator. The following procedure for repair to the bracket can be made if the forward mounting hole and aft bushing have elongated. 1.

Drill the forward hole to .625/.626 diameter. (Discard bracket if .625-.626 does not remove all elongation of original hole.) Care must be taken to keep the centerline of the hole parallel to the centerline of the bolt.

2.

Press the part no. 643928 bushing into the hole with the bushing flush to .010 below the surface.

3.

Press out the bushing in the aft hole and replace with a new part no. 643934 bushing.

CAUTION...When reinstalling the alternator be sure to use a special washer, part number 638115-1 between the alternator and bracket as shown.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-13R1 Supersedes M81-13 Technical Portions are FAA-DER Approved

18 July, 1981 TO:

All Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

SLICK SERVICE BULLETIN 1-81 (Revised)

MODELS AFFECTED:

A65, A75, C75, C85, C90, O200, IO360, TSIO360, O470, IO470, IO520 and TSIO520 which may have the Slick Model Magneto as listed on page 1 of Slick Service Bulletin 1-81 (revised) installed.

Gentlemen: The attached Slick Service Bulletin No. 1-81 (revised) must be complied with as applicable. Please see the revised Slick Bulletin 1-81, revision dated 6-29-81 which follows. The revisions to the bulletin are in the serial numbers affected, the affected dates of field installed coils, inspection procedures and the labor allowance.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Aircraft Ignition Parts . . . 530 BLACKHAWK PARK AVENUE, ROCKFORD, ILLINOIS 61101 PHONE 815 965-7704 April 6, 1981 June 29, 1981 (Rev'd.) SERVICE BULLETIN 1-81 (Revised) Possible Magneto Malfunction Due to Cracking of the Coil Potting Compound BACKGROUND There have been magneto malfunctions reported recently that have resulted from a crack in the orange potting compound of the magneto coil. The crack is observable as emanating from the high voltage output post of the coil, on the ends near the corners of the bridge, or across the rear of the coil. EQUIPMENT AFFECTED Only the following magneto model numbers are affected: 4201, 4201R 4230, 4230R 4251. 4251R

4252, 4252R 4281, 4281R 4250, 4250R

4216, 4216R 6210, 6210R 6214. 6214R

The serial number range of these magnetos includes Serial Number

Month of Manufacture

8100000 - 8109999 8110000 - 8119999 8120000 - 8129999 9010000 - 9019999 9020000 - 9029999 9030000 - 9039999 9040000 - 9049999 9050000 - 9059999 9060000 - 9069999 9070000 - 9079999 9080000 - 9089999 9090000 - 9099999 9100000 - 9019999 9110000 - 9119999 9120000 - 9129999 0010000 - 0019999 0020000 - 0029999 0030000 - 0039999 0040000 - 0049999

October, 1978 November, 1978 December, 1978 January, 1979 February, 1979 March, 1979 April, 1979 May, 1979 June, 1979 July, 1979 August, 1979 September, 1979 October, 1979 November, 1979 December, 1979 January, 1980 February, 1980 March, 1980 April, 1980

It also includes all coils that have been field-installed (in magneto models listed above) as replacements between October 1, 1978, and today's date. Coil manufacturing dates are stamped on each coil and agree with magneto manufacturing date. Only coils manufactured between October 1, 1978, and April 30, 1980, are affected.

Service Bulletin 1-81 (Revised June 29, 1981) COMPLIANCE

Page 2

For engine model numbers affected, please refer to Teledyne-Continental Service Bulletin #M81-13 (Rev. 1) and Avco Lycoming Service Bulletin #457A. The coil must be visually inspected within the next 25 hours of service, or no later than August 31, 1981. No material and/or labor claims will be honored if submitted later than September 30, 1981, for domestic claims, or November 30, 1981, for international claims. Coils should be re-inspected for cracks as a routine matter at each 500-hour service interval. Our service manual currently recommends that our magneto be opened at 500-hour intervals as normal procedure. To check the coil for cracks, remove the magneto from the engine, and remove the coil from the magneto. This must be done in accordance with our Detailed Instructions in this Service Bulletin. The labor allowance will be: Coil Inspection, Replacement if necessary, and Reassembly .....1.5 hrs./magneto - at current posted shop rate Claims are to be handled by any Slick distributor listed in the back of this Bulletin. All claims for labor for coil inspection must be accompanied by our Pro Rata Form #1030, filled out completely with magneto model number, serial number, total hours, date stamped on coil, and the shop labor rate. All claims for parts and labor (for coil inspection and replacement with a new coil) are to be submitted with the old coil and Form #1030, filled out as noted above. All 4200 series magnetos use Slick Coil part number M-3114. All 6200 series magnetos use Slick Coil part number M-3009. CERTIFICATION OF COMPLIANCE All magnetos inspected and/or serviced as per this Service Bulletin must have the letter "C" stamped into the metal name plate following the last digit of the magneto serial number. DETAILED INSTRUCTIONS 4200/6200 SERIES AIRCRAFT MAGNETOS MAINTENANCE AND OVERHAUL INSTRUCTIONS 1. Before beginning disassembly, proceed as if you were timing the magneto to the engine and follow the engine manufacturer's procedure. It will be necessary to remove the top #l spark plug and rotate the propeller until compression is noted in #l cylinder with your thumb. Continue rotating the propeller until the impulse coupling trips. Now reverse the propeller and stop at the engine specification timing mark noted on the name plate of the engine. 2. Remove the harness cap from the magneto by removing the 3 screws that secure it. When removing the cap, place a visible mark on the harness cap and an adjacent mark on the distributor housing. This will insure that the cap is properly oriented upon re-assembly. 3. To remove the magneto from the engine, proceed as follows:

Service Bulletin 1-81 (Revised June 29, 1981)

Page 3

(a) Remove the wire that connects the ignition switch to the condenser on the magneto (P-lead). (b) Remove the 2 nuts, washers and clamps that secure the magneto to the engine. (c) The magneto can now be removed from the engine for inspection. NOTE:

USE OF THE SLICK T-100 ASSEMBLY AND TIMING KIT IS STRONGLY RECOMMENDED FOR DISASSEMBLY AND ASSEMBLY OF THE MAGNETO. THE 1037-A SERVICE MANUAL —4200/6200 Series Aircraft Magnetos Maintenance and Overhaul Instructions — IS AVAILABLE FROM YOUR LOCAL SLICK DISTRIBUTOR. THESE INSTRUCTIONS SHOULD BE USED IN CONJUNCTION WITH THE FOLLOWING INFORMATION.

4. Remove the 4 screws that secure the distributor housing to the frame. Break the housing loose from the frame, but do not remove completely. The condenser wire that is mounted in the distributor housing must be disconnected from the contact breaker assembly mounted in the frame before the housing is completely removed. Remove the housing. The orange coil should be visible. 5. To remove the coil from the magneto, proceed as follows: The T-122 Wedge Extractor that comes with the T-100 tool kit should be used to pry the coil wedges (M-3040) loose. The coil can then usually be removed from the magneto by holding the coil by the protruding tower and shaking the coil from side to side until it comes loose. 6. Inspect the coil for visible cracks. The crack is observable as emanating from the high voltage output post of the coil, on the ends near the corners of the bridge, or across the rear of the coil. (See Fig. I attached for typical cracks.) If any cracks are evident, regardless of size or location, the coil should be re-placed. IF THE COIL HAS NO VISIBLE CRACKS BUT HAS BEEN IN SERVICE LESS THAN 250 HOURS, IT SHOULD BE REPLACED, REGARDLESS OF WHETHER CRACKS ARE OBSERVED. If the coil has been in service for more than 250 hours and has no visible cracks, replacement is not necessary. NOTE:

While the magneto is disassembled, the opportunity exists to perform routine maintenance on the other components: (1) Check the stop pin that protrudes from the bottom of the magneto, for wear. If any deformation is noted, the frame and the impulse coupling should be replaced. If the stop pin is loose, the entire frame should be replaced. (2) Check the contact breaker assembly for point wear. If there is pitting or wear on the contact points, both the breaker assembly (M-3081) and the condenser (M-2766) should be replaced. (3) Disassemble the distributor block assembly from the distributor housing by removing the two screws that hold the assembly to the housing. Examine the high voltage contact terminals in the distributor block, the carbon brush on the shaft of the gear,

Page 4

Service Bulletin 1-81

and the centerwiper electrode that is connected to the nylon gear for pitting or material breakdown of any kind. If wear is observed, the entire assembly (M-3122, 6-Cyl.; M3121, 4-Cyl.) should be replaced. (4) Inspect internal and external threads of all threaded hardware. Damaged or worn parts should be replaced. (5) Inspect the magneto frame as well as the distributor housing for cracks or other damage. Inspect the mounting flange of the frame for possible cracks, and move from side to side to check for looseness if the magneto is still on the engine. Any cracks or damage should result in replacement. RE-ASSEMBLY PROCEDURES 1. If the coil has been removed, it should be replaced as follows: Seat the new coil in the frame, making sure that the coil bridge is touching the mounting pads by pressing firmly against the coil housing. Drive the 2 wedges tight using a hammer and a flat punch. Attach the white or black ground wire of the coil to the frame using the screw and lockwasher provided. Tighten to 20 inch-lbs. 2. Check the bent metal portion of the high tension lead of the coil, making sure it protrudes 1/16" beyond the face of the frame. This provides spring pressure against carbon brush electrodes on the distributor gear and the thrust bearing in the distributor block. IMPORTANT:

IF THIS HIGH VOLTAGE LEAD IS NOT FIRMLY PRESSING AGAINST THE CARBON ELECTRODE, THE ELECTRODE WILL WEAR RAPIDLY. THIS COULD LEAD TO MALFUNCTION OF THE COIL AND/OR MAGNETO.

3. If the breaker assembly has been removed, proceed as follows: (a) Assemble the contact point kit on the bearing plate, using screws from the kit. Insert the black plastic cam in the cam slot with a screw- driver blade, and tap with a light hammer. Drive the cam all the way to the bottom of the cam slot. (b) Assemble the rotor gear onto the rotor shaft, making sure the key slot of the gear fits into the cam slot of the rotor. Tap with a light hammer until the gear bottoms on the shaft. 4. The next operation is to time the magneto internally and assemble the distributor housing onto the frame. (a) To time the magneto internally, place the magneto on the T-100 assembly and timing tool base, making sure the coupling lugs are in the slots of the index plate. Swing the frame counterclockwise against the pin, which will line up the rotor and cam for E gap position. (b) Attach either the red or the green wire of the timing light to the bronze point terminal, and the black wire to the frame of the magneto. With a screwdriver, adjust the points so the timing light indicates that the points are just opening. Secure the points by tightening the screws. This will provide a point gap of .008 - .010". Attach the coil wire to the

Service Bulletin 1-81 (Revised)

Page 5

vertical bronze male terminal of the point assembly. Apply cam grease M-1827 sparingly to each lobe of the cam. (c) Assemble the condenser into the distributor housing, being careful to rotate the condenser wire the same rotation as the condenser is tightened in the housing. Torque to 110 inch-lbs. Assemble the distributor gear in the distributor block, with the L & R facing you. Assemble the bearing bar to the distributor block so that the open side of the dust collector is toward the air vent and hood. Assemble the distributor block in the distributor housing, with the cut-away toward the condenser. Use screws and lockwashers. Torque to 18-20 inch-lbs. (d) Connect the condenser wire to the slip terminal on the point assembly. BE SURE THAT THE CONDENSER WIRE IS NOT ALLOWED TO RUB AGAINST THE ROTOR GEAR. THIS CAN BE ACCOMPLISHED BY GIVING THE WIRE A TWIST IN THE APPROPRIATE DIRECTION TO HOLD THE WIRE AWAY FROM THE GEAR. Align the L or R (depending on magneto rotation) on the rotor gear so it points toward the high tension lead of the coil. (e) Align the L or Ron the distributor gear with the L or Ron the distributor block, and insert the timing pin (T-118) through the block into the gear. (a) (f) CAUTION: MAKE SURE THAT THE FLAT HIGH TENSION LEAD OF THE COIL PROTRUDES 1/16" ABOVE THE FACE OF THE MAGNETO HOUSING BEFORE REASSEMBLY. (f) Fit the distributor, housing to the frame, making sure the bosses of the distributor housing are seated in the slots of the frame. Start by fitting the top boss (next to the vent) and assemble the distributor housing into place. (g) Secure the distributor housing to the frame with screws and lockwashers. Torque to 18-20 inchlbs. 5. Take the following precaution in re-mounting the magneto onto the engine: CAUTION:

TIGHTEN BOTH FLANGE-CLAMP NUTS BY HAND TO FINGER TIGHTNESS. TIGHTEN EACH NUT TO 8 FT.-LBS., AND THEN TIGHTEN THEM ALTERNATELY IN SEVERAL STEPS TO 17 FT.-LBS. EXCEEDING 17 FT.-LBS. MAY CAUSE THE MOUNTING FLANGE TO CRACK.

6. After the magneto is installed on the engine, remove the timing pin. 7. The timing of the magneto to the engine should be done per the engine manufacturer's specifications.

Page 6

Service Bulletin 1-81

Fig.1 Typical Coil Cracks

SLICK ELECTRO, INC. Domestic Aircraft Distributors (Listed Alphabetically by State) Name Hughes Aviation Services Van Dusen Aircraft Supplies Atco-Spad Cooper Airmotive, Inc. Cutter Aviation Van Dusen Aircraft. Supplies Atco-Spad Atco-Spad Cooper Airmotive , Inc . Cooper Airmotive, Inc. E1 Cajon Aircraft Supply Hagelin Aircraft Supply Omaha Airplane Supply Sacramento Sky Ranch Superior Air Parts, Inc. Van Dusen Aircraft Supplies Van Dusen Aircraft Supplies Aviation Sales, Inc. Combs-Gates Denver, Inc. Atlantic Aviation Aviation Supply Corp. Aviation Supply Corp. Aviation Supply Corp. Aviation Supply Corp. Cooper Airmotive, Inc. Universal Export Van Dusen Aircraft Supplies Aviation Supply (before May 1) Aviation Supply (before May 1) Aviation Supply (after May 1) Cooper Airmotive, Inc. Van Dusen Aircraft Supplies Atco-Spad Cooper Airmotive, Inc. Cooper Aviation Supply Edgecomb/G & N, Inc. Schneck Aviation, Inc. Van Dusen Aircraft Supplies Combs-Gates Indianapolis, Inc. G & N Aircraft, Inc. Airparts Company, Inc. Aviation Distributors, Inc. Cooper Airmotive, Inc. Van Dusen Aircraft Supplies Cooper Airmotive, Inc. Van Dusen Aircraft Supplies

Location Anchorage, Alaska “ Phoenix, AZ “ “ “ Long Beach, CA San Jose, CA San Leandro, CA Van Nuys, CA EI Cajon, CA Long Beach, CA Long Beach, CA Sacramento, CA Signal Hill, CA So. San Francisco, CA Van Nuys, CA Denver, CO “ Wilmington, DE Ft. Lauderdale, FL Tampa, FL Orlando, FL Opa Locka, FL Ft. Lauderdale, FL Miami, FL Miami Springs, FL Atlanta GA Atlanta, GA College Park, GA College Park, GA Atlanta, GA Honolulu, Hawaii Wheeling, IL Elk Grove Village, IL Elgin, IL Rockford, IL Elk Grove Village, IL Indianapolis, IN Griffith, IN Wichita, KS Olathe, KS Overland Park, KS Wichita, KS Lafayette, LA East Boston, MA

Phone (907) 277-6573 (907) 243-3454 (602) 273-7451 (602) 275-4434 (602) 273-1237 (602) 275-4493 (213) 421-8431 (408) 926-2505 (415) 638-8736 (213) 997-0242 (714) 448-9000 (213) 421-1771 (213) 595-4301 (916) 421-7672 (213) 595-8556 (415) 589-3133 (213) 988-7308 (303) 398-5410 (303) 398-5400 (302) 322-7433 (305) 764-4156 (813) 251-1857 (305) 894-9611 (305) 685-3522 (305) 525-8265 (305) 592-2627 (305) 885-3481 (404) 997-4000 (404) 768-1000 (404) 765-1850 (404) 997-3935 (404) 766-8334 (808) 737-5719 (312) 541-7040 (312) 364-2600 (312) 741-5180 (815) 965-4001 (312) 437-5230 (317) 243-8311 (219) 924-7110 (316) 943-2377 (913) 764-3150 (913) 314-2999 (316) 943-9301 (318) 233-8930 (617) 567-3000

Page 2

Slick Domestic Aircraft Distributors Name Cooper Airmotive, Inc. Q'Air Parts Van Dusen Aircraft Supplies Cooper Airmotive, Inc. Tasco Aviation Supply Van Dusen Aircraft Supplies Aviation Distributors, Inc. Cooper Airmotive, Inc. Omni Air, Inc. Van Dusen Aircraft Supplies Atco-Spad Omaha Airplane Supply Co. Hughes Aviation Service Sky Ranch Airparts Eastern Aero Supply, Inc. Van Dusen Aircraft Supplies Cutter Flying Service Cooper Airmotive, Inc. Mattituck Aviation Corp. Cooper Airmotive, Inc. General Aviation, Inc. T. W. Smith Engine Co. Van Dusen Aircraft Supplies A.A.R. of Oklahoma, Inc. Cooper Airmotive, Inc. Omni Air, Inc. Van Dusen Aircraft Supplies A.A.R. Western Skyways, Inc. Cooper Airmotive, Inc. Cooper Airmotive, Inc. Van Dusen Aircraft Supplies Atlantic Aviation Supply Co. Ellis-Horn Company, Inc. Cooper Airmotive, Inc. Cooper Airmotive, Inc. Cooper Airmotive, Inc. Omni Air, Inc. Schneck Aviation, Inc. Atco-Spad Superior Airparts Van Dusen Aircraft Supplies Van Dusen Aircraft Supplies Hughes Aviation Service Van Dusen Aircraft Supplies Atco-Spad Hughes Aviation Services Melridge Aviation Co. Van Dusen Aircraft Supplies

Location Romulus, MI Pontiac, MI “ Minneapolis, MN St. Paul, MN Edina, MN Chesterfield, MO “ Kansas City, MO St. Louis, MO Kansas City, MO Omaha, Nebraska Las Vegas, NV Reno, NV Millville, NJ Teterboro, NJ Albuquerque, NM Bohemia, NY Mattituck, L.I., NY Cinciannati, OH Willoughby, OH Cincinnati, OH Vandalia, OH Oklahoma City, OK Tulsa, OK Tulsa, OK Oklahoma City, OK Troutdale, OR Fiarview, OK Philadelphia, PA New Cumberland, PA Anderson, SC Memphis, TN Dallas, TX Ft. Worth, TX Houston, TX Dallas, TX San Antonio, TX Dallas, TX Addison, TX Dallas, TX Houston, TX Salt Lake City, UT Sandston, VA Seattle, WA “ Vancouver, WA Seattle, WA

Phone (313) 946-9110 (313) 666-3001 (313) 666-2240 (612) 884-4441 (612) 224-5788 (612) 835-6988 (314) 532-3581 (314) 532-3458 (816) 421-6733 (314) 731-1703 (816) 842-3903 (402) 422-6666 (702) 739-9322 (702) 786-7278 (609) 825-2500 (201) 288-1861 (505) 241-3791 (516) 567-2002 (516) 298-8330 (513) 871-6623 (216) 942-3500 (513) 871-3500 (513) 898-4672 (405) 681-2361 (918) 838-3316 (918) 836-7194 (405) 682-4496 (503) 665-1181 (503) 667-5068 (215) 677-9700 (717) 774-3511 (803) 226-3461 (901) 362-6710 (214) 357-1811 (817) 626-3795 (713) 645-3376 (214) 350-5531 (512) 924-9261 (214) 386-7426 (214) 233-4433 (214) 352-2611 (713) 643-8566 (801) 523-5194 (804) 222-7287 (206) 762-0550 (206) 762-4871 (206) 695-1233 (206) 763-1544

SLICK ELECTRO, INC. Canadian Aircraft Distributors (Listed Alphabetically by State) Name Leavens Brothers, Ltd. Leavens Brothers, Ltd. Standard Aero, Ltd. Standard Aero, Ltd. Van Dusen Aircraft Supplies Standard Aero, Ltd. Van Dusen Aircraft Supplies Standard Aero, Ltd. Van Dusen Aircraft Supplies Standard Aero, Ltd. Leavens Brothers, Ltd. Standard Aero, Ltd. Standard Aero, Ltd. Van Dusen Aircraft Supplies Leavens Brothers, Ltd. Standard Aero, Ltd. Van Dusen Aircraft Supplies

Location Calgary, Alberta Edmonton, Alberta Calgary, Alberta Edmonton, Alberta Edmonton, Alberta Vancouver, British Columbia Richmond, British Columbia Winnipeg, Manitoba Winnipeg, Manitoba Fredericton, New Brunswick Mississauga, Ontario Ottawa, Ontario Mississauga, Ontario Mississauga, Ontario Lachine, Quebec Lachine, Quebec Lachine, Quebec

Phone (403) 276-9283 (403) 477-5568 (403) 276-4471 (403) 453-3502 (403) 452-7036 (604) 273-8621 (604) 270-8166 (204) 775-9711 (204) 775-8004 (506) 455-1551 (416) 678-1234 (613) 737-3985 (416) 676-2578 (416) 677-0654 (514) 636-0868 (514) 636-9215 (514) 636-1470

SLICK ELECTRO, INC. Foreign Aircraft Distributors Aeronautica Van Dusen, S.A. Comair Johannesburg, Cooper Airmotive Cooper Airmotive Cooper Airmotive Rex Aviation, Ltd. Dalhoff & King Aviation, Ltd. Rolls Royce Motors, Ltd. Satair Standard Aero, Ltd.

Mexico City, Mexico South Africa Melbourne, Australia Oxford, England Germiston, South Africa Bankstown, NSW, Australia Paupakura, New Zealand Crewe, Cheshire, England Copenhagen, Denmark London, England

Van Dusen Aircraft Supplies, Ltd. Van Dusen SarI Van Dusen Aircraft Supplies Co. Van Dusen Airstocks Van Dusen Aircraft Supplies Co., S.A. Van Dusen Aircraft Supplies Co. Van Dusen Aircraft Supplies, GmbH Van Dusen Aircraft Supplies Austrailia, Ltd.

Melbourne, Australia Aeroport de Bourget, France Oxford, England Kowloon, Hong Kong Transvaal, South Africa Helsingborg, Sweden Englsbach, West Germany New South Wales, Australia

Avco Lycoming Distributors which stock Slick parts C.S.E., Ltd. Fenwick Aviation Motoren-Und Turbinum Union A.B. Nyge Aero Osterman's Aero AB Aerospares (pty.) Ltd. N.Z. Aerospace, Ind. Ltd. Airwork (N.Z.) Ltd.

Oxford, England Paris, Cedex, France Munich, West Germany Nykaping, Sweden Barkarbyvagen, Sweden Transvaal, South Africa Hamilton, New Zealand Christchurch, New Zealand

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-15 (Rev. 1) Technical Portions Are FAA-DER Approved

16 June, 1983 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. PRESTOLITE 100 AMP ALTERNATOR EXCHANGE IO520M, MB, TSIO520B, BB, E, J, K, L, LB, N, NB, UB, VB, WB and GTSIO520H, L, M, N

Gentlemen: Teledyne Continental Motors, Aircraft Products Division wishes to announce that many engines originally equipped with 50 or 100 Amp Prestolite gear driven alternators may now be serviced with the Teledyne Cirttenden 100 Amp alternators. In order to accomplish the conversion on applicable Cessna aircraft, Kit P/N SK421-92A will be required in addition to the Teledyne Crittenden alternator and coupling assembly P/N 642056A2R (rebuilt). In order to accomplish the conversion on Beech Aircraft, Kit P/N 58-3007 1 will be required in addition to the Teledyne Crittenden alternator and coupling assembly P/N 642056A2R (rebuilt). See your Beech distributor for your particular application. On twin engine aircraft, if one engine is converted it will be necessary to convert both engines.

 TELEDYNE INDUSTRIES, INC. 1983

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-16 Technical Portions Are FAA-DER Approved

27 July, 1981 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. TURBOCHARGER CENTER HOUSINGS TSIO-470, TSIO-520, GTSIO-520 AND TSIO-360A, B, C, D, & H Engines.

Gentlemen: The attached Airesearch Service Letter is offered for you information and compliance as applicable.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-17 Technical Portions Are FAA-DER Approved

27 July, 1981 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. BY-PASS VALVE MODIFICATION TSIO-520UB

Gentlemen: The attached Airesearch Service Letter TP61-0039 is offered for you information and compliance as indicated.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-18 Technical Portions Are FAA-DER Approved

5 August, 1981 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. AIR REFERENCE HOSES TSIO-520UB

Gentlemen: A redesigned deck pressure air reference hose has been introduced on later model A36TC Bonanza's using the TSIO520UB engines. These redesigned hoses have threaded end connections with fire sleeves. The service history on the hoses has been very good so we are offering it as a field replacement for owners of the earlier A36TC Bonanza's serial #EA1 thru #EA146. The necessary hoses and fittings are included in kit #EQ6560. These kits may be procured from Beech Aircraft. Installation instructions for this kit are shown on the illustration.

REWORK PROCEDURE 1.

REPLACE 632115 ELBOW ON FUEL PUMP WITH 628436 ELBOW.

2.

REPLACE 640692 JUNCTION BOX ASSY, AN816-6B NIPPLE & MS28778-6 "O" RING ON THROTTLE BODY AIR REF PORT WITH 632017 ELBOW, MS20826-6B TEE & 639522 REDUCER.

3.

REPLACE 633721 BARBED COUPLING ON AIR REF MANIFOLD WITH AN910-2 COUPLING & AN816-6B NIPPLE (USE NIPPLE REMOVED IN STEP #2).

4.

REPLACE 628555-19 HOSE & 536388-75 CLAMPS WITH 641047 S65 37.00 HOSE ASSY.

5.

REPLACE 628555-2 HOSE & 536388-.50 CLAMPS WITH 641047S4S 15.00 HOSE ASSY.

6.

POSITION NEW FITTINGS APPROX AS SHOWN TO ALLOW BEST ROUTING OF HOSE ASSYS.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-19 Technical Portions are FAA-DER Approved

August 5, 1981 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

AVAILABILITY OF NEW TCM P/N 646220 AND 646019 FLEXIBLE ELBOWS

MODELS AFFECTED:

TSIO520J, JB, N, NB

Gentlemen: A new design for the flexible elbows has been developed for use on subject engines. They are being installed on current production engines, both new and rebuilt. The new design features a bead on the end of the flexible elbow similar to the bead on the intake elbow or intercooler neck. The new design elbow is manufactured without the silicone rubber in the clamping area to provide a more solid clamping surface. Any operators experiencing difficulties retaining the flexible elbow on the intake manifold are advised to install the new part number elbow. See Table below for application/ OLD P/N

NEW P/N

APPLICATION

643019

646020

TSIO520NB Spec. 5,6,8,9,10 & 12

643009

646019

TSIO520J, N, NB (Except NB Spec. 5, 6,8,9,10 & 12.

When installing the new elbow make sure clamp is fitted between the bead on the flexible elbow and the bead on the intake elbow or intercooler neck. All parts must be clean and free of oil prior to installation. Use a new clamp, Cessna P/N B35A-21P, U84-260-SH or U84-270-SH. The clamp torque is to be 35-40 in. lbs. above the running torque. Within a week of installation, the clamp should be checked and re-torqued.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-23 Rev. 1 Supersedes M81-23 FAA-DER Approved

12 February, 1982 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

360 SERIES OIL PUMP DRIVE GEAR

MODELS AFFECTED:

Serial Number Effectivity on New Engines unless AD 80-07-03 already complied with IO360C,D,G,H,J & K, All serial numbers IO360AB, All serial numbers IO360CB, All serial numbers through 350075 IO360DB, All serial numbers through 351368 IO360GB, All serial numbers through 352894 IO360HB, All serial numbers through 353350 (Except 353075) IO360JB, All serial numbers IO360KB, All serial numbers through 356721 (Except 356652, 356672, 356674, 356675 and 356706 through 356719) TSIO360A, B, C, D, E, F & H, All serial numbers TSIO360CB, All serial numbers through 300667 (Except 300658, 300659, 300662, 300663 & 300666) TSIO360DB, All serial numbers TSIO360EB, All serial numbers through 311689 (Except 311528, 311538 through 311543, 311546 through 311555, 311656, 311658 through 311660) TSIO360FB, All serial numbers through 310610 (Except 310469, 310507 through 310520, 310606 & 310607) TSIO360GB, All serial numbers through 309582 (Except 309436, 309437, 309439, 309440, 309446 through 309453, 309455, 309457 through 309461, 309565, 309566, 309570 through 309574.) TSIO360HB, All serial numbers through 308127 TSIO360JB, All serial numbers through 313015 TSIO360KB, All serial numbers through 315030 LTSIO360E, All serial numbers LTSIO360EB, All serial numbers through 312680 (Except 312567 through 312569, 312571, 312574, 312577 through 312587, 312632, 312634 through 312639) LTSIO360KB, All serial numbers through 313048 (Except 314028) Serial Number Effectivity on Rebuilt Engines unless AD 80-07-03 already complied with IO360A, All serial numbers through 20128R IO360C, All serial numbers through 60516R and 60519R IO360D, All serial numbers through 628823R (Except 628818R and 628821R) IO360G, All serial numbers through 224840R IO360H, All serial numbers through 226506R IO360J, All serial numbers through 238702R IO360CB, All serial numbers through 236502R

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

M81-23 Rev. 1

12 February, 1982 Page 2 IO360DB, All serial numbers through 239608R IO360GB, All serial numbers through 236604R IO360KB, All serial numbers through 235811R TSIO360A, All serial numbers through 197085R TSIO360C, All serial numbers through 230698R TSIO360E, All serial numbers through 225076R TSIO360F, All serial numbers through 232759R TSIO360H, All serial numbers through 233252R TSIO360AB, All serial numbers through 237609R TSIO360CB, All serial numbers through 236022R (Except 236012R, 236015R, 236016R, 236019R) TSIO360DB, All serial numbers through 238401R TSIO360EB, All serial numbers through 234613R (Except 234611R & 234612R) TSIO360FB, All serial numbers through 237331R TSIO360GB, All serial numbers through 237403R TSIO360HB, All serial numbers through 239956R LTSIO360E, All serial numbers through 225581R LTSIO360EB, All serial numbers through 233818R (Except 233812R, 233813R, 233814R & 233816R)

Gentlemen: For those engines covered by the Gold Medallion Warranty, Teledyne Continental Motors will provide parts and labor necessary to comply with Revised Airworthiness directive 81-13-10 in accordance with the terms of that warranty. A warranty labor allowance of 1.5 hours has been established for the initial inspection required by the above Airworthiness Directive. The amount of other labor costs allowed will be in accordance with warranty labor allowance schedules published by Teledyne Continental Motors. For those engines not covered by the Gold Medallion Warranty, Teledyne Continental Motors will provide a replacement oil pump drive gear in exchange for any such gear replaced pursuant to the above Airworthiness Directive at the net price equal to the current list price of the gear divided by the recommended time between overhaul of the engine in question and then multiply by the total number of hours on the engine. All claims must be submitted through a Teledyne Continental Motors Distributor.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-25 Technical Portions are FAA-DER Approved

November 30, 1981 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

EXHAUST FLANGE TO CYLINDER INSTALLATION PROCEDURES

MODELS AFFECTED:

All

Gentlemen: Successful performance and service of an aircraft engine exhaust system is dependent on secure fastening and sealing of the exhaust flange at the engine cylinder exhaust port. These are recommended procedures to be followed when an exhaust flange is installed on a cylinder: 1)

Before assembling the exhaust system to the cylinders, inspect the cylinders, exhaust flanges and exhaust studs for damage and cleanliness. (See applicable manufacturer's publications.)

2)

Install gaskets and properly position the exhaust system on the cylinders. Insure that the exhaust flanges are all firmly seated to the cylinders. In several steps evenly tighten all exhaust nuts to the specified torque value.

3)

After ground run-up to normal operating temperature for inspection purposes and prior to return to flight service, re-torque all exhaust nuts to the specified torque values.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

30 November, 1981

M81-25

Page 2

Listed below are the exhaust gaskets and nuts recommended for use on TCM engines. Also listed are the specified torque values for the nuts. ENGINE

GASKET

NUT

TORQUE

A65 C75 C85 C90 O200 C125 C145 O300 GO300 E165 E185 E225 O470A O470E O470J IO470J IO470K

627429 Spiral Wound or 632837 Stainless Steel

22022

IO360 TSIO360 LTSIO360

630365 Stainless Steel 22022 200-210 in. lb. 16.7-17.5 ft. lb. (Use two each gaskets per cylinder - flat sides together)

200-210 in. lb. 16.7-17.5 ft. lb.

O470-letter 628260 Spiral Wound or IO470 631544 Stainless Steel IO520 (Except those listed above)

643967

100-110 in. lb

8.3-9.2 ft. lb

TSIO470 TSIO520 LTSIO520 GTSIO520

643967

100-110 in. lb.

8.3-9.2 ft. lb.

628260 Spiral Wound

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-26 Technical Portions are FAA-DER Approved

4 December, 1981 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

PRESSURIZATION OF MAGNETOS IN MOONEY M20K AIRCRAFT

MODELS AFFECTED:

TSIO-360GB Spec. 1 & 3 Engines.

Gentlemen: For improved altitude performance, we recommend that owners of TSIO-360GB engines equipped with Bendix S6RN-20 magnetos install the pressurization kit EQ6565 in accordance with Figure 1. Bendix Service Bulletin 612 should also be complied with at this time. Installations with Slick Magnetos can be pressurized using kit EQ6569 in accordance with Figure 2. Reset timing in accordance with instructions in Overhaul Manual form X30030A. Reference Mooney Service Instruction M20-58 for airframe installation information. Pressurization kits EQ6565 and EQ6569 are available only through the Mooney distributor organization.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

4 December, 1981 Page 2

FIGURE 1

M81-26

4 December, 1981 Page 3

FIGURE 2

M81-26

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-28 Rev. 1 Supersedes M81-28 Technical Portions are FAA-DER Approved

23 August, 1982 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

OIL FILTERS

MODELS AFFECTED:

TSIO520N, NB AND TSIO520VB Engines

Gentlemen: The small full flow oil filter P/N 643226 (Approx. 4.80 in. high) has been replaced by the large full flow oil filter P/N 643227 (Approx. 5.80 in. high) on current production new and rebuilt TSIO520N, NB and TSIO520VB engines having the following serial numbers: TSIO520NB (New)

S/N 512241 and subsequent

TSIO520NB (Rebuilt)

S/N 234059 and subsequent

TSIO520VB (New)

S/N 516837 and subsequent

TSIO520VB (Rebuilt)

S/N 234534 and subsequent

The use of the larger full flow oil filter allows a longer recommended oil and filter change interval. See the latest TCM Service Bulletin titled "Recommended Fuel and Oil Grades" for details concerning recommended change intervals. The larger oil filter may also be installed as a customer option on such engines built prior to those listed above. In order to install the larger oil filter on engines currently utilizing the small filter, it will be necessary to comply with Cessna Service Information Letter No. ME82-1 Rev. 1. All engines of the models listed above will be shipped with the larger oil filter. If the above Cessna Service Information letter is not complied with, the short filter must be installed.

 TELEDYNE INDUSTRIES, INC. 1982

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-4 Rev. 1 Supersedes M81-4 Technical Portions Are FAA-DER Approved

29 April 1983 TO: SUBJECT: MODELS AFFECTED: COMPLIANCE:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. AID SERVICE BULLETIN TP60-0120 AID SERVICE LETTER TP61-0046 New or Rebuilt TSIO520J, JB, K, KB, L, LB, N, NB, WB; GTSIO520C, D, H, L, M, built between October 1977 and February 1981 As Noted

We recommend compliance with the attached AID Service Bulletin TP60-0120. Service Letter TP61-0046 has been cancelled as of December 31, 1982. Service Letter TP61-0046 concerns Airesearch warranty information. Please remove from your bulletin file.

 TELEDYNE INDUSTRIES, INC. 1983

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TP60-120 AIRESEARCH INDUSTIRAL DIVISION GARRETT R

SUBJECT: TURBO INSPECTION

A.

EFFECTIVITY AiResearch turbocharger model TH08A for the following variations: NEW TURBO AID P/N

MODEL TH08A67 TH08A68 TH08A68 TH08A70 TH08A70 TH0867 TH0871

OVERHAULED TURBO AID P/N

407810-1 409680-1* 409680-11* 465930-2 465930-3 406990-4 408610-1

407810-9001 409680-9001 409680-9011 465930-9002 465930-9003 406990-9004 408610-9001

CUSTOMER P/N 635630 640327-1 640327-11 641672-2 641672-3 633274-4 637374-1

Serial No. Prefix: GH GI GH GK GL HA HB HC

GHR GIR GHR GKR GLR HAR HBR HCR

HD HE HF HG HH HI HJ HK

HDR HER HFR HGR HHR HIR HJR HKR

HL IA IB IC ID IE IF IG

HLR IAR IBR ICR IDR IER IFR IGR

IH II IJ IK IL JA JB JC JD

IHR IIR IJR IKR ILR JAR JBR JCR JDR

*The –1 part number includes valve which is not affected by this service bulletin. Replacement for –1 turbocharger is only the –11 part which does not include the bypass valve and actuator. B.

REASON AiResearch has become aware that under certain conditions it is possible for the stainless steel sheet metal turbine wheel shroud to deteriorate and/or come in contact with the turbine wheel damaging the wheel and shroud. Either condition will reduce the performance of the engine, and if allowed to continue there can be a significant reduction in engine power.

C.

DESCRIPTION Refer to available sources of troubleshooting information and supplementary information under “ACCOMPLISHMENT INSTRUCTIONS”,” below.

1-15-81

Page 1 of 3

TP60-120 AIRESEARCH INDUSTRIAL DIVISION Los Angeles California

GARRETT R

D.

COMPLIANCE AiResearch recommends compliance within the next 50 hours of time in service for all turbochargers either, (1) now having (three hundred) 300 hours of service or more as of the date of this bulletin; or (2) upon reaching 300 hours of service. Thereafter, compliance is recommended at each one hundred (100) hour interval. Compliance is not required if the turbocharger has been rebuilt, overhauled, or otherwise serviced to incorporate the use of a cast iron turbine wheel shroud (AID P/N 407657-2). Compliance is further recommended by AiResearch, as soon as practical, in the event of an unexplained reduction in engine power, as set forth more particularly in the Accomplishment Instructions.

E.

ACCOMPLISHMENT INSTRUCTIONS a. Remove the turbocharger turbine exhaust duct to gain visual access to the turbine wheel through the discharge port of the turbine housing. b. Using a small flexible probe light, inspect the turbine blade tips for signs of damage. c. Inspect the face of the shroud (areas shown in figure 1) for signs of damage the shroud or contact marks from rubbing against the wheel. d. Remove and replace any turbocharger with damaged turbine blades or shroud, or evidence of turbine wheel rubbing against the shroud. If, at any time, a reduction in power is detected (lower-than-normal manifold pressures), refer to the appropriate airframe manufacturer’s service manuals for troubleshooting information covering induction, exhaust, and turbocontrol systems before performing steps a, b, c, and d, above. Automatic turbocontrol systems used in many applications tend to compensate for minor turbocharger performance losses due to turbine rubbing or wear conditions. It is therefore recommended that maximum power critical altitude flight checks prescribed by the aircraft manufacturer be performed when abnormal functional conditions are suspected. In event that the troubleshooting activities cited above fail to diagnose or correct such deficiencies, perform steps a, b, c, and d, as outlined above.

F.

MATERIAL INFORMATION New replacement units are available from Teledyne Continental Motors and overhauled replacement units are available from authorized distributors and will be identified by serial number prefixes beginning with JE, JER or later (e.g., JF/JFR or KA/KAR, first letter indicating year, second letter indicating month, and third letter indicating overhauled).

1-15-81

Page 2 of 3

TP60-120 AIRESEARCH INDUSTRIAL DIVISION GARRETT R

Figure 1. Inspection of Turbine Wheel and Shroud

1-15-81

Page 3 of 3

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-6 Rev. 2 Supersedes M81-6 Rev.1 FAA Approved

29 January 1982 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. FUEL HOSES IO470D, U, V; TSIO470B, C, D; TSIO520B, BB, E, EB; AND GTSIO520C, D & H New and Rebuilt engines used on certain Cessna Aircraft. See Attachment A following for engine specs affected.

Gentlemen: Effective December 2, 1981, all fuel hoses supplied by Teledyne Continental Motors Aircraft Products Division on the subject engines will incorporate a fire sleeve. In order to install the new hoses, it will be necessary to remove and discard the fuel control assembly shroud and related parts. Where the shroud attaching parts are used to attach additional equipment, it will be necessary to add new attaching hardware. The old hose assembly part numbers, the replacement hose assembly part numbers, the parts to be removed and discarded and any new attaching hardware to be added are listed in the Attachment A following this service bulletin. On the GTSIO520C, D & H engines all fuel hoses are supplied by Cessna. On those engines it will be necessary to remove and discard the fuel control assembly shroud and related parts. Reference Cessna Service Information Letter ME 81-17 concerning additional airframe parts and information required to complete the installation of the new fuel hoses. An "R" preceding an engine model number designates a rebuilt engine.

 TELEDYNE INDUSTRIES, INC. 1982

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

M81-6 Rev. 1

January 29, 1982

Page 2 ATTACHMENT A

IO470D Specs 1, 12, 15, 19, 30, 42, 44 and 52 OLD P/N

DESCRIPTION

NEW P/N

635158S4S15.00 635158S4S17.00 635158S4S40.00

HOSE ASM HOSE ASM HOSE ASM

646021S4S16.00 646021S4S18.00 646021S4S40.00

DELETE P/N

DESCRIPTION

627544 627545 AN526-1024-6 537911 636879-1 625302-12.00 625302-16.00 AN737RM38

SHROUD BOTTOM ASSY SHROUD COVER ASSY SCREW "J" NUT GROMMET DUCT FLEX 12" LG DUCT FLEX 16" LG CLAMP, HOSE

QUANTITY 1 1 2 2 2 1 1 2

IO470U - All Specs; IO470D Spec 27 OLD P/N

DESCRIPTION

NEW P/N

635158S4S15.00 635158S4S17.00 635158S4S40.00

HOSE ASM HOSE ASM HOSE ASM

646021S4S16.00 646021S4S18.00 646021S4S40.00

P/N

DESCRIPTION

QUANTITY

627544 627545 AN526-1024-6 537911 636879-1 625302-16.00 AN737RM38

SHROUD BOTTOM ASSY SHROUD TOP ASSY SCREW "J" NUT GROMMET DUCT FLEX 16" CLAMP HOSE

DELETE

1 1 2 2 2 1 2

M81-6 Rev. 1

January 29, 1982

Page 3

IO470V - All Specs OLD P/N 635158S4S16.00 635158S4S18.00 635158S4S40.00

DESCRIPTION HOSE ASM HOSE ASM HOSE ASM

NEW P/N 646021S4S16.00 646021S4S18.00 646021S4S40.00

DELETE P/N

DESCRIPTION

633198 633195 626879-1 AN526-1024-6 537911 625302-16.00 AN737RM38

SHROUD COVER ASSY SHROUD BOTTOM ASSY GROMMET SCREW "J" NUT DUCT - FLEX 16: LG CLAMP - FLEX DUCT

QUANTITY 1 1 1 2 2 2 2

R-TSIO470B Spec 2, TSIO470C - All Specs, R-TSIO470D Spec 2 OLD P/N 635158S4S16.00 635158S4S16.00 635158S4S32.00

DESCRIPTION HOSE ASM HOSE ASM HOSE ASM

NEW P/N 646021S4S16.00 646021S4S16.00 646021S4S32.00

R-TSIO470B Spec 3, R-TSIO470D Spec 1 OLD P/N 635158S4S16.00 635158S4S16.00 635158S4S32.00

DESCRIPTION HOSE ASM HOSE ASM HOSE ASM

NEW P/N 646021S4S16.00 646021S4S16.00 642021S4S32.00

DELETE P/N

DESCRIPTION

629722 629723 AN526-1024-6 537911 626879-1

SHROUD BOTTOM ASSY SHROUD COVER ASSY SCREW "J" NUT GROMMET

QUANTITY 1 1 2 2 1

M81-6 Rev. 1

January 29, 1982

Page 4

TSIO520B, BB Specs 5, 9, 11; R-TSIO520B Specs 1, 5, 9, 11; TSIO520E, EB Specs 3, 5, 8, 14; R-TSIO520E Specs 1 & 8; R-TSIO520EB Spec 8 OLD P/N 635158S4S13.00 635158S4S13.00 635158S4S36.00

DESCRIPTION HOSE ASM HOSE ASM HOSE ASM

NEW P/N 646021S4S14.00 646021S4S14.00 646021S4S36.00

TSIO520B, BB Specs 10 & 12; R-TSIO520B Specs 2, 10, 12; TSIO520E, EB Specs 4, 9, & 10; R-TSIO520E Specs 2, 4, 9, 10; R-TSIO520EB Spec 9 OLD P/N 635158S4S14.00 635158S4S14.00 635158S4S36.00

DESCRIPTION HOSE ASM HOSE ASM HOSE ASM

NEW P/N 646021S"S14.00 646021S4S14.00 646021S4S36.00

DELETE P/N

DESCRIPTION

633615 633622 2437 626891 20522 AN936-A416 630387

SHROUD BOTTOM ASSY SHROUD TOP ASSY NUT BUMPERS - RUBBER WASHER LOCKWASHER STUD

P/N

DESCRIPTION

537629 501867

BOLT TAB WASHER

QUANTITY 1 1 3 2 3 3 3

ADD QUANTITY 3 3

DELETE P/N

DESCRIPTION

632665 632664 626891 AN526-1024-4 537911

SHROUD - TOP SHROUD - BOTTOM BUMPER - RUBBER SCREW - TRUSS HD NUT - SPEED

QUANTITY 1 1 2 4 4

M81-6 Rev. 1

January 29, 1982

Page 5

GTSIO520H 1A, 1B; GTSIO520D 1B, 3B, 5, 9, 21B DELETE P/N

DESCRIPTION

635077 633780 626981 AN526-1024-4 537911 635081 635084

SHROUD TOP SHROUD - BOTTOM BUMPER - RUBBER SCREW - TRUSS HD NUT - SPEED ADAPTER ELBOW RETAINER WIRE

QUANTITY 1 1 2 4 4 1 1

GTSIO520H 2A, 2B; GTSIO520D 10, 2B, 4B, 6, 22B DELETE P/N

DESCRIPTION

635079 633780 626891 AN256-1024-4 537911

SHROUD ASSY TOP SHROUD ASSY BOTTOM BUMPER - RUBBER SCREW - TRUSS HD NUT - SPEED

QUANTITY 1 1 2 4 4

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety

M81-8R1 Supersedes M81-8 Technical Portions are FAA Approved

Original issue: 9 February 1981 Revision issued: 31 January 2001

TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines. FUEL PUMP SCREEN RESTRICTION

All “A” series, “C” series and O-200 engines with AC Fuel Pumps P/N 40585, 40695 or 631391 installed.

Gentlemen: To prevent a possible fuel flow restriction caused by a clogged screen in subject fuel pumps a repair kit, P/N EQ 6561 is available. Compliance with this bulletin is required within 60 calendar days or the next 50 hours time in service (whichever is sooner) and at intervals not to exceed 12 months time in service thereafter, unless already accomplished. To comply with this bulletin, accomplish the following: 1. 2. 3. 4.

5. 6.

Remove safety wire and bolt from fuel pump top cover. Discard fiber washer under bolt. Remove fuel pump top cover. Discard cork cover gasket. Remove fuel pump screen. Inspect the fuel pump and fuel pump screen for contamination. a. If contaminated, clean fuel pump and screen. b. If fuel pump is damaged by corrosion, replace with the proper serviceable fuel pump. c. If the fuel pump screen is damaged by corrosion or handling, replace with serviceable screen, P/N 643913. Reinstall fuel pump cover with new cork gasket, P/N 643915 and bolt gasket P/N 643914. Torque bolt to 30 ± 5 in. lbs. Re-Safety wire fuel pump top cover bolt.

Revision to original issue of this service bulletin is made to provide a source for the parts required to comply with this service bulletin and AD81-07-06. 1.

Teledyne Continental Motors currently has an adequate supply of fuel pump cover gasket P/N 643915. However, our inventory of cover bolt gasket P/N 643914 and fuel screen P/N 643913 have been depleted. This service bulletin revision has been approved by the Manager, Atlanta Aircraft Certification Office, ACE-115A, by letter dated January 23, 2001, as an alternate method of Compliance (AMOC) for AD 81-07-06, paragraph (e). The AMOC authorizes the use of Aero Accessories, Inc. gasket P/N AF-766 in lieu of TCM P/N 643914. The AF-766 gasket is contained in

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

09

1981

02

05

2001

CONTINENTAL MOTORS

© 2001 TELEDYNE TECHNOLOGIES, INC.

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

1 of 2 M81-8

R1

Fuel Screen Service Kit P/N AF-6561 or may be purchased seperately. Aero Accessories, Inc. P/N AF-766 and AF-6561 are FAA-PMA approved. The fuel pump Fuel Screen Service Kit P/N AF-6561 or cover bolt gasket P/N AF-766 required to comply with this service bulletin and AD 81-07-06 may be purchased from: Aero Accessories, Inc. 1240 Springwood Avenue Gibsonville, NC 27249 1-800-822-3200 / 1-336-449-5054 FAX: 1-336-449-5461 www.aeroaccessories.com

2.

Additionally, TCM has determined that several EQ6561 Fuel Pump Kits are still available in the after market from both TCM Distributors and Independent Parts Suppliers. You may access this information via www.partsbase.com, or call your local TCM Distributor.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

09

1981

02

05

2001

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

2 of 2 M81-8

R1

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M81-9 Supersedes M80-20 Technical Portions Are FAA-DER Approved

9 March 1981 TO: SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. NOSE SEAL RETAINER PLATES New TSIO520M engines before serial No. 520188, TSIO520P engines before serial No. 513621, and TSIO520R engines before serial No. 517962. All rebuilt TSIO520M, P, and R engines manufactured before 9/5/80.

Gentlemen: To preclude the possibility of the nose seal coming out, it has been determined that the nose seal retainer plates Part Number 641361 must be installed on the above listed engine models. To accomplish this, the following parts are required: 2 ea. 642361 Plates 4 ea. 628321-.38 Screws The screws must be torqued to 21-25 in. lbs. The above must be complied with within the next 50 hours of operation. The subject parts will be covered per the applicable warranty plus one hour labor for those engines that fall within the warranty period. The nose seal plates are also available for installation on the O470R, S & U; IO520D, F & L and the TSIO520C, G & H.

 TELEDYNE INDUSTRIES, INC. 1981

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M82-13 Technical Portions are FAA-DER Approved

27 October 1982 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FUEL CONTROL INLET FITTING

MODELS AFFECTED:

TSIO-520-AE and LTSIO-520-AE

Compliance:

At Next 100 Hour Inspection

Current production engines are being manufactured with a tee which has an orifice size of 0.039 - 0.041. Those tees which have been modified at the factory have been identified with a spot of green paint and a new P/N 646289. At the next 100 hour inspection or sooner at the owners discretion, check the fuel orifice in the tee with a plug or wire gage. The orifice size of the original fitting (P/N) 632119) was 0.031 0.032. The original fitting must either be replaced or modified by drilling the orifice with a number 60 drill to the new size. Prior to re-installing the fitting, clean the threads with clean degreaser or Loctite "Loquic Primer T" to be sure all oil and dirt is removed. Blow dry with compressed air. Apply Loctite Hydraulic Sealant 69 or 569 sparingly 3/4 of the way around on the male thread only. To avoid contamination of the fuel cavity, do not apply sealant to the 1st thread. Install the fitting until tight and properly aligned. Allow sealant to cure for 30 minutes. Place mixture control in idle cut-off and manually activate the aircraft fuel boost pump to pressure test the fitting. Make a log book entry indicating method of compliance with this bulletin.

 TELEDYNE INDUSTRIES, INC. 1982

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M82-3 Technical Portions Are FAA Approved

8 March 1982 TO: SUBJECT:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines. LEAR SIEGLER, INC., ROMEC DIVISION, FUEL PUMP, TCM P/N 643367A1

MODELS AFFECTED: COMPLIANCE:

GTSIO-520N Serial Numbers 610001 thru 610269 except 610121, 610128, 610164, 610174, 610180, 610182 thru 610185, 610187, thru 610189, 610191 thru 610210, 610213 thru 610268

Gentlemen: Teledyne Continental Motors Aircraft Products Division recommends that the attached Lear Siegler, Inc., Romec Division Service Bulletin No. 101SB009 be complied with as follows: 1. At the next scheduled maintenance period or within 100 hours after receipt of this bulletin or 2. If the engine driven fuel pump is unable to maintain fuel pressure within specified limits for normal engine operation. Request payment for allowable labor by properly filing a warranty claim form through an authorized distributor. A labor allowance of one-half (.5) hours maximum per engine will be accepted. Order TCM P/N CRA36445 to accomplish fuel pump modification.

 TELEDYNE INDUSTRIES, INC. 1982

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M82-5 Technical Portions are FAA-DER Approved

April 26, 1982 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FUEL PRESSURE REGULATOR 642100-5 & 642100-6 ON ENGINES INSTALLED IN CESSNA 340 AND 414 SERIES AIRCRAFT.

MODELS AFFECTED:

NEW ENGINES TSIO-520NB Serial Numbers 519735 thru 519738, 519781 thru 519785, 519885 thru 519890, 519893 thru 519897, 519899 thru 519915, 519929 thru 519933, 519935 thru 519937, 519939 thru 519962, 521026 thru 521045, 521049 thru 521074, 521085 thru 521088, 521097, 521141 thru 521168, 521170 thru 521183, 521187 thru 521237, 521239 thru 521247, 521249 thru 521255, 521257, 521258, 521260 thru 521281, 521284 thru 521305, 521307 thru 521335, 521339, 521340, 521342 thru 521345, 521347, 521349, 521351, 521353, 521354, 521357, 521358, 521362, 521365, 521366, 521371, 521378, 521384, 521385, 521393, 521395, 521398, 521413 thru 521418, 521441, 521442, 521455, 521461. REBUILT ENGINES TSIO-520J, JB Serial Numbers 218830, 218831, 218836, 218838 thru 218873, TSIO-520K, KB Serial Numbers 224563, 224565 thru 224573, TSIO-520N Serial Numbers 228231, 228243, 228248 thru 228250, 228255, 228262 thru 228363, 228365 thru 228368, 228373, TSIO-520NB Serial Numbers 233976, 233982, 233986, 233987, 233989 thru 234058, 234060 thru 234069, 234071 thru 234074, 234077, 234078.

COMPLIANCE:

Immediately Upon Receipt of This Bulletin

Gentlemen: We have received reports of fuel seepage at the fuel fitting locations of the subject regulators on low time engines. For applicable engines, prior to the next flight place mixture control in idle cut-off and manually activate the aircraft boost pump to static check the fuel pressure regulator for leaks. Visually inspect the fuel pressure regulator for the presence of fuel stains. If either inspection indicates a leak, comply with paragraph "A" immediately. If no leaks are indicated, comply with paragraph "A" within the next 10 operating hours. A. Remove the fuel fittings from the regulator and inspect the thread bores in the regulator and the threads on the fittings. If the threads appear damaged, cut or chipped (when compared to a normal pipe thread) install a new fuel pressure regulator P/N 642100-5 (TSIO-520J, JB, K, KB all specs. TSIO-520N spec 1, 2, 4 or TSIO-520NB spec 1, 2, 4, 13, 14 and 16) or 642100-6 (TSIO-520N spec 5, 6, 8 or TSIO-520NB spec 5, 6, 8, 9, 10 or 12). Prior to installing the fittings in the present or replacement new regulator, clean the threads with clean degreaser, or Loctite

 TELEDYNE INDUSTRIES, INC. 1982

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

April 21, 1982

Page 2

M82-5

"Loquic Primer T" to be sure all oil and dirt is removed. Blow dry with dry compressed air. Apply Loctite Hydraulic Sealant 69 or 569 sparingly 3/4 of the way around on the fitting threads only. To avoid contamination of the fuel cavity do not apply sealant to the first thread. Install the fittings until tight (at least 3-5 threads engagement). Allow sealant to cure for 30 minutes. Place mixture control in idle cut-off and manually activate the aircraft boost pump to pressure test the fuel pressure regulator. Labor and parts coverage will be administered through your distributor in accordance with the Gold Medallion Policy. Allow 1/2 hour for inspection detailed in paragraph "A". Allow an additional hour if replacement of regulator is necessary. Make log book entry to indicate compliance with this bulletin.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M82-7 Technical Portions are FAA-DER Approved

13 May, 1982 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

TUBE ASSEMBLY (Air Reference Tube)

MODELS AFFECTED:

TSIO-360GB (Installed in Mooney 231) Prior to S/N 309749

Gentlemen: Teledyne Continental Motors has received reports of fractures in the air reference tube, P/N 641082, on engines installed between the air throttle adapter and the fuel pump in Mooney 231 aircraft. See Figure 1. Since any bending of this preformed tube can cause damage which can result in a fracture, it is extremely important that the tube not be bent from its original configuration. The tube has been reconfigured to provide additional clearance and the material from which the tube is fabricated has been changed to steel in order to reduce the potential of damage to the tube. The redesigned tube assembly is P/N 646114. (See Parts Catalog, Form X30031A.) Teledyne Continental Motors recommends that within the next 50 hours or next scheduled maintenance, whichever occurs first, the air reference tube, P/N 641082, on engines installed in affected Mooney 231 aircraft be visually inspected for any cracking, crazing or deformity from its preformed configuration and that any tube having any such discrepancy be replaced with P/N 646114.

FIGURE 1

 TELEDYNE INDUSTRIES, INC. 1982

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M83-3 Technical Portions are FAA-DER Approved

14 February, 1983 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

ROTO MASTER (Rajay) SERVICE LETTER 27 REVISION A DATED SEPTEMBER 24, 1982 AND ADDENDUM THERETO DATED FEBRUARY 9, 1983 IN RESPONSE TO FAA AD 82-07-03.

MODELS AFFECTED:

New and Rebuilt L/TSIO-360E, EB, F, FB, GB and KB engines having the following serial numbers: NEW TSIO-360E New Serial No's TSIO-360EB New Serial No's LTSIO-360E New Serial No's LTSIO-360EB New Serial No's TSIO-360F New Serial No's TSIO-360FB New Serial No's TSIO-360GB New Serial No's TSIO-360KB New Serial No's LTSIO-360KB New Serial No's

303252 thru 303999, 304736 thru 304849, 307000 thru 307367 307391 thru 307999, 311000 thru 311715 304367 thru 304999, 306000 thru 306360 306382 thru 306999, 312000 thru 312700 305000 thru 305704 305737 thru 305999, 310000 thru 310831 309004 thru 309779 315001 thru 315537 314000 thru 314516

REBUILT TSIO-360E Rebuilt Serial No's. TSIO-360EB Rebuilt Serial No's. LTSIO-360E Rebuilt Serial No's. LTSIO-360EB Rebuilt Serial No's. TSIO-360F Rebuilt Serial No's. TSIO-360FB Rebuilt Serial No's. TSIO-360GB Rebuilt Serial No's. TSIO-360KB Rebuilt Serial No. LTSIO-360KB Rebuilt Serial No.

225000 thru 225102 234551 thru 234666 225500 thru 225599 233751 thru 233863 232751 thru 232777 237301 thru 237370 237401 thru 237414 242901 242922

COMPLIANCE: Within the next 50 hours of operation, the next annual or 100 hour inspection, whichever comes first and at each 200 hour interval thereafter until the P/N 643931 housing is installed.

A new turbocharger, part number 646396, with a new exhaust housing is now in production on the above listed engine models. The new turbocharger has serial numbers 203570 thru 203654 and 204000 and after.

 TELEDYNE INDUSTRIES, INC. 1983

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

All affected engines must comply with the attached Roto Master Service Letter 27 Rev.A. All affected housings have the single letter "N" cast on the housing. The new housing, P/N 643931 are manufactured using ni-resist D5S material and are identified by the letters "DN" cast on the housing. 1.

GOLD MEDALLION COVERAGE

If compliance with the above Service Letter required replacement of the turbine housing within the first six (6) months or 240 hours of operation (whichever occurs first) of any engine covered by the Gold Medallion Warranty, TCM will replace the housing, TCM P/N 643931, and gasket TCM P/N 643932, and pay for one (1) hour of labor costs associated with such replacement. 2.

ADDITIONAL PARTS COVERAGE

If compliance with the above Service Letter required replacement of the turbine housing after the expiration of the applicable six (6) month or 240 hour period described above and before the expiration of a total of 12 months. TCM will replace the housing, TCM P/N 643931, and gasket, TCM P/N 643932, but will pay no labor costs in connection with such replacement. 3.

SPECIAL POLICY DUE TO AD 82-17-03

After expiration of the 12 month period described above on those housings with 300 hours or less time in service, TCM will supply replacement housing at no charge pending verification by inspection that replacement was in accordance with Roto Master Service Letter 27 Revision A. No labor will be authorized. This special program expires on February 1, 1984. All claims and parts must be submitted to TCM by April 15, 1984. When purchasing the above parts for replacement under any of the adjustments specified above, please refer to Service Bulletin M83-3 and the warranty claim number. Replacement parts will be available for purchase for engines not qualifying for any of the adjustments described above. The standard replacement parts warranty (Aircraft Engine Parts, Component and Accessory Warranty) will apply to such purchases. NOTE...The 2 P/N 633358 clamps that attach the tail pipe and exhaust system to the turbocharger utilize two different style attach bolts. These clamp attach bolts are interchangeable and both are acceptable.

PAGE 1 OF 9 SEPTEMBER 24, 1982 REVISION A 7101 FAIR AVENUE - NORTH HOLLYWOOD, CALIFORNIA 91605 - (213) 982-4500

SERVICE LETTER NUMBER 27 FAA APPROVED

REFERENCE:

AD 82-27-03 (Effective December 30, 1982)

SUBJECT:

Rajay Turbocharger Model 325E10 Inspection of Turbocharger

Turbine

Housings

P/N

TC-60-11

and

airplanes

and/or 600510-01, 600510-02.

EQUIPMENT AFFECTED:

Applies

to

all

affected

engines

certificated in all categories that have installed Rajay turbocharger model 325E10.

DISTRIBUTION TO:

Aircraft ManufacturersAircraft Engine ManufacturersAircraft Maintenance and/or Modification Bases

Time of Compliance:

Inspection of the turbocharger turbine housing required: Within 50 hours unit time in service, or at the next aircraft annual or 100 hour inspection, whichever comes first, and Then at 200 hour time-in-service intervals.

Reason: Formation of hairline cracks has been discovered in the inlet area of the turbocharger turbine housing (Rajay part number TC-60-11 or 600510-02) used on Model 325E10 Rajay turbochargers in production since June 1976. In some cases, the crack in the above referenced area (tongue area) may have propagated through the outer wall of the turbine housing.

SERVICE LETTER NUMBER 27 PAGE 2 OF 9 SEPTEMBER 24, 1982 Therefore, visual inspection is required as referenced in above "Time of Compliance" paragraph to detect the possible formation and/or propagation of subject hairline cracks in the turbine housing. Upon replacement of the subject turbine housing per instructions Ala, A2b(2) with a new improved-material turbine housing (D5S Ductile Ni-Resist), P/N 600510-04 (TCM P/N 643931**), this Service Letter no longer applies. DESCRIPTION: Perform a visual inspection of the turbine housing P/N TC-60-11 and/or P/N 600510-01, 600510-02, to determine existence of cracks as indicated in Figure 2, Views 1, 2 and 3. A.

Turbocharger Inspection

(See

Section B for

detailed

inspection

instructions) 1.

Inspection of Turbocharger Installed on Engine - After the initial 50 hours Turbocharger time-in-service operation and/or at next aircraft annual and/or 100 hours inspection, whichever occurs first, and thereafter at every 200 hours unit time-in-service, but not later than May 31, 1983.

Visually inspect the Turbocharger turbine housing to

ascertain possible presence of cracks penetrating the outer wall as shown in View 3. a. If Outer Wall Is Penetrated - Replace the turbine housing and gasket with a new P/N 600510-04 (TCM P/N 643931**) housing and new P/N 600400-00 (TC-6-30) (TCM P/N 643932**) gasket prior to the next flight. 2.

Inspection of Turbocharger Removed from Engine – Visually inspect the

turbocharger

turbine

housing

through

presence of cracks as shown in View 1.

the

exhaust

port

for

SERVICE LETTER NUMBER 27 PAGE 3 OF 9 SEPTEMBER 24, 1982 a. If No Cracks Are Found - on the inner or outer wall of the turbine housing, reinstall turbocharger, and at the 200 hours time-inservice repeat the inspection of the unit per A.1. above b. If An Internal Crack Is Found - remove turbine housing and inspect for cracks as shown in View 3. (1) If All Internal Cracks are found within the limits of Views 1, 2 and 3, then the turbine housing may be returned to service, but continue

to

monitor

the

crack

propagation

at

next

and

subsequent 200 hours time-in-service. (2) If An Internal Crack Exceeds The Limit - as shown in Views 1, 2 or 3, then the turbine housing and gasket must be replaced with new housing as specified in A. 1.a above. CAUTION In any case, when a crack penetrates the outer wall of a turbine housing as shown in View 3, the turbine housing and gasket must be replaced prior to the next flight. If

a

crack

has

penetrated

the

housing,

inspect

the

surrounding

engine

components, hoses, clamps and mounts for possible heat damage and replace as necessary. If unable to determine the part number or revision letter of the turbine housing, assume it is an affected part and perform inspections per this Service Letter.

SERVICE LETTER NUMBER 27 PAGE 4 OF 9 SEPTEMBER 24, 1982 B.

Detail Inspection Instructions In certain aircraft installations, it may be possible to inspect the turbine housing inner and outer walls for penetrating cracks per Views I and 3, without removal of the turbocharger from the aircraft. the

exhaust

manifold

must

be disconnected

from

In the

any

event,

coupling

V-

band so that the turbine housing internal area near the nozzle can be seen as shown in View 2.

If a thermal blanket is installed on the

turbine housing, it must be removed. (See Figure 1.) To inspect the turbine housing for internal the

complete

turbocharger

from

cracks per View 2, remove

the

aircraft

as

per aircraft

maintenance manual. CAUTION Before removing the turbocharger, make sure spare turbine housing gaskets

are available.

Do not

attempt

to reuse the gasket.

(P/N

600400-00 or TC-6-30 or TCM P/N 643932**) 1. Remove the turbine housing blanket

(if

installed).

(See Figure

1.) 2. Disconnect

the

exhaust

manifold

by

removing

the

coupling V-

bands. 3. Make "index marks" on the turbine housing and on the aluminum bearing housing so the turbine housing will be reinstalled in the same correct rotational position. 4. Remove

the

V-band

nut

and

carefully

remove

the

bearing

housing V-band (P/N 600391). 5. Remove

the

turbine

housing

from

inspect per Description A.1. and 2.

the

bearing

housing

and

Light tapping at the joint with a

rawhide mallet will help separate them. 6. While

the

housing

is

off,

inspect

the

turbine

shield for condition and/or foreign object damage.

wheel

and heat

SERVICE LETTER NUMBER 27 PAGE 5 OF 9 SEPTEMBER 24, 1982 NOTE: be

in

should

When the turbine housing is off, the turbine wheel should contact with be

the

difficult.

If

adjacent not,

a

heat

shield

Roto-Master

and rotating it

or

TCM

service

representative should be contacted. 7.

Carefully remove all parts of the turbine housing gasket and replace with a new P/N 600400-00 or TC-6-30 or TCM P/N 643932** gasket.

8.

If a new turbine housing

is needed,

order Roto-Master P/N

600510-04 (or TCM P/N 643931**). 9.

After inspection, clean the two mating diameters and gasket surfaces on the turbine housing and bearing housing.

10.

Reinstall

the

same

or

a

new

turbine

housing

as

appropriately mandated by this inspection onto the bearing housing in the original rotational position. NOTE: The

turbine

housing

and

bearing

housing

must

together while the V-band is being reinstalled.

be

pressed

A light tapping on

the V-band with a rawhide mallet will help to tighten and seat the V-band. 11.

Assure

that

the

turbine

housing

is

in

the

exact

same

rotational position (use the marks made earlier), the V-band is in the approximate same position and tighten the V-band 15 to 20 inch/pounds torque. 12.

Reinstall

the turbine blanket

for

rotation

free

of

the

nut

to

Do not overtighten. (if used - see Figure

turbine

wheel.

Do

1) and check

not reinstall

if

rotation is difficult or scraping noises are heard. 13.

Reinstall

the

turbocharger

maintenance manual.

on

the

aircraft

per

Take special care that all oil

fittings are clean, undamaged and unobstructed.

aircraft lines and

SERVICE LETTER NUMBER 27 PAGE 6 OF 9 SEPTEMBER 24, 1982

14.

If housing -is replaced because of cracks, complete the FAA Malfunction or Defect Report, Form 8330-2 and submit to the local FAA GADO office.

15.

Check that the V-band torque is

still

15 to 20 inch/pounds

after next flight or run-up. References and Notes: ** Teledyne Continental Motors (TCM) part numbers.

Roto-Master plans to offer a rebuilt exchange program.

For additional information, contact: Roto-Master, Inc. 7101 Fair Avenue North Hollywood, CA 91605 ATTN: Aircraft Field Sales Manager

SERVICE LETTER NUMBER 27 PAGE 7 OF 9 SEPTEMBER 24, 1982

ROTO-MASTER INC.

SERVICE LETTER NUMBER 27 PAGE 8 OF 9 SEPTEMBER 24, 1982

VIEW 1

Turbine Housing Exhaust Inlet Internal Cracks.

FIG. 2 TURBINE HOUSING VIEWS

ROTO-MASTER INC.

SERVICE LETTER NUMBER 27 PAGE 8 OF 9 SEPTEMBER 24, 1982

VIEW 2

View of Turbine Housing with turbo center section removed.

VIEW 3

View of Turbine Housing with external cracks

FIG. 2 (cont.) TURBINE HOUSING VIEWS

SERVICE LETTER NUMBER 27 ADDENDUM FEBRUARY 9, 1983 PAGE 1 OF 1

SERVICE LETTER 27A ADDENDUM The following information is an addendum to Roto-Master Service Letter 27A and should be attached thereto and made a part thereof. The model number 325E10 includes models 325E10-1 and 325E10-2. The new Rajay model number 3AT6EE10J2 is identical to the older model number 325E10-1 and is also affected by AD 82-27-03. Roto-Master turbochargers after serial number 203570 came equipped with a 600510-04 D5S Ductile Ni-Resist turbine housing and are therefore not affected by AD 82-27-03. The 600510-02 Type 3 Ni-Resist housing that is affected by AD 82-27-03 has the letter "N" cast on the outside of the scroll. The 600510-04 D5S Ductile NiResist turbine housing that terminates this AD has the letters "DN" cast on the outside of the scroll. The following Rajay engine STC's are affected by AD 82-27-03: STC SE14WE SE154SO SE32WE

ENGINES LYC 10-320, LIO-320 LYC 0-360 LYC 10-360, LIO-360

The TCM TSIO-360 engine is affected by AD 82-27-03 when it is equipped with a Rajay turbocharger that has a serial number prior to 203570. The other engines mentioned in the AD do not come factory equipped with a Rajay model 325E10 turbocharger. The Rajay systems for these engines do not use a model 325E10 turbocharger. These engines are affected by AD 8227-03 only when model 325E10 or 3AT6EE10J2 has been installed in place of the original turbocharger by an FAA field approval or a non Rajay STC. The engines that fall into this catagory are as follows: Lycoming 0-320, TO-360, 0-540, and TIO-540 Continental 0-470, 10-470, 10-520, and TIO-540 The Rajay turbine inlet gasket part number is RJ0115. The Rajay turbine discharge gasket part number is RJ0114. The turbine inlet and discharge Vband clamps are tightened to 20-30 in. Ibs. The TCM TSIO-360 does not use turbine inlet or discharge gaskets.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M83-5 Technical Portions Are FAA-DER Approved

7 March 1983 TO: Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines SUBJECT: SLICK SERVICE BULLETIN 3-82 MODELS AFFECTED: COMPLIANCE:

C-90, O-200, IO-360, TSIO-360, LTSIO-360, O-470, IO-470, IO-520, TSIO-520 and LTSIO-520 See Slick Bulletin

Teledyne Continental recommends compliance that the attached Service Bulletin 3-82 be complied with.

 TELEDYNE INDUSTRIES, INC. 1983

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M83-6 Technical Portions Are FAA Approved

7 March 1983

TO:

SUBJECT: MODELS AFFECTED: COMPLIANCE:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engine. SLICK SERVICE BULLETIN 2-82 O-470, IO-470, IO-520, LTSIO-360 AND TSIO-520 See Slick Bulletin

Teledyne Continental Motors recommends that the attached Slick Service Bulletin 2-82 be complied with.

TELEDYNE INDUSTRIES, INC. 1983 Aircraft Products P.O. Box 90 • Mobile, Alabama 36601

Aluminum Die Castings and Precision Screw Machine Parts . . . 530 BLACKHAWK PARK AVENUE, ROCKFORD ILLINOIS 61101 PHONE 815 965-7704

Dec. 1, 1982 SERVICE BULLETIN 2-82 Distributor Block Mounting Screws Background

There have been reports that the distributor block, Slick P/N M1067, has been found to be loose in the distributor housing, Slick P/N M-1259.

In all cases the cause has been tracked to the wrong screws being used to hold the distributor block in place. Equipment Affected

All Slick 662, 664, 667 and 680 series new and remanufactured magnetos.

Compliance

At the next magneto overhaul, or when the magneto has been opened up for any reason, the distributor block should be checked for tightness.

DetaIis of Maintenance

The distributor block should be secured to the distributor housing with three 8-32 x 5/8 long round-head screws and lockwashers. Great care should be taken not to confuse the correct screws with the almost identical but shorter screws (8-32 x 9/16) used to secure the M-1071 bearing plate. Torque on screws should not exceed 18-20 in. – lbs.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M83-8 Rev. 1 Technical Portions are FAA-DER Approved

15 July, 1983 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT:

FUEL PUMP REPLACEMENT

MODELS AFFECTED:

TSIO-520M spec. 1, 2; TSIO-520P spec. 1, 2; TSIO-520R spec. 1, 3; and TSIO-520C, G & H (all specs.)

Compliance:

At Owners Discretion

The subject fuel pump is being installed on current production TSIO-520M spec. 3, 4; TSIO520P spec. 3 and the TSIO-520R spec. 4, 5 engines. The fuel pump aneroid valve is relocated to make the pressure adjusting screws more accessible. When making the conversion the air manifold to fuel pump tube assembly must also be replaced. See chart for parts replacement. PART NO. (Old)

Qty.

Nomenclature

Part No. (New)

Qty.

642004

1

Tube Assy. Air Manifold to F.P.

643746

1

632818-7A3

1

Fuel Pump Assembly (M,P,R)

642651-1A2

1

632818-5A4

1

Fuel Pump Assembly (C,G,H)

642651-2A1

1

 TELEDYNE INDUSTRIES, INC. 1983

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M84-13 Technical Portions Are FAA-DER Approved

27 October 1984 TO: Aircraft Manufacturers, Distributors, and SUBSCRIBERS SUBJECT: SLICK SERVICE BULLETIN NO. SB 1-84 MODELS AFFECTED: COMPLIANCE:

TSIO-520 See Slick Service Letter

Teledyne Continental recommends that the attached Slick Service Bulletin SB1-84 be complied with.

 TELEDYNE INDUSTRIES, INC. 1984

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

SLICK

SB 1-84

Service Bulletin TO: INFORMATION:

Owners of Cessna T210, P210 and T303 Aircraft The Service History of Slick Aircraft 6220 and 6224 Magnetos installed on Cessna T210, P210 and T303 aircraft indicates that certain magnetos manufactured between October 1981 and March 1982 may requires service prior to the initial 500 hour maintenance inspection as outlined in Slick Maintenance and Overhaul Manual L-1037. Slick has been working closely with Teledyne Continental Motors to determine the cause and extent of these magneto malfunctions. We have isolated the service problem to a particular component assembly and magneto serial number range. Slick, therefore, recommends that affected magnetos be removed from Cessna T210, P210 and T303 aircraft and the M-3122 distributor block assembly replaces. Slick is prepared to provide replacement component assemblies for all affected magnetos at no charge. Slick will also grant labor allowances up to 1-1/2 hours per magneto with less than 500 log hours, provided the terms and conditions outlined in this bulletin are satisfied by April 30, 1985.

COMPLIANCE:

As required

PROOF OF COMPLIANCE:

Appropriate logbook entries.

AFFECTED:

Slick 6220 and 6224 Magnetos installed on Cessna T210, P210 and T303 aircraft with magneto serial numbers that begin with one of the following 3-digit numbers. Only magnetos with these serial numbers will be considered for warranty compensation. 101 110 111 112 210 202 203

ISSUED MO DAY 10 01

YR 84

REVISED MO DAY YR -

Example: 1120045

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

1 OF 3

NONE

SLICK Service Bulletin

SB1-84

MAINTENANCE PARTS AFFECTED: None. PARTS REQUIRED PER BULLETIN:

M-3122 Distributor Block Assembly

PARTS REQUIRED PER BULLETIN:

Continued

TOOLS REQUIRED PER BULLETIN:

Slick T-100 Timing Assembly Tool Kit and Standard Shop Tools

WEIGHT CHANGE:

None.

DETAILED INSTRUCTIONS: 1. Verify that the first three digits of the magneto serial number begins with one of the following number combinations. Only magnetos with these serial numbers will be considered for warranty compensation. 101 110 111 112 210 202 203

Example: 1120045

2. Purchase replacement Slick M-3122 Distributor Block Assembly from any Slick Distributor. Request a Slick Warranty Form L-1042 from the distributor. 3. Remove affected magnetos from aircraft engine. 4. Install replacement components per Slick Maintenance and Overhaul Manual L-1037. 5. Install magnetos on aircraft engine. 6. Complete Slick Warranty Form L-1042 in full and attach the appropriate receipts and work orders. If the magnetos have been in service less than 500 hours, your mechanic should list any labor charge associated with the replacement of the distributor block assembly in the appropriate space provided. Slick will grant labor allowances for these magnetos up to 1-1/2 hours per magneto at posted shop rates.

ISSUED MO DAY 10 01

YR 84

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

2 OF 3

NONE

SLICK Service Bulletin SB1-84 7. Return the affected distributor block assemblies and warranty form to the distributor that supplied the replacement parts. Retain the yellow copy of the warranty form for your records. If a labor allowance is claimed, copies of the engine logbook showing magneto log hours must accompany the warranty form. 8. Make all appropriate logbook entries. 9. Slick will verify that the magneto parts were replaced per these instructions and will process the claim for warranty compensation. 10. A credit memo for the amount of the replacement parts and the labor allowance (where applicable) will be sent to the appropriate distributor provided all paperwork is completed properly and the parts are replaced per these instructions 11. Upon receipt of the Slick credit memo, the distributor will credit you for the amount of the replacement parts and the labor allowance (where applicable). Slick understands that some Cessna T210, P210 and T303 owners may have already replaced Slick 6220 and 6224 Magnetos having a serial number that is noted in Step 1, or M-3122 Distributor Block Assemblies which malfunctioned during the first 500 hours of operation. These owners should also complete a warranty form, including copies of receipts for the purchase of replacement units. These warranty forms and accompanying documents should be sent directly to Slick for processing at the following address: Slick Aircraft Products Attn: SB 1-84 530 Blackhawk Park Avenue Rockford, Illinois 61108 WARRANTY:

Replacement parts and labor allowance up to 1-1/2 hours per magneto as stated in Detailed Instructions, Step 6. CHECK WITH SLICK TO BE SURE YOU HAVE THE MOST CURRENT REVISIONS OF SLICK MANUALS F-1020 AND L1037 AND PERTINENT SLICK SERVICE BULLETINS BEFORE PERFORMING MAINTENANCE OR OVERHAUL.

ISSUED MO DAY 10 01

YR 84

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

3 OF 3

NONE

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M84-15 SUPERSEDES M76-18 Rev.1 Technical Portions are FAA Approved

21 December 1984

TO:

SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines. CYLINDER LEAKAGE CHECK (Compression)

ALL

The differential pressure test is an accepted method of determining cylinder condition by measuring air pressure loss past the pistons, rings and valves. The operation of the equipment is based on the principle that, for any given airflow through a fixed orifice, a constant pressure drop across that orifice will result. On many engines it is now a regular part of the 100 hour or annual inspection. We have received reports of incorrect cylinder leakage check results caused by improper use of test equipment and/or by the use of faulty test equipment. To help you accurately accomplish a leakage check, we submit the following information on leakage and use of the Master Orifice Tool (Ref. Figure 1) to calibrate the leakage checking equipment used on Teledyne Continental engines. LEAKAGE CHECKS Cylinder leakage is broken down into two areas of concern, the "Static Seal" and the "Dynamic Seal.” Static Seal The static seal consists of the valve to valve seat seals, spark plug to spark plug port seals and cylinder head to barrel seal (Ref. Figure 2). No leakage of the static seal is permissible. Dynamic Seal The dynamic seal consists of the piston rings to the cylinder wall seal (Ref. Figure 2). This seal leakage can vary from engine to engine by the cylinder displacement, cylinder choke, ring end gap and piston design.

TELEDYNE INDUSTRIES INC. 1984 Member of GAMA

TELEDYNE CONTINENTAL MOTORS Aircraft Products Division P.O. Box 90 • Mobile, Alabama 36601

21 December 1984

Page 2

M84-15

FACTORY CALIBRATED ORIFICE

DUST CAP

(Clean with soft brush. Do not alter size)

DUST CAP

SPARK PLUG THREADS (18mm)

NOTE: THREAD HAND TIGHT TO SPARK PLUG ADAPTER

FIGURE 1. MASTER ORIFICE ASSEMBLY TOOL BORROUGHS P/N 646953 Borroughs Tool & Equipment Corp. 2429 N. Burdick St. Kalamazoo, MI 49007 Tel. 616/345-2700

STATIC EXHAUST VALVE SEAL

SPARK PLUG SEAL

DYNAMIC INTAKE VALVE SEAL

CYLINDER HEAD & BARREL SEAL

CYLINDER WALL DIMENSION & CHOKE

1ST & 2ND COMPRESSION RING GAP

PISTON DIMENSION

FIGURE 2.

21 December 1984

Page 3

M84-15

B. EQUIPMENT Testing equipment must be kept clean and checked periodically for accuracy as follows: Using a line pressure of 100 to 120 P.S.I., close the cylinder pressure valve, then set the regulator pressure valve to 80 P.S.I. The pressure in both gages should stabilize with no leakage. The restrictor orifice dimension in the differential pressure tester for Teledyne Continental aircraft engines must be 0.040 inch orifice diameter, 0.250 inch long with 60 degrees approach angle, and must flow 120 + or - 5 cubic feet per hour at 30 P.S.I. differential pressure. Master Orifice Tool For conformity in tester equipment, a Master Orifice Tool has been developed to calibrate equipment and determine the low indicated leakage limit prior to the engine leakage check. Connect compressed air at 100-120 P.S.I. to the tester with cylinder pressure valve closed. Turn the regulator pressure valve on, adjusting pressure to indicate 80 P.S.I. Remove the dust caps from both ends of the Master Orifice Tool and install onto your cylinder spark plug adapter. Turn the cylinder pressure valve on and readjust regulator pressure gage to read 80 P.S.I.. At this time the cylinder pressure gage indication will be the low allowable limit for cylinder leak checks. The low allowable limit is referred to as the master orifice calibrated pressure reading. After the master orifice calibrated pressure reading has been recorded, close regulator pressure valve and remove Master Orifice Tool from your cylinder adapter. A schematic diagram of a typical differential pressure tester is shown in Figure 3. C. PERFORMING THE CHECK The following procedures are listed to outline the principles involved, and are intended to supplement the manufacturer's instructions for the particular tester being utilized. CAUTION...Magnetos and fuel must be shut off prior to test to make certain that the engine cannot accidentally fire. (a)

Perform the test as soon as possible after the engine is shut down to ensure that the piston rings, cylinder walls, and other engine parts are well lubricated and at running tolerance.

(b)

Remove the most accessible spark plug from each cylinder.

(c)

Turn the crankshaft by hand in the direction of rotation until the piston (in the cylinder being checked) is coming up on its compression stroke.

(d)

Install an adapter in the spark plug hole and connect the differential pressure tester to the adapter. (NOTE: Cylinder pressure valve is in the Closed position). Slowly open the cylinder pressure valve and pressurize the cylinder not to exceed 20 P.S.I..

Continue rotating the engine against this pressure until the piston reaches top dead center (TDC). Reaching TDC is indicated by a flat spot or sudden decrease in force required to turn the crankshaft. If the crankshaft is rotated too far, back up at least one-half revolution and start over again to eliminate the effect of backlash in the valve operating mechanism and to keep the piston rings seated on the lower ring lands. This is critical because the slightest movement breaks this piston ring sealing and allows the pressure to drop. CAUTION...Care must be exercised in opening the cylinder pressure valve, since sufficient air pressure will be built up in the cylinder to cause it to rotate the crankshaft if the piston is not at TDC. It is recommended that someone hold the propeller during check to prevent possible rotation.

21 December 1984

Page 4

M84-15

(e)

Open the cylinder pressure valve completely. adjust, if necessary, to 80 P.S.I..

Check the regulator pressure gauge and

(f)

Observe the pressure indication on the cylinder pressure gage. The difference between this pressure and the pressure shown by the regulator pressure gage is the amount of leakage through the cylinder. If the cylinder pressure gage reading is higher than the previously determined master orifice calibrated pressure reading, proceed to the next cylinder leak check. If the cylinder pressure gage reading is lower, proceed with the following. CYLINDER ADAPTER CYLINDER PRESSURE VALVE

CYLINDER ADAPTER

CYLINDER PRESSURE VALVE

CYLINDER PRESSURE GAUGE

CYLINDER PRESSURE GAUGE

RESTRICTOR ORIFICE

RESTRICTOR ORIFICE

REGULATOR PRESSURE GAUGE

MASTER ORIFICE (HAND TIGHT)

REGULATOR PRESSURE VALVE

REGULATOR PRESSURE GAUGE

CYLINDER

REGULATOR PRESSURE VALVE

COMPRESSED AIR SOURCE

COMPRESSED AIR SOURCE

FIGURE 3 – DIFFERENTIAL PRESSURE TESTER Static Seal Check (Table 1) (g)

The source of air leakage should first be checked for the static seal. Positive identification of static seal leakage is possible by listening for air flow sound at the exhaust or induction system cylinder port. When checking for cylinder head to barrel leakage, use a soapy solution between the fins and watch for bubbles. Use a soapy solution also around both spark plug seals for leakage. NO LEAKAGE IS ALLOWED IN STATIC SEALS.

(h)

If leakage is occurring in the intake or exhaust valve areas, it may be possible to correct a low reading by staking the valves. This is accomplished by placing a fiber drift on the rocker arm directly over the valve stem and tapping the drift several times with a hammer to dislodge any foreign material that may be between the valve face and seat.

CAUTION...When correcting a low reading in this manner, rotate the propeller so the piston will not be at TDC. This is necessary to prevent the valve from striking the top of the piston in some engines. Rotate the propeller again before rechecking leakage to reset the valves in the normal manner. NOTE...When the rocker cover is removed, inspect valve springs, valve retainers, and valve stem for wear. This may have contributed to the valve leakage. (i)

If leakage is noted between the cylinder head and barrel, REPLACE THE CYLINDER. If leakage cannot be corrected at the valves by "staking", the cylinder must be removed and repaired before a Dynamic Seal Check.

21 December 1984

Page 5

M84-15

NOTE...When the cylinder is removed, with the spark plugs installed, inspection can be accomplished by filling the inverted cylinder bore with nonflammable solvent and then inspected for leaks at the static seal areas. (j)

If the cylinder was removed for static leakage, replacement or repair, inspect piston ring gap and cylinder wall for tolerance (Ref. Dynamic Seal, Figure 2). Once the piston and the cylinder have been cleaned, inspected, and ring gap tolerances have been met, reassemble to the engine.

Dynamic Seal Check (k)

To check the dynamic seal of a cylinder, proceed with the leakage test and observe the pressure indication of the cylinder pressure gage. The difference between this pressure and the pressure shown by the regulator gage is the amount of leakage at the dynamic seal.

(l)

If the leakage is below the previously determined low cylinder gage reading, loss past the dynamic seal may be due to piston ring end gap alignment or by the piston and piston rings angular direction in the cylinder bore see Figure 4. First assure that the piston and piston rings are centered. This may be accomplished by reducing regulator pressure to 20 P.S.I. and working piston through TDC several times, bringing the piston to TDC in the normal direction of engine rotation. Adjust regulated pressure to 80 P.S.I. and determine amount of loss. If the gage reading is higher than the previously determined master orifice calibrated reading, proceed to next cylinder to be tested. TOP COMPRESSION RING GAP T.D.C.

DIRECTION OF MOVEMENT

TOP COMPRESSION RING GAP

T.D.C.

DIRECTION OF MOVEMENT

FIGURE 4. NOTE...Piston ring rotation within the ring land is a normal design characteristic. As illustrated in Figure 4, the compression ring location may have a direct bearing on the dynamic seal pressure check. Therefore, we suggest you complete the test in the opposite direction if readings are below prescribed limits.

21 December 1984 (m)

Page 6

M84-15

If recheck of cylinder pressure gage reading indication remains below allowable loss, engine may be run-up to operating temperature and rechecked prior to cylinder being removed and repaired. Rework of cylinders should be accomplished as outlined in the engine overhaul manual and service bulletins.

FIRST CHECK

CHECK FOR

Intake Valve to Seat Seal

METHOD

Listen for Air Flow in Intake Port

STATIC SEAL (NO LEAKAGE PERMISSIBLE) Exhaust Valve to Seat Seal

SECOND CHECK

DYNAMIC SEAL

Listen for Air Flow in Exhaust Port

1. DISCREPANCY

2. CORRECTIVE ACTION

Carbon

Stake Valve

Cracked Cylinder

Replace Cylinder

Seat worn or burned

Grind or Replace

Valve worn or burned

Grind or Replace

Carbon

Stake Valve

Cracked Cylinder

Replace Cylinder

Seat worn or burned

Grind or Replace

Valve worn or burned

Replace

Loose Heli-Coil

Replace Heli-Coil

Cracked Cylinder

Replace Cylinder

Spark Plug (2) to Port Seal

Apply Soapy Solution Around Spark Plug

Cylinder Head to Barrel Seal

Apply Soapy Solution Between Head and Barrel

Bubbles

Replace Cylinder

Cylinder Head Cracks

Apply Soapy Solution Around Fins

Bubbles

Replace Cylinder

1. DISCREPANCY

2. CORRECTIVE ACTION

CHECK FOR

Leakage By Piston Rings

METHOD

Test Gauge Below Tolerance

Test Gauge Above Tolerance

Piston cracked or out of limits

Replace Piston

Worn Rings

Replace Rings

Cylinder Wall dimensions out of limits

Replace Cylinder

None

None

TABLE 1

2. CORRECTIVE ACTION

Reinspect

Reinspect Reinspect

2. CORRECTIVE ACTION

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M84-3 Technical Portions are FAA-DER Approved

18 January 1984 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT: INDUCTION MANIFOLD HOSE INSPECTION MODELS AFFECTED:

TSIO-520AE prior to S/N 523254, LTSIO-520AE prior to S/N 524255.

COMPLIANCE: At next scheduled maintenance and each 100 hours, until hoses are replaced. WARRANTY: The action required to comply with this service bulletin is covered by TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

We have received some reports indicating that the hose clamps are wearing and/or cutting into the 643777 (blue) hoses installed at the rear of the engine. These hoses are subjected to movement generated during engine operation. It is suggested that the hoses installed in the locations indicated in Figure 1 be inspected at the next scheduled maintenance and, if wearing or cutting exists, replace them with hose P/N 642917-1 (red). When installing the replacement hoses, assure that clamps are fitted flush on the base and torqued to 35-40 in. lbs. All parts must be clean before installation. The clamps should be checked and retorqued within one week of operation. Old Part Number

New Part Number

Application

643777 (Blue)

642917-1 (Red)

L/TSIO-520AE

 TELEDYNE INDUSTRIES, INC. 1984

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

M84-3

FIGURE 1

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M84-5 Supersedes M80-8 Rev. 1 Technical Portions are FAA-DER Approved

13 February, 1984 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines.

SUBJECT: GEAR DRIVEN ALTERNATOR INSPECTION PROCEDURE MODELS AFFECTED:

All 520 Series Engines With Gear Driven Alternators

COMPLIANCE: Following any indication of alternator electrical system malfunction. WARRANTY: The action required to comply with this service bulletin is covered by TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

Following any indication of alternator electrical system malfunction, investigation of alternator related systems must be performed in conformance with airframe manufacturers' service or maintenance information prior to further operation. If investigation of airframe related systems fails to reveal the source of alternator electrical system malfunctions, the alternator installation inspection procedure must be performed as follows: Remove the alternator from the engine and perform electrical checks in compliance with troubleshooting instructions contained in applicable airframe manufacturers' maintenance manual. Repair or replace the alternator as required. If no electrical malfunctions are isolated, inspect the alternator for signs of mechanical malfunctions in the following areas: 1.

While holding the external hub of the driven gear coupling, manually apply torque to the gear. If slippage is evident, the alternator and hub assembly must be replaced.

2.

While holding the alternator in a horizontal position, rotate the shaft in both directions. If the shaft does not turn freely, internal rotor rubbing or bearing distress conditions are indicated, the alternator and hub assembly must be replaced.

3.

If bearing roughness or noticeable shaft displacements are detected when the shaft is manually rotated or pushed in any direction, the alternator and hub assembly must be replaced.

4.

Visually inspect for damaged alternator driven gear. If the alternator driven gear is damaged, the alternator and hub assembly must be replaced.

 TELEDYNE INDUSTRIES, INC. 1984

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

M84-5 If any one of the above conditions are detected, inspect the oil filter and the interior of the engine through the alternator mount pad opening for signs of metal or rubber contamination. Visually inspect the engine face gear for distress. If no contamination or distress is noted, the engine may be returned to service with proper corrective action to resolve above conditions. However, if internal engine contamination is noted, remove the oil sump and clean thoroughly. Remove and completely clean the oil pump suction tube of any and all contamination. If the pickup tube cannot be completely cleaned, it should be replaced. If face gear distress is detected through the alternator mount pad opening, contact your nearest Teledyne Continental Service Representative for further instructions.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M84-7 Technical Portions are FAA-DER Approved

18 April, 1984 TO:

SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. 643797 TURBO INLET CHECK VALVE TSIO-520UB New Prior to S/N 527030 And Rebuilt Prior to S/N 240975.

COMPLIANCE:

Comply with, in conjunction with Beechcraft Service Bulletin 2027 at the next scheduled maintenance.

WARRANTY:

The action required to comply with this service bulletin is covered by TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

We have reports that the inlet check valve P/N 643797 to the turbocharger has been leaking oil into the turbocharger center housing after engine shutdown. To eliminate this condition a new check valve P/N 646717 has been incorporated on new production engines beginning with S/N 527030 and Rebuilt S/N 240975. Prior to Serial Numbers listed, replace check valve P/N 643797 with new check valve P/N 646717 or as an option you can modify the P/N 643797 valve by removing the internal O-ring and O-ring seat as illustrated. This can be accomplished by first unscrewing the threaded cap end from the main body of the valve and removing the O-ring and seat. When reassembling the valve an approved thread sealant, (example: Loc-Tite #290) should be applied to the female thread on the cap end. Torque the cap end to 100-150 in. lbs. into the main body. Visually inspect the re-installed valve and lines for oil leakage prior to flight. Make an appropriate log book notation indicating your method of compliance with this bulletin. NOTE...Prior to engine shutdown a four minute idle RPM (including normal taxi) should be observed to allow temperature stabilization within the turbocharger to reduce coking.

 TELEDYNE INDUSTRIES, INC. 1984

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

18 April, 1984

Page 2

Old Style Check Valve Part No. 643797.

M84-7

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M84-8 Supersedes M80-21 Technical Portions are FAA-DER Approved

19 June, 1984 TO: Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors’ Aircraft Engines. SUBJECT: MAGNETO TIMING INDICATOR PLATE MODELS AFFECTED:

O-470, IO-470, TSIO-470, IO-520 and TSIO-520

COMPLIANCE: At next starter adapter rework or engine overhaul. WARRANTY: The action required to comply with this service bulletin is not covered by the TCM Gold Medallion Warranty. Magneto timing errors may be attributed to improper use of timing indicator plates. Therefore, we have eliminated using the timing plate, part number 628760, on all current production new and rebuilt engines. All affected publications will reflect this part removal as they are revised. We recommend using the magneto timing procedures as listed on our current service bulletin M80-27 for accurate magneto timing.

 TELEDYNE INDUSTRIES, INC. 1984

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-10 Technical Portions are FAA-DER Approved

18 July 1985 SUBJECT: CYLINDER HOLD DOWN NUTS MODELS AFFECTED:

IO550 Series and Any Other Engines Incorporating the 7th Stud Hold Down Nuts

COMPLIANCE: At Cylinder Installation The clamping arrangement for engines incorporating the 7th stud cylinder deck configuration requires the use of beveled seat brackets P/N 646297 and P/N 646298 on the 7th stud. For alignment purposes, this bracket nut seat is beveled; therefore, a self-aligning nut P/N 646312 is required. (Ref. Figure 1). For identification purposes this nut P/N 646312 is now zinc plate color coded. Revised copies of overhaul manuals and parts catalogs will include this information. All other cylinder hold down nuts are the standard flat seat P/N 531001 nuts. (Ref. Figure 2). Refer to the appropriate overhaul manual for proper torque and sequence.

FIGURE 1

FIGURE 2

(FOR APPLICATION SEE CRANKCASE ILLUSTRATION BELOW)

RIGHT CRANKCASE

 TELEDYNE INDUSTRIES, INC. 1985

LEFT CRANKCASE

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-11 Technical Portions are FAA-DER Approved

18 July 1985 SUBJECT: REPLACEMENT OF P/N 632834A1 TORSIONAL DAMPER ASSEMBLY MODELS AFFECTED:

All GTSIO-520 Series Engines

COMPLIANCE: At Major Overhaul WARRANTY: The action required to comply with this Service Bulletin is not covered by the TCM Gold Medallion Warranty.

The torsional damper is a sealed unit containing a silicone fluid utilized to dampen torsional vibration in the above referenced engines. Depending on the requirements for absorption of vibration and engine compartment temperature levels, the fluid may solidify making the damper less effective. This, in turn, may manifest itself in starter adapter shaft and needle bearing distress. We are recommending that the damper be considered for replacement if adapter shaft and needle bearing distress is detected, and that the damper be replaced at major overhaul if it does not meet the conditions outlined in the following paragraph. This inspection information will be included in the next revision of the appropriate overhaul manual. The damper manufacturer has designed and utilizes a 3/4" diameter twister bar machine to evaluate damper acceptability. The damper is set in resonance in order to establish the dampening time limits which are 1.7 to 10.0 seconds. Dampers with obvious damage are not acceptable for testing and should not be re-used. Through the TCM distributor organization dampers with no obvious damage may be exchanged for new or rebuilt dampers. Rebuilt dampers P/N 632834A1 are sold on an exchange basis only. New outright or exchange P/N 632834A1 dampers may be ordered through your TCM distributor.

 TELEDYNE INDUSTRIES, INC. 1985

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-14 Technical Portions are FAA-DER Approved

23 September 1985 SUBJECT: MAGNETO PRESSURIZATION FILTER MODELS AFFECTED:

All Pressurized Magneto Installations

COMPLIANCE: As Required at Next Scheduled Maintenance

To prevent pressurization hoses from disengaging from the magneto air filter, P/N 643955, at altitude, it is recommended that at the next scheduled maintenance the following modification be performed, if not already accomplished. Loosen both clamps as illustrated in Figure 1 Slide pressurization hoses from air filter. Holding body of filter in hand, roughen both ends of the filter with #280 grit (or equivalent) sandpaper in a clockwise direction. Wipe sanded areas clean of abrasives prior to reinstalling hoses and securing clamp. Make Log Book entry reflecting compliance.

FIGURE 1. MAGNETO PRESSURIZATION FILTER

 TELEDYNE INDUSTRIES, INC. 1985

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-3 Technical Portions Are FAA Approved

4 February 1985 SUBJECT: EXHAUST VALVES IN P/N 646680 CYLINDER ASSEMBLIES MODELS AFFECTED:

Teledyne Continental Motors New and Rebuilt Engines IO470C, S/N 242071 through 076; O470K, S/N 49390 through 394; O470L, S/N 69640 through 642; O470M, S/N 54141 through 142; O470R, S/N 238170, 171, 176, 177, 179 through 185, 187 through 190, 193, 195 through 200, 202 through 204, 206 through 210, 213, 215 through 218, 223, 224, New S/N 466653 and 654; O470S, S/N 226443, 444, 446 through 457; All New P/N 646680 Cylinder Assemblies in inventory or installed on engines since March, 1984, on IO470C and O470G, K, L, M, R,S.

COMPLIANCE: WARRANTY:

Prior to further flight The action required to comply with this service bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

Some Teledyne Continental Motors new and rebuilt engines of the affected models and all P/N 646680 cylinder assemblies sold in the aftermarket since March, 1984, were assembled with exhaust valves and guides with material incompatibility. We suggest that the cylinders on your engine be checked for identification by inspecting for the part number stamped on the base flange. If the cylinders are the P/N 646680, they will have to be removed and the exhaust valve P/N 626540 replaced with the P/N 637781 exhaust valve. At this time, any pickup or metal transferred to the guide should be removed. Using a 1/4" diameter by approximately 8" long mandrel wrapped with 180 grit crocus paper, polish the guide only enough to remove the transferred material. After polishing, the guide I.D. must not exceed .4405 service limit. Upon reinstallation use the procedures as outlined in form X30022A, O470 and IO470 Series Maintenance and Overhaul Manual. When this work has been accomplished, restamp the cylinder P/N 646680A7 and make appropriate log book notations. The parts necessary to accomplish the above should be purchased through your local TCM distributor. Parts required are the following: 6 ea 637781 Exhaust valve 6 ea 534857 Gasket, rocker cover 6 ea 532200 Base seal

 TELEDYNE INDUSTRIES, INC. 1985

6 ea 628260 Exhaust gasket 6 ea 536413 Gasket, intake

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-6 Supersedes M84-14 Technical Portions Are FAA Approved

25 April 1985

SUBJECT: GARRETT SERVICE LETTER TP61-0001, Rev. E MODELS AFFECTED: COMPLIANCE: WARRANTY:

TSIO-520-B, BB, E, EB Next Turbocharger Replacement The action required to comply with this service bulletin is not covered by the TCM Gold Medallion Warranty.

Teledyne Continental Motors recommends that the attached Garrett Service Letter TP61-0001 be complied with.

 TELEDYNE INDUSTRIES, INC. 1985

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-7 Supersedes M77-10 Technical Portions are FAA-DER Approved

23 May, 1985

SUBJECT: CURRENTLY ACTIVE FACTORY APPROVED SPARK PLUGS

The following charts list only the most active spark plugs. Additional listings can be found in FAA and spark plug manufacturer's data. To find the gap of each spark plug, match the letter in the column marked "Gap" with the same letter on the gap chart. To find the correct spark plug to engine application, match the engine model on left hand side of each chart with its corresponding part number listed at the top of each chart in the column marked "Part Number." The letter "X" in the charts listed, indicates the spark plug is approved and recommended for use. The dash (-) indicates the spark plugs not approved and not recommended. Spark plugs should be torqued to 25-30 foot pounds or 300-360 inch pounds.

 TELEDYNE INDUSTRIES, INC. 1985

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

H15 632274

SL350

PL350 635148

632465

PH26

PH260 635147

635146

SH150 632467

SH26

SH260 632463

632462

SH15

SH200A 632461

632460

SH20A 627892

291

293 635860

635859

281

283 632740

632738

273 630533

HSR93

271 630532

635861

HSR88 626362

627450

HSR86 626364

SR93

HSR83P 626363

635862

SR38P

SR87 627449

625350

A88

260

290-300

250

215

260

330

380

330

380

380

380

230

200

230

270

270

200

270

270

360

360

180-210

A-65-75 A-80 A-100 C-75-85-90-115-125 E-165-185-225 O-200-A, B, C O-300-A, B, C, D, C-145 IO-346-A, B GO-300-A, B, C, D, E, F IO-360-A, C, D, E, G, H, J, K IO-360-B TSIO-360-A, B TSIO-360-C,D,E,EB,F,FB,G,GB,H, HB TSIO-360-K, KB LTSIO-360-E, EB, K, KB O-470-A, E, J, K, L, R, S O-470-B, G, H, M, N, P O-470-T, U O-470-2 O-470-4, 11, 12, 13A, 15 IO-470-C, G, R, P, T IO-470J, K IO-470-D, E, F, H, L, M, N, S, U, V GIO-470-A TSIO-470-B, C, D IO-520-A, B, C, D, E, F, J, K, L, M, BA TSIO-520-B,C,D,E,F,H,J,K,L,M,N,P TSIO-520-R, T, U, V TSIO-520-AE,AF,BE,CE,UB,VB,WB GTSIO-520-C,D,E,F,G,H,K,L,M,N,P IO-550-B IO-550-C 6-285-B,C,BA,CA, 6-230-A,B W-670

260

I.M.E.P. RATING

250

GAP

{ } { } } { { { } | ~ ~ ~ ~ { { { { { { } } | ~ {     € € € € € € € € € € €   €  € € €  € €  ‚ E A E A A A E E A A A A A A A A E E A A E A A A A E 260

FOOTNOTES

539432

TELEDYNE PART NUMBER

AUTOLITE

215

MANUFACTURER PART NUMBER

HSR87

AUBURN

SPARK PLUG

X X X X X X X X X

X X X X X X X X X X X X

X X X X X X

X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X X

X X X X X X X X -

X X X X X X

X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X

X X X X X X -

X X X X X X X X X X -

X X X X X X -

X X X X X X X X X X -

X X X X X X -

X X X X X X X X X X -

X X X X X X X X X X X X X X X

X X X X X X X X X X X

X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X -

X X X X X X X X X X X X X X X X X X -

X X X X X X X X X X X

X X X X X X X X X X -

X X X X X X X X X -

X X X X X X X X X X -

X X X -

X X X X X X -

FOOTNOTES: { 18mm Massive Electrode (Short Reach) | 18mm Massive Electrode (Long Reach) } 18mm Fine Wire (Short Reach) ~ 18mm Fine Wire (Long Reach)  5/8-24 Shielding Thread € 3/4-20 Shielding Thread  Unshielded ‚ No Resistor

GAP CHART CODE GAP A .015-.018 B .016-.021 C .017-.020 D .018-.021 E .019-.022

RHM40E

RHU27E

RSH35-8R/1 RSH101R

RSH35-8R

RSE23-3R

RSH23-3R

RSE35-8R/1

RSE23-3R/1

RSH23-3R/1

636344

646090 636609

641977

642097

642098

646089

646091

646092

RHB32S 646632

RHM38S

RHB32E 634675

627978

REM40E 627643

646630

REM38S 646629

RHB36S

REM38E 628325

RHM38E

M41E 635149

630049

EM41E

HM41E

GAP

B

B

B

B

B

B

B

B

B

B

B

B

B

C D

C

C

C

C

C

C

I.M.E.P. RATING

200

200

280

280

230

370

370

340

280

280

230

340

370 470

470

370

370

370

305

305

‚ ‚ ‚    € € € € € € € ~ ~ ~ } } ~ } }  €  { } { | ~ ~ { } { | € € €  €   € { { {

200

FOOTNOTES

635150

TELEDYNE PART NUMBER

635863

MANUFACTURER PART NUMBER

SMITH

646631

CHAMPION

SPARK PLUG

X X X X X X X X X X X X

X X X X X X X X X X X X

X X X X X X X -

X X X X X X X X X X -

X X X X X X X X X X X X X

X X X X X X X X X X X X X X X

X X X X X X X X X X X -

X X X X X X X X X X X -

X X X X X X X -

X X X X X X X X X X X -

X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X

X -

X X X X X X X X -

X X X X X X X X -

X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X -

X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X

A-65-75 A-80 A-100 C-75-85-90-115-125 E-165-185-225 O-200-A, B, C O-300-A, B, C, D, C-145 IO-346-A, B GO-300-A, B, C, D, E, F IO-360-A, C, D, E, G, H, J, K IO-360-B TSIO-360-A, B TSIO-360-C,D,E,EB,F,FB,G,GB,H, HB TSIO-360-K, KB LTSIO-360-E, EB, K, KB O-470-A, E, J, K, L, R, S O-470-B, G, H, M, N, P O-470-T, U O-470-2 O-470-4, 11, 12, 13A, 15 IO-470-C, G, R, P, T IO-470J, K IO-470-D, E, F, H, L, M, N, S, U, V GIO-470-A TSIO-470-B, C, D IO-520-A, B, C, D, E, F, J, K, L, M, BA TSIO-520-B,C,D,E,F,H,J,K,L,M,N,P TSIO-520-R, T, U, V TSIO-520-AE,AF,BE,CE,UB,VB,WB GTSIO-520-C,D,E,F,G,H,K,L,M,N,P IO-550-B IO-550-C 6-285-B,C,BA,CA, 6-230-A,B W-670

FOOTNOTES: { 18mm Massive Electrode (Short Reach) | 18mm Massive Electrode (Long Reach) } 18mm Fine Wire (Short Reach) ~ 18mm Fine Wire (Long Reach)  5/8-24 Shielding Thread € 3/4-20 Shielding Thread  Unshielded ‚ No Resistor

X X X X X X

X -

GAP CHART CODE GAP A .015-.018 B .016-.021 C .017-.020 D .018-.021 E .019-.022

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M85-9 Rev. 1 Supersedes M85-9 Technical Portions are FAA-DER Approved

6 August 1985 SUBJECT: PISTON TO CYLINDER DOME CLEARANCE MODELS AFFECTED:

470, 520, 550 Series Engines

COMPLIANCE: Cylinder Overhaul or Repair Prior to Installation. To assure proper piston clearance in the combustion chamber of the engines listed above, measure the UNOBSTRUCTED sidewall clearance as illustrated. The UNOBSTRUCTED clearance above the steel cylinder barrel into the aluminum cylinder head must be a minimum of .120 in. If clearance is not adequate, material may be removed by grinding or honing the aluminum cylinder head to obtain this clearance with a corner radius of .62 in. as illustrated.

 TELEDYNE INDUSTRIES, INC. 1985

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M86-13 Rev. 1 Supersedes M86-13 Technical Portions are FAA-DER Approved

17 October 1986 SUBJECT: CAMSHAFT PLUG INSPECTION AND OVERHAUL MANUAL REVISION MODELS AFFECTED:

New or rebuilt engines purchased from Teledyne Continental Motors from January 1, 1982, through May 1, 1986, and engines overhauled in the field after January 1, 1982, consisting of the following models: IO520B, BA, BB, C, CB, M, MB; TSIO520B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB; IO550B, C.

COMPLIANCE: Next annual or 100-Hour Inspection It has come to our attention that the expansion plug in the front of the camshaft could be installed improperly during engine manufacture, rebuild or field overhaul. The purpose of this inspection is to insure the proper installation of the expansion plug in the front of the camshaft. This is a one time inspection. 1.

Remove the camshaft cover plate. (This plate is directly under the prop shaft flange.)

2.

Visually inspect the expansion plug in the camshaft to insure the plug is installed to a depth that will sufficiently clear the Woodruff key. In some aircraft installations the use of a mirror may be required to view the expansion plug in the camshaft. NOTE: If the Woodruff key has made contact with the expansion plug, contact Teledyne Continental Motors for disposition. See Figure 2. Attention:

3.

Service Department P. O. Box 90 Mobile, AL 36601 Telephone: 205 438-3411

If no interference is noted, as in Figure 1, reinstall cover plate and make required Log Book entry.

REVISION TO OVERHAUL MANUALS MANUALS AFFECTED:

ADD:

IO520, Form No. X30039, Section 6.19 TSIO520, Form No. X30574A, Section 72-40-04 IO550, Form No. X30568A, Section 72-40-04

Visually inspect and measure depth of expansion plug in the front of the camshaft to insure positive clearance of the Woodruff key way. Insure a minimum depth of one inch from the end of the camshaft to the edge of the expansion plug (not the center of the plug). See Figure 3. At this point the expansion plug should be seated against the step in the camshaft I.D.

 TELEDYNE INDUSTRIES, INC. 1986

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

FIGURE 1. CORRECT INSTALLATION

FIGURE 2. INCORRECT INSTALLATION

FIGURE 3.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M86-14 Technical Portions are FAA-DER Approved

1 October 1986

SUBJECT: CAMSHAFT 629726 REWORK MODELS AFFECTED:

IO520B, BB, BA, C, CB, M, MB; TSIO520B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB

COMPLIANCE: At the time of next major overhaul or the next time the crankcase halves are split for any reason. This camshaft has been in production on all above models since 1963 with an excellent service history. However, we have received reports of a small number of fatigue fractures which have been experienced at the flange end, originating at the edge of the cross holes machined for oil transfer through the rear main bearing. This type of fracture can be prevented by taking the following corrective action if it has not already been accomplished. This should be accomplished at the next major overhaul or the next time the crankcase halves are split for any reason. NOTE...Camshafts manufactured to Change Letter A thru Z and AA are not qualified for the repair procedure outlined below and should not be reworked or reused. Only camshafts with Change Letter AB and after are qualified for the repair procedure outlined below. 1.

Dress the outer edges of the cross holes, approximately .010-.020, with the use of a Dremel tool and emery wheel point No. 953 (or equivalent) paying particular attention to the edge of the cross hole where it intersects the fillet of the groove.

2.

Shot peen the entire groove including its radii using SAE 330 shot to an intensity of .013 to .015 inches with an A2 strip.

3.

Comply with all other procedures and inspection requirements set forth in the applicable overhaul manual including, but not limited to, the procedures and inspection requirements relating to magnetic particle inspection and dimensional and visual inspection.

4.

Identify reworked cams: vibro etch M86-14 after the part number to show compliance with this service bulletin. - WARNING -

The benefits of the above repair procedure may be negated if the camshaft bearing surface or its supports in the crankcase are worn so as to exceed running clearance of .001 to .005 specified in the table of limits contained in the applicable overhaul manuals.

 TELEDYNE INDUSTRIES, INC. 1986 Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

{ | } ~

Oil transfer groove Cross holes Part number location Location for rework identification

DETAIL I

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M86-20 Technical Portions are FAA-DER Approved

15 December 1986

SUBJECT: AIR/OIL SEPARATOR DRAIN MODIFICATION MODELS AFFECTED: TSIO520BE - S/N 528001 thru 528229, 528231 thru 528269, 528271 thru 528302, 528304, 528305, 528306, 528307, 528308, 528312, 528317, 528319, 528329, 528332, 528334, 528338. COMPLIANCE: At Next Scheduled Inspection Event but not to Exceed 25 hours.

TCM has developed an improved method for the air/oil separator drain return to the engine. This method improves the air/oil separator's effectiveness in returning oil in the breather system to the engine. It is currently being installed on production engines and is therefore being offered for field installation. This modification can be accomplished as follows: Parts Required:

1 ea. 646699 - 21.5 hose & 2 ea AN737TW26 clamp (On early aircraft only, see step #16.) 1 ea. 633343 - 90 degree street elbow 1 ea. 646701 - 45 degree hose fitting 1 ea. 649483 - tapered plug

1. Remove top and LH side cowl. NOTE:

If aircraft is not equipped with air conditioning, proceed to Step #12.

2.

Remove RH side baffle/aftercooler support bracket bolts (1 ea. cylinder).

3.

Remove RH rear baffle lower flange screws (5 pcs.) and forward RH side baffle attaching screws (2 pcs.).

4.

Remove rear baffle center attaching screws.

5.

Disconnect fuel pressure and deck pressure lines forward and aft of RH rear baffle.

6.

Disconnect sonic nozzle and inlet and outlet tubes from RH aftercooler.

 TELEDYNE INDUSTRIES, INC. 1986

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

Page 2 M86-20 15 December 1986 7. Remove upper thru bolt nut on air conditioning bracket and push thru bolt in until flush with bracket. NOTE:

Do not push any further as damage may occur to "O" ring beneath bracket.

8.

Raise RH side baffle up enough to clear cylinder heads and swing out approximately 2".

9.

Loosen idler pulley retaining bolt and adjusting bolt. Remove drive belt.

10.

Disconnect electrical connector at compressor clutch.

11.

Remove the 2 lower bracket attaching bolts and pull bracket off the thru bolt and lift out. Swing the bracket and compressor as an assembly forward and lay on top of the engine.

CAUTION: 12.

Do not loosen freon lines on compressor.

With a good 3/16" allen wrench properly seated, remove the 1/8" Pipe plug at the 1 o'clock position on the scavenge pump body. NOTE:

Use caution so as not to strip this plug.

13.

Apply approved thread sealant and install the 90 degree street elbow, P/N 633343, and preliminary clock to LH rear of engine compartment to 45 degrees off centerline. (See Figure A)

14.

Apply approved thread sealant and install the 45 degree hose fitting, P/N 646701, into the street elbow with a 45 degree angle directed down. (See Figure B).

15.

Tighten 90 degree street fitting, preliminarily clocked in Step #13 until 90 degrees off centerline of engine. (See Figure C)

16.

Remove air/oil separator drain hose. Earlier hoses approximately 20" long with a braided metal outer jacket should be discarded and replaced with a new fire shielded hose, P/N 646699-21.5. If a fire shielded hose is already installed, its length should be checked and cut to 21.5" if required. Hose should be cut with a hacksaw and deburred. NOTE:

All hoses should be flushed with mineral spirits and blown out with compressed air prior to installation.

Page 3 M86-20 15 December 1986 17. Connect the hose to the existing fitting on the separator and route the hose down between hoses at the oil cooler, under the fuel pump and up to the fitting at the scavenge pump and connect. (See Figure D). Insure that hose is completely engaged on the fittings. 18.

Install and tighten clamps and safety. NOTE:

19.

Assure that connection is secure but use caution not to strip clamp.

Install tapered plug P/N 649483 into stub pipe on oil filter tube where air/oil separator drain hose was removed. Tap until flush. CAUTION:

Do not use excessive force or drive at an angle which could cause stub pipe to crack or break.

20.

Reassemble in reverse order.

21.

Pressure check fuel fittings at rear baffle.

22.

Tension compressor belt per airframe manufacturer's specification.

23.

Ground run and inspect for leaks.

WARRANTY:

Parts - No charge. Labor - Up to three (3) hours for engines with air conditioning and one (1) hour for engines without air conditioning at posted shop rates. Warranty claims may be filed through any TCM distributor for parts and labor.

Make appropriate logbook entry for modification per this service bulletin.

M86-20

FIGURE A

Page 4

FIGURE B

FIGURE D

15 December 1986

FIGURE C

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M86-4 Technical Portions are FAA-DER Approved

9 January 1986 SUBJECT: FUEL PUMPS MODELS AFFECTED:

IO360, L/TSIO360, IO470, IO520, IO550, L/TSIO520, GTSIO520

COMPLIANCE: Anytime fuel pump pressures deteriorate or fuel pump pressure will not stay in adjustment per Service Bulletin M86-4, Rev. 1, or subsequent revision. WARRANTY: The action required to comply with this Service Bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

Teledyne Continental Motors recommends that if the following engine driven fuel pumps will not stay in adjustment, the pump should be removed from service, starting with S/N A028401B thru S/N F088501B.

MODELS OF FUEL PUMPS AFFECTED Part Numbers

Part Numbers

646210 646211 646212 646758 646759

646764 646765 646766 646767 646768

NOTE...The serial numbers affected were manufactured between January 2, 1984 and June 8, 1985.

A

January

 TELEDYNE INDUSTRIES, INC. 1986

Date (2nd)

02

84

Year (1984)

01

B

1st Pump of the Day

Fuel Pump

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M86-5 Technical Portions are FAA-DER Approved

4 February 1986 SUBJECT: MANIFOLD PRESSURE LINE ADAPTER IMPROVEMENT MODELS AFFECTED:

TSIO520BE (In Piper Malibu Aircraft prior to S/N 46-8608001

COMPLIANCE: Next Scheduled Maintenance WARRANTY: The action required to comply with this service bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. If fluctuating manifold pressure indications are encountered during engine operation in high humidity conditions, the above described symptom may be corrected using the following procedure: Remove 628434 fitting from AN912-2 Reducer Bushing. Remove AN912-2 Reducer Bushing from Intake Manifold Assembly and replace with 649196 Adapter Assembly. Be sure the dimple on adapter lines-up as indicated in Detail "B", with Manifold Flange. Reinstall 628434 Fitting being sure not to turn 649196 Adapter.

 TELEDYNE INDUSTRIES, INC. 1986

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M86-9 Technical Portions are FAA-DER Approved

20 March 1986 SUBJECT: CRANKCASE MODIFICATION MODELS AFFECTED:

C90 AND O200

PURPOSE: To modify crankcase when replacing crankshaft P/N 530182 with replacement crankshaft P/N 531434, or converting puller to pusher type engine. TCM is no longer manufacturing new crankshafts P/N 530182. The replacement crankshaft P/N 531434 has a design change in the slinger ring and can be used in either O200A (puller type engine) or O200B (pusher type engine) applications. When replacing crankshaft P/N 530182 with P/N 531434, the O200A crankcase has to be modified in order to accept crankshaft P/N 531434. The modification consists of machining the crankcase slinger ring retaining flange in order to enlarge the retaining flange diameter from 2.300 to 3.00 inches. See Illustration A. If the O200A (puller type engine) is being converted to the O200B (pusher type engine), the oil drain hole, as shown in Illustration B must be drilled using a size "D" -.246 drill, to a depth of 1/2 inch, and tapped using a 1/16-27 NPT size tap. An AN932-1 pipe plug coated with Thread Sealant P/N 646941 (or Loctite #271) must be installed with the top of the plug recessed in the hole to insure proper seating of the crankshaft main bearing.

 TELEDYNE INDUSTRIES, INC. 1986 Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-14 Rev. 1 Supersedes M87-14 Technical Portions Are FAA-DER Approved

8 October 1987 SUBJECT: TURBOCHARGER CHECK VALVE CLAMPS MODELS AFFECTED:

COMPLIANCE:

TSIO360GB – All TSIO360LB (New) - All through S/N 316128 TSIO360LB (Rebuilt) - All through S/N 247112 TSIO360MB - All through S/N 317141 Within the next 25 hours

The clamp retaining the check valves and hoses on the above mentioned engines have, in some cases, exhibited premature deterioration of the rubber which then allows the metal band of the clamp to chafe directly on the hose or check valve as the case may be. If not corrected this chafing could wear through the check valve or hose and cause oil exhaustion and subsequent engine failure. It is, therefore, required that these clamps be replaced with the current part number clamp. Inspect the check valves and hose for evidence of chafing. If present, the valve(s) or hose must also be replaced. The new clamp part numbers are shown in Figure 1. (A total of three clamps.) These new clamps incorporate a cushion that is yellow in color; the clamps being replaced have a cushion that is black in color. Installation of these clamps and routing of these hoses must be done in such a manner as to avoid placing the check valves in a bind in the clamp as this could cause a similar wear pattern. WARRANTY: Parts and labor (up to 1 hour) required to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

Page 1 of 2 (Continued)

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

FIGURE 1

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-15 Technical Portions Are FAA-DER Approved

13 July 1987

SUBJECT: ALTERNATOR GROUND STRAP MODELS AFFECTED: COMPLIANCE:

All At engine or alternator replacement

It has come to the attention of TCM that at the time of engine and/or alternator replacement the alternator ground strap (air frame supplied) is not being transferred to the new installation. Alternators are needlessly being returned as inoperative. It must be noted that all installations do not require this external ground but those that do will not function without it. If the replaced engine or alternator was equipped with an external alternator ground strap it must be transferred to the new installation. For proper operation ensure the serviceability of the ground strap prior to installation.

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-16 Technical Portions Are FAA-DER Approved

14 August 1987 TO: Aircraft Manufacturers, Distributors, Subscribers SUBJECT: SLICK SERVICE BULLETIN SB1-86A MODELS AFFECTED: COMPLIANCE: WARRANTY:

O-200, O-300, O-470, IO-470, IO-520, IO-550, TSIO-360, TSIO-520, or any Continental Engine equipped with Slick Magnetos. See Slick Service Bulletin SB1-86A TCM does not supply internal magneto parts. warranty through any Slick Distributor.

Order parts and file

Teledyne Continental Motors recommends compliance of the attached Slick Service Bulletin SB1-86A as published.

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

SLICK

SB 1-86A

Service Bulletin TO:

SUBJECT: BACKGROUND INFORMATION:

Aircraft Manufacturers, Aircraft Engine Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Slick Aircraft Magnetos. Impulse Coupling Inspection The Service History of Slick Aircraft Magnetos indicates that the required 500 hour inspection of impulse couplings is not being performed or is being performed incorrectly. Other factors influencing the airworthiness of Slick impulse couplings are operational inactivity and reinstallation at overhaul resulting in operation beyond TBO. Failure to perform the prescribed 500 hour inspections, maintenance, and operating of the magneto beyond the engine TBO voids Slick warranty and may jeopardize the airworthiness of these components. This bulletin supercedes SB1-86 dated 8/10/86.

COMPLIANCE:

As required

PROOF OF COMPLIANCE:

Appropriate logbook entries.

MAINTENANCE PARTS AFFECTED: None. PARTS REQUIRED PER BULLETIN:

Magneto Model 447 662 664 667 668 676 680 4201 4216 4230 4251 4252 4281 6210 6214

ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Impulse Coupling Assembly M-2374 M-2639 M-2370 M-2371 M-2372 M-2373 M-2369 M-3007 M-3076 M-3068 M-3163 M-3100 M-3007 M-3050 M-3089

Rotor

Frame

M-989 M-1310 M-1295 M-1219 M-1936 M-1395 M-1310 M-3073 M-3047 M-3065 M-3158 M-3158 M-3158 M-3047 M-3093

M-1202 M-1176 M-1202 M-1202 M-1896 M-1202 M-1896 M-3095 M-3094 M-3094 M-3095 M-3095 M-3095 M-3101 M-3102

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

1 OF 9

A

SB 1-86A

SLICK Service Bulletin PARTS REQUIRED PER BULLETIN:

Continued Magneto Model 6220 6224 6251 6252 6280

TOOLS REQUIRED PER BULLETIN:

WEIGHT CHANGE: MAGNETO MODELS AFFECTED: ENGINE MODELS AFFECTED: DETAILED INSTRUCTIONS:

Impulse Coupling Assembly M-3050 M-3089 M-3333 M-3333 M-3050

Rotor

Frame

M-3047 M-3093 M-3327 M-3416 M-3047

M-3101 M-3102 M-3095 M-3095 M-3101

Slick T-106 impulse coupling hub puller, 0.140 inch feeler gage, 0.150 inch feeler gage, Slick Master Service Manual F-1100, standard shop tools. None. All Slick impulse coupling equipped 400, 600, 4200, and 6200 series magnetos. All engines equipped with equipped 400, 600, 4200, and 6200 series impulse coupled Slick magnetos. 500 HOUR INSPECTION: The following inspection procedures may be used for all 400, 600, 4200 and 6200 series magneto impulse couplings, except where noted. The 500 hour impulse coupling inspections is to be performed each time the magneto accumulates 500 hours of operation from the time of last inspection or since new or factory rebuilt. See magneto maintenance and overhaul manuals L-1020 and L1037 for overhaul instructions. 1. Pre-Teardown Operation Inspection A. Prior to removing the impulse coupling from the magneto, spin the impulse coupling in the direction of rotation stated on the magneto dataplate. B. The impulse coupling should engage the stop pin in the magneto below approximately 140 RPM. If the impulse coupling pawls slip past the stop pin or engage intermittently, the impulse coupling is not operating properly. NOTE:

ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

The speed at which the coupling pawls engage or disengage cannot be determined accurately when spinning the coupling by hand. Accurate R.P.M. Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

2 OF 9

A

SLICK Service Bulletin

SB 1-86A

readings for such coupling engagement or disengagement can only be made when the magneto is driven at a constant speed by an electric motor or similar device. CAUTION: The magneto will produce spark voltage when impulse coupling is operated. Keep hands away from the distributor block and condenser stud when impulsing the magneto. 2. Remove impulse coupling. A. Remove cotter pin, nut, washer and drive gear. NOTE:

Impulse coupling washer may be scored slightly from coupling nut. This condition is normal and does not require replacement.

B. Grasp shell of the impulse coupling assembly and gently pull the assembly outward to clear the unlatching ears of the impulse coupling hub assembly. CAUTION: Strong spring tension. C. Turn shell to release spring tension. D. Remove impulse shell and attach impulse spring. E. Engage Slick T-106 Impulse Coupling Hub Puller into grooves in the hub assembly. Tighten T-106 Puller Bolt and remove the impulse coupling hub assembly. 3. Clean Impulse Coupling A. All portions of the impulse coupling must be cleaned, exposing bare metal, to ensure a reliable inspection. B. Use a suitable grease dissolving solvent to remove all oil or sludge buildups on impulse coupling. 4. Inspect Coupling

FIGURE ONE ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

3 OF 9

A

SLICK Service Bulletin

SB 1-86A

NOTE: Impurity stringers, inclusions and heat checks may appear as surface discontinuities on impulse coupling components. These conditions are normal and generally do not, by themselves, require impulse coupling replacement. A. Using acceptable procedures, inspect the impulse coupling shell for cracks, or corrosion. Neither of these conditions is acceptable. Replace impulse coupling as necessary. B. Inspect the impulse coupling hub for cracks, or corrosion. Neither of these conditions is acceptable. Replace impulse coupling as necessary. C. Inspect the hub shaft and keyway for deformation or damage. Replace impulse coupling as necessary. D. Inspect impulse coupling pawls. If the latching end that contacts the stop pin in the magneto frame is rounded, peened, or excessively worn, replace the impulse coupling. E. Inspect pawl retaining rivets. If rivets are finger loose or show indications of movement, then replace the impulse coupling. F. Measure the clearance between the boss on the underside of each (2) impulse pawl and the pawl plate using a feeler gage. Position the latching end of the impulse pawl over the pawl plate as shown in Figure Two.

FIGURE TWO G. Maximum clearance for pawls with one (1) boss is 0.150 inch. Maximum clearance for pawls with two bosses is 0.150 inch for left hand rotation couplings and 0.140 inch for right hand rotation impulse couplings. If the feeler gauge can pass between the full width of the boss and the pawl plate replace the impulse coupling. See Figure three. For coupling rotation see magneto data plate.

ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

4 OF 9

A

SLICK Service Bulletin

SB 1-86A

FIGURE THREE H. Inspect magneto rotor shaft. Remove burrs and chips from shaft with a fine abrasive cloth and clean all surfaces. Chips and other abrasives must not contact oil seal. Dimples in the rotor shaft that affect the performance of the impulse coupling require rotor shaft replacement. See Figure Four.

FIGURE FOUR 5. Reassemble Impulse Coupling. A. Lubricate the pawl assembly with aircraft engine oil. Ensure that the pawls move freely. B. Lubricate the hub and spring with aircraft engine oil. C. Assemble the inner eye of the spring into the groove in the hub. Set the shell on the hub. There should be no spring tension in this position. D. Hold the shell in one hand and the pawls with the thumb and forefinger of the other hand. E. Pull the hub straight back slowly and far enough to clear the projections on the shell. F. Hold the shell stationary and rotate the hub to wind the spring until the projections on the outer section of the pawl plate pass the projections on the shell. (Approximately one quarter revolution, 90°) DO NOT WIND SPRING MORE THAN ¼ TURN. ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

5 OF 9

A

SLICK Service Bulletin

SB 1-86A

G. Make sure that the shell is seated on the hub and that it turns freely. 6. Inspect Stop Pin A. 400/600 Series Magnetos

FIGURE FIVE 1. Verify that the stop plate is held securely by the M-912 snap ring. 2. Remove M-908 stop plate by prying M-912 snap ring from the magneto frame retaining groove using a small screwdriver. 3. Inspect the M-908 Stop Plate for cracks, or corrosion. Replace as necessary. 4. Inspect the snap ring for deformation, replace as necessary. 5. Inspect the snap ring groove in the magneto frame. The groove must be intact and unbroken, replace magneto frame as necessary. 6. Inspect the retaining teeth of the stop plate and mating magneto frame. All eight (8) retaining teeth must be engaged in the magneto frame. No broken, missing, or deformed teeth in the magneto frame are allowed within (4) teeth either side of the stop plate. If teeth are broken, missing, or deformed, the magneto frame must be replaced. 7. Reinstall M-908 stop plate and M-912 snap ring into magneto frame. NOTE: The correct orientation of the stop plate is shown with matching arrows.

ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

6 OF 9

A

SLICK Service Bulletin

SB 1-86A

B. 4200/6200 Series Magnetos 1. Inspect the stop pin for looseness, cracks, or corrosion. None of these conditions are acceptable. Replace magneto frame as necessary. See Figure Six.

FIGURE SIX 2. Inspect the stop pin for flat spots. Flat spots are a normal sign of wear and do not, by themselves, require corrective action. If the flat spots are excessive and cause the impulse coupling pawl to slip past the stop pin, either the impulse coupling, magneto frame, or both components need replacement. Refer to Section 1 for operation inspection and Section 3 for impulse coupling inspection. 1. Install Impulse Coupling A. Install impulse coupling assembly onto the rotor shaft. B. Install magneto drive gear onto the magneto impulse coupling where applicable C. Place the removed impulse coupling washer on the shaft or magneto drive gear and washer as required. D. Place the removed impulse coupling nut onto the rotor shaft and torque to 120-180 in/lbs. E. Insert a cotter pin through the nut castellations and rotor shaft and secure appropriately. NOTE: If the cotter pin will not align with pin hole in the specified torque range, remove the nut and lightly tap the bottom of the nut with a piece of emery cloth and repeat steps D and E. ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

7 OF 9

A

SB 1-86A

SLICK Service Bulletin

F. Grasp the magneto impulse coupling and “snap” through several times to insure impulse coupling functions properly and does not bind. The coupling should return freely to the relaxed position. CAUTION:

The magneto will produce spark voltage when impulse coupling is operated. Keep hands away from the distributor block and condenser stud when impulsing the magneto.

8. Post-Teardown Operation Inspection A. After installing the impulse coupling in the magneto, spin the impulse coupling in the direction of rotation stated on the magneto data plate. B. The impulse coupling should engage the stop pin in the magneto below approximately 140 RPM. If the impulse coupling pawls slip past the stop pin or engage intermittently, the impulse coupling is not operating properly. NOTE:

The speed at which the coupling pawls engage or disengage cannot be determined accurately when spinning the coupling by hand. Accurate R.P.M. readings for such coupling engagement can only be made when the magneto is driven at a constant speed by an electric motor or similar device.

CAUTION:

The magneto will produce spark voltage when impulse coupling is operated. Keep hands away from the distributor block and condenser stud when impulsing the magneto.

GENERAL MAINTENANCE Slick impulse couplings are designed to last to the TBO of the aircraft engine. However, several non-magneto related factors affect and reduce the impulse coupling’s operational life. To ensure consistent and reliable operation these guidelines should be followed. A. Perform 500 hour inspection. B. Relubricate the coupling at the 500 hour inspection and each time the magneto is removed from the engine. C. Exercise the engine once a week or according the engine manufacturers specifications. D. Change engine specifications.

ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

oil

according

to

engine

manufacturer’s

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

8 OF 9

A

SLICK Service Bulletin

SB 1-86A

E. No attempt should be made to repair impulse couplings. MAGNETO OVERHAUL Magneto impulse couplings must be removed and discarded at engine overhaul or recommended engine TBO. Magneto impulse couplings that are currently in service that were not replaced at magneto overhaul must be removed and discarded. Install replacement Slick impulse couplings. WARRANTY: Void if prescribed maintenance schedules are not followed. THIS SERVICE BULLETIN IS A SUPPLEMENT TO SLICK MAINTENANCE AND OVERHAUL MANUALS L-1020 AND L-1037. CHECK WITH SLICK TO BE SURE YOU HAVE THE MOST CURRENT REVISION OF SLICK MANUALS L-1020 AND L-1037 AND PERTINENT SERVICE LETTERS AND BULLETINS BEFORE PERFORMING MAINTENANCE OR OVERHAUL.

ISSUED MO DAY 08 10

YR 86

REVISED MO DAY YR 01 87

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

9 OF 9

A

CONTINENTAL AIRCRAFT ENGINE

M87-17

service bulletin

Technical Portions Are FAA Approved

28 August 1987 SUBJECT: MODELS AFFECTED:

COMPLIANCE:

IMPROVED OIL PUMP SUCTION TUBE ASSEMBLY TSIO-520BE - New: S/N 528001 thru 528396 Except 528377, 528382, 528384, 528390 Rebuilt: S/N 273500 thru 273510 At next scheduled inspection event but not to exceed 25 hours.

TCM has developed an improved oil pump suction tube assembly. This assembly improves the inlet condition to the oil pump which in turn improves the pump efficiency throughout its operating range. It is currently being installed in production engines and is, therefore, being offered for field installation. Installation can be accomplished as follows: Part Required:

1 ea. 534743 1 ea. MS35769-12 1 ea. MS35769-15 1 ea. 649807 1 ea. 646942

Gasket, Oil Sump Gasket, Annular Gasket, Annular Tube Assembly, Oil Pump Suction TCM Gasket Maker

1.

Remove top, LH and RH side cowl.

2.

Drain oil. NOTE:

If oil is not being drained in conjunction with a scheduled oil change it should be drained into a clean container for reuse after tube assembly change.

3.

Remove the RH tail pipe and disconnect the link that secures the exhaust bypass to the number 1 cylinder exhaust tee.

4.

Disconnect the clamp that secures the case breather to the wastegate assembly and pull breather tube from the tailpipe. Disconnect the clamp that secures the LH tailpipe to the turbo. Pull the tailpipe, wastegate and bypass (as an assembly) AFT to release them from the number 1 and 2 cylinder exhaust tees.

5.

Disconnect the RH bypass from the LH bypass and remove.

6.

Leave the oil lines to the wastegate attached and rotate the LH tailpipe, wastegate and bypass to gain access to the engine to mount attach bolt. Remove the lower two (2) attaching screws that secure the LH rear shock mount heat deflector and raise to gain access to the engine mount attach bolt. (continued)

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

28 August 1987

Page 2

7.

Attach an engine hoist to the engine and a tail support stand to the airframe.

8.

Remove the four (4) engine to mount attach bolts and shock mounts.

M87-17

CAUTION: Note the location of the shock mounts and associated hardware prior to removal as they must be installed in the same location when engine is reinstalled. 9.

Disconnect the electrical wires to the alternator and the propeller heat brush block. NOTE:

Tag wires for proper location for reinstallation.

Disconnect the clamp that secures the starter ground strap to the rear baffle. 10.

With the engine hoist, raise the engine high enough to allow removal of the sump (approximately four inches).

11.

Remove the bolts and washers that secure the oil sump assembly to the crankcase and lower the oil sump assembly to gain access to the oil pump suction tube assembly. NOTE:

12.

Remove the threaded plug and annular gasket that secures the oil pump suction tube assembly to the engine oil pump housing. NOTE:

13.

Do not remove the oil sump assembly from the aircraft at this time.

This threaded plug and annular gasket are on the outboard side of the engine oil pump housing located on the lower RH rear of the engine (as viewed from the pilot seat).

Remove the bolt, nut and washers that secure the oil pump suction tube to the crankcase belly. CAUTION: Note the location of the washers prior to the removal as they must be installed in the same location when the replacement oil pump suction tube is installed.

14.

Pull the oil pump suction tube forward out of the crankcase and remove it from the engine and discard. Remove the sump by pulling it forward between the engine and the engine mount.

15.

Remove the sump gasket and discard.

16.

Thoroughly clean the crankcase and sump mating surface of all sealants and gasket material in preparation for reinstallation.

17.

Apply a film of TCM gasket maker, P/N 646942 compound on the sump side ONLY of the sump gasket and position it on the sump.

18.

Position the sump under the engine by sliding it AFT between the engine and the engine mount.

(continued)

28 August 1987

Page 3

M87-17

19.

Install a new annular gasket MS35769-15 on the oil pump suction tube. Insert the threaded end of the tube through the crankcase into the oil pump housing. Install the bolt, nut and washers removed in Step 13 to secure the oil pump suction tube to the crankcase belly. Tighten finger tight. See warning in Step 13 for washer positioning.

20.

Install a new annular gasket MS35769-12 on the threaded plug removed in Step 12. Install the threaded plug into the oil pump suction tube and torque to 190 to 210 inch pounds.

21.

Return to Step 19 and torque the hardware left finger tight to 90 to 110 inch pounds.

22.

Position the sump to the crankcase and secure with the attaching bolts and washers removed in Step 11. Torque to 155 to 175 inch pounds.

23.

Lower the engine and reinstall the shock mounts and associated hardware removed in Step 8. Torque the attach bolts to 500 inch pounds. WARNING: Use extreme caution to assure proper alignment of the shock mount to the engine mount bracket and engine mount frame. Misalignment can result in cross threading of the attach bolts in the engine mount bracket. DO NOT FORCE THE BOLTS.

24.

Remove the engine hoist and tail support stand.

25.

Reconnect the wires and clamp disconnected in Step 9.

26.

Reinstall the exhaust system components removed in Steps 3, 4, 5 and 6. Tap the outer periphery of the turbo to tailpipe attach clamp during the tightening process to assure proper seating of the clamp. Torque to 55 to 65 inch pounds.

27.

Service engine oil to the 8 qt. level on the oil gauge rod.

28.

Ground run the engine for a short period to assure proper oil pressure and to check for leaks. CAUTION: Limit this run to short duration, low power and monitor temperatures closely. Excessive ground running without proper cooling can damage the engine.

29.

Install the cowling and flight check the aircraft.

30.

Make appropriate logbook entry of compliance to this service bulletin. WARRANTY: The action required to comply with this service bulletin is covered by the TCM Gold Medallion warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. Parts - No charge. Labor - up to four (4) hours at current posted shop rate.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-21 Technical Portions Are FAA Approved

7 October 1987 SUBJECT: MODELS AFFECTED: COMPLIANCE:

OPERATION AND SERVICE TSIO520BE - ALL This engine is used in the Piper Malibu aircraft. Within the next 25 hours

This information is being written in service bulletin form in an attempt to bring to the attention of Piper Malibu owners/operators and service personnel some items of extreme importance that are not being given proper attention. I.

OPERATIONS A.

Lean of Peak: Field reports and Analytical evaluations indicate that in many instances this engine is being operated in the cruise configuration at mixture settings other than 50 degrees F lean of peak.

II.

SERVICE A.

Manufacturers are in a never ending struggle to supply service information to the owners/operators and maintenance personnel. One of these vehicles is in the form of SERVICE BULLETINS. Inspection reports from the field, factory evaluations and compliance records indicate that many engines have not complied with some of the bulletins or have not complied properly. 1.

Service Bulletin M86-17 Subject: Thru Bolt Torque This service bulletin was published September 20, 1986. Failure to comply with this Service Bulletin (M86-17) could result in premature engine wear and/or damage.

2.

Service Bulletin M86-20 Subject: Air/Oil Separator Drain Modification This service bulletin was published December 15, 1986. Failure to comply with this Service Bulletin (M86-20) could result in premature engine wear and/or damage. (Continued)

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

7 October 1987

3.

Page 2

M87-21

Service Bulletin M87-12 Subject: Recommended Fuel and Oil Grades This service bulletin deals with fuels and oils for use in TCM engines. It also addresses the proper oil and filter changes intervals. This service bulletin states, "When using larger (approximately 5.80" high) full flow oil filters, the recommended number of operating hours between oil changes and filters can be increased to 100 hours." Per the TCM parts book the larger (long) filter is specified for the TSIO520BE engine. From engines returned to TCM and others inspected in the field, we find that in many instances the smaller (approximately 4.80" high) filter is being installed. The smaller (short) filter is NOT approved for this engine. Oil and filter change intervals in many instances are not being accomplished as recommended.

Failure to comply with this Service Bulletin (M87-12) could result in premature engine wear and/or damage.

CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-23 Technical Portions Are FAA Approved

24 November 1987

SUBJECT:

CRANKSHAFT COUNTERWEIGHT IDENTIFICATION AT OVERHAUL

MODEL AFFECTED:

All Incorporating Crankshaft with Counterweights

COMPLIANCE:

At Overhaul or Anytime Crankshaft/Counterweight Maintenance is Performed

Analytical inspection of core engines returned to TCM have revealed a very dangerous field practice of identifying counterweight to crankshaft location by punching identification marks on the crankshaft cheek. This practice can and does cause crankshaft failure. WARNING: Under no circumstances should this practice be continued. If identification is required, it should be done by tagging or any method that does not mar the crankshaft (i.e., ink stamp, dye, etc.). The crankshaft is nitrided and anytime it is punched or marred it can fracture the nitride case which reduces the strength of the crankshaft. NOTE: Identification marks done at TCM are accomplished prior to the nitride process.

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M87-24 Supersedes M87-13 Technical Portions Are FAA Approved

15 December 1987

SUBJECT: MODELS AFFECTED:

BROKEN STARTER ADAPTER SHAFTS IO520BA, IO520BB, IO550B, TSIO520BE, TSIO520LB, TSIO520UB & TSIO520WB

NEW ENGINES:

All Serial Numbers

REBUILT ENGINES:

All Serial Numbers THESE ENGINES ARE USED IN BEECH BONANZA, BARON AND PIPER MALIBU AIRCRAFT

COMPLIANCE:

Before Further Flight

Some Teledyne Continental Motors' engines have continued to experience broken starter adapter shafts on aircraft that are equipped with air conditioning. (Ref. Mandatory Service bulletin M87-13). The following action is therefore required on the above referenced engines if they are equipped with air conditioning. I.

Gain access to the drive sheave mounted on the rear of the starter shaft. This sheave is concave and approximately 3.375 inch in diameter (3-3/8 inch).

II.

With a light and mirror, determine if the sheave is a steel locking type. (See Figure B.) A.

If the nut is a steel locking type (See Figure B), remove the freon compressor drive belt. This can most easily be accomplished by cutting the belt.

B.

If the nut is castellated (See Figure A), ascertain via log books and maintenance records that the castellated nut is the original nut and has not been substituted for a steel locking type nut. 1.

If the castellated nut is the original, no further action is required. Make the appropriate log book entry stating compliance with this service bulletin and return the engine to service. (Continued)

 TELEDYNE INDUSTRIES, INC. 1987 Member of GAMA

General Aviation Manufacturer’s Association

TELEDYNE CONTINENTAL MOTORS

Aircraft Products Division PO Box 90 Mobile Alabama 36601

15 December 1987

Page 2

2.

M87-24

If the castellated nut is not the original but a substitution for the originally installed steel locking type nut, remove the freon compressor drive belt. This can most easily be accomplished by cutting the belt.

NOTE...REMOVAL/CUTTING OF THE BELT IS REQUIRED IF THE STEEL LOCKING TYPE NUT IS INSTALLED OR HAS PREVIOUSLY BEEN INSTALLED REGARDLESS OF THE SHAFT TYPE (COTTER KEY HOLE OR NO COTTER KEY HOLE). III.

Make appropriate log book entry stating compliance to this service bulletin and return the engine to service.

NOTE...This action is an interim measure. Shaft redesign and testing are ongoing at this time. Instructions to restore use of the air conditioner will be promulgated as soon as possible. WARRANTY:

The action to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE M87-25 Supersedes M86-17

MANDATORY service bulletin

Technical Portions Are FAA Approved

15 December 1987 SUBJECT:

PISTON PIN REPLACEMENT AND THRU BOLT TORQUE CHECK NOTE . . . The thru bolt torque check requirement of this service bulletin supersedes Service Bulletin M86-17.

MODELS AFFECTED:

TSIO520BE - This engine is used on the Piper Malibu Aircraft S/N 528001 through 528337

COMPLIANCE:

Before further flight.

A broken piston pin, P/N 643846, has been confirmed to have been the cause of a recent engine failure. The following action is therefore required on the above referenced engines. I.

A. Insure that the magnetos are properly grounded. Remove one spark plug (the most accessible) from each cylinder. Attach a spring scale to the propeller blade at the 36 inch station. Rotate the propeller in normal direction of rotation via the attached scale and record the pounds required to rotate the propeller. Normal range is approximately 10 to 20 pounds. While holding opposite propeller blades as close to the hub as possible, move the crankshaft fore and aft to assure the crankshaft has end play. NOTE...If the recorded pounds are not within the normal range or there is no crankshaft end play, contact your local Teledyne Continental Motors representative (See Page 4) for disposition. WARNING...Use extreme caution in the area of the propeller while performing this check. B. Gain access to the eight (8) crankcase thru bolt nuts. With a cylinder base wrench, loosen the eight (8) thru bolt nuts and back them off approximately 1/2 inch. Liberally lubricate the exposed thru bolt threads and the nuts with clean 50 weight engine oil. Torque the nuts to a preliminary torque of 350 inch pounds, then repeat final torque to 700 inch pounds each. It may be necessary to retain the opposite nuts to prevent thru bolt rotation.

(Continued)

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

15 December 1987

Page 2

M87-25

C. Repeat paragraph IA above and record the pounds required to rotate the propeller. If after torquing the thru bolts per paragraph IB, the effort (pounds) to rotate the propeller has increased above that previously recorded or there is no crankshaft end play, contact your local Teledyne Continental Motors representative (See Page 4) for disposition. If no special disposition is required, proceed to Section II. II.

A. Gain access to the piston pins by removal of all cylinders. NOTE...DO NOT REMOVE THE PISTON FROM THE CYLINDER. REMOVE ONLY TO A POINT TO GAIN ACCESS TO THE PISTON PIN. REMOVE THE PISTON PIN, THEN THE PISTON AND CYLINDER AS ONE UNIT. B. With cylinders and pistons removed, visually inspect the number 1, 2, 3, and 4 crankcase main bearings for any signs of bearing rotation within the case; bearing movement fore or aft within the case or crankcase material distress. Particular attention should be given to number 2 and 3. The crankshaft should be moved fore and aft while performing this inspection. The crankshaft will also require rotation to allow for unobstructed view of the bearings.

NOTE...The crankcase main bearings are numbered from number 1 in the rear of the engine and progressing forward. (Toward the propeller flange).

Figure A depicts how bearing should generally appear.

Figure B depicts a bearing that has shifted.

NOTE...Contact your local Teledyne Continental Motors representative (See Page 4) for disposition of any bearing appearing as in Figure B or with any signs of crankcase material distress. C. If no problems are detected during the inspection outlined in paragraph IIB, proceed with the installation of new piston pins P/N 630046 and the reassembly of the engine. D. The cylinders should be installed in sequence and torqued in sequence per the instructions in Figure C. New cylinder gasket sets should be used, 6 each P/N 646565A1. NOTE...Liberally apply clean 50 weight engine oil on the rod bushing, piston pin and valve mechanism during engine reassembly. (Continued)

15 December 1987

III.

Page 3

M87-25

A. Finalize reassembly of the cylinders to the point of rocker cover installation. At this point repeat paragraph IA above and record the pounds required to rotate the propeller. If the effort (pounds) to rotate the propeller has increased above that previously recorded in paragraph IC or there is no crankshaft end play, contact your local Teledyne Continental Motors representative (See Page 4) for disposition. If no discrepancies are noted, finalize reassembly of the engine. B. Perform appropriate testing, make appropriate log book entry stating compliance to this service bulletin and return the engine to service.

WARRANTY:

The action to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. When submitting the warranty claim for compliance with this service bulletin, you must enter the pounds required to rotate the propeller as recorded in paragraph IA, IC, IIIA. It should be recorded in the CONDITIONS REPORTED SECTION of the warranty claim.

EXAMPLE:

Compliance with Service Bulletin M87-25 Paragraph IA - 12 pounds Paragraph IC - 12 pounds Paragraph IIIA - 14 pounds

TCM will allow 32 hours labor at current posted shop rates to comply with this service bulletin and the following parts: 6 each P/N 630046 piston pin 6 each P/N 646565A1 gasket set

(Continued)

15 December 1987

M87-25

Page 4

Address: Teledyne Continental Motors Attn: J. Black/C. McClellan P.O. Box 90 Mobile, AL 36601 (205) 438-3411

David Blanchard P.O. Box 427 Scarborough, ME 04074 (207) 883-3150

J. A. Buskirk 10014 Venetian Way Dallas, TX 75229 (214) 351-3149

R. A. Deets 14611 Chalet Lane Huntingdon Beach, CA 92647 (714) 895-5597

R. W. Lambrix 3661 Duffer Court Zellwood, FL 32798 (305) 880-1221

R. M. Robbins 11477 Wolftooth Pass Littleton, CO 80127 (303) 979-7923

Tom Thys/Tony Evanson Room 4, 19 The Square Sand Bach, CW11 OAT Chesire, ENGLAND 44 270 76-7339

Edgardo Martedi R Charles S Chaplin 85 Apartment #23 05642 Sao Paulo BRAZIL 55 11 299-2666

15 December 1987

Page 5

FIGURE B (Continued)

M87-25

15 December 1987

28

32

34

30

9

13

M87-25

Page 6

15

11

1

5

7

17

3 17

CYL# 1 31

35

33

36 29 12

CYL# 3

16

14

37 10

4

CYL# 5

8

6

21

23

1

CYL# 6

38 2

19

5

7

CYL# 4

20

24

22

18

13

15

26 4

8

6

11 28

CYL# 2

25

20

9

3

2

12

27 16

14

10

31

CAUTION...Before proceeding note that the six nuts utilized with the seventh stud (positions 25, 26, 27, 36, 37, 38) have a conical seat and can only be used in these positions. NOTE...Nuts on both ends of thru bolts must be torqued and all studs and thru bolt threads are to be lubricated with clean 50 weight engine oil before installing nuts. ASSEMBLY AND PRELIMIANRY TORQUE 1. Install cylinders 4 & 5. Tighten stud nuts (2, 3, 5, 6, 7, 8) and thru bolts (1 & 4) to 300-400 inch lbs. in sequence shown above. 2. Install cylinders 2 & 3. Tighten stud nuts (10, 11, 13, 14, 15, 16) and thru bolts (9 & 12) to 300-400 inch lbs. in sequence shown above. 3. Install cylinder #6. Tighten stud nuts (18, 19, 21, 22, 23, 24) and thru bolts (17 & 20) to 300400 inch lbs. in sequence shown above. 4. Install cylinder #1. Tighten stud nuts (29, 30, 32, 33, 34, 35) and thru bolts (28 & 31) to 300400 inch lbs. in sequence shown above. 5. Install 7th stud brackets & nuts (25, 26, 27, 36, 37, 38) and tighten to 300-400 inch lbs. (See Caution above). 6. Finish torquing thru bolts and stud nuts to their final torque values in sequence shown above. FINAL TORQUE VALUES INCH LBS. Thru Bolts

1, 4, 9, 12, 17, 20, 28, 31

690-710

Stud Nuts

2, 3, 5, 6, 7, 8, 10, 11, 13 Thru 16, 18, 19, 21 Thru 27, 29, 30, 32, Thru 38

490-510

NOTE...Repeat torquing sequence with final torque values to insure that all thru bolts and stud nuts have been torqued. FIGURE C

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M87-26 Technical Portions Are FAA Approved

21 December 1987 SUBJECT: MODELS AFFECTED:

PISTON PIN REPLACEMENT AND THRU BOLT TORQUE CHECK TSIO520CE - This engine is used on the Cessna P210 and T210 Aircraft S/N 530001 through 530140

COMPLIANCE:

Within the next 25 hours of operation. NOTE...The engine must be operated in accordance with the related FAA Airworthiness Directive until this Service Bulletin (M87-26) is complied with.

A broken piston pin, P/N 643846, has been confirmed to have been the cause of a recent engine failure. The following action is therefore required on the above referenced engines. I.

A.

Insure that the magnetos are properly grounded. Remove one spark plug (the most accessible) from each cylinder. Attach a spring scale to the propeller blade at the 30 inch station. Rotate the propeller in normal direction of rotation via the attached scale and record the pounds required to rotate the propeller. Normal range is approximately 10 to 20 pounds. While holding opposite propeller blades as close to the hub as possible, move the crankshaft fore and aft to assure the crankshaft has end play. NOTE...If the recorded pounds are not within the normal range or there is no crankshaft end play, contact your local Teledyne Continental Motors representative (See Page 4) for disposition. WARNING...Use extreme caution in the area of the propeller while performing this check.

B.

Gain access to the eight (8) crankcase thru bolt nuts. With a cylinder base wrench, loosen the eight (8) thru bolt nuts and back them off approximately 1/2 inch. Liberally lubricate the exposed thru bolt threads and the nuts with clean 50 weight engine oil. Torque the nuts to a preliminary torque of 350 inch pounds, then repeat final torque to 700 inch pounds each. It may be necessary to retain the opposite nuts to prevent thru bolt rotation. (Continued)

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

21 December 1987

II.

Page 2

M87-26

C.

Repeat paragraph IA above and record the pounds required to rotate the propeller. If after torquing the thru bolts per paragraph IB, the effort (pounds) to rotate the propeller has increased above that previously recorded or there is no crankshaft end play, contact your local Teledyne Continental Motors representative (See Page 4) for disposition. If no special disposition is required, proceed to Section II.

A.

Gain access to the piston pins by removal of all cylinders. NOTE...DO NOT REMOVE THE PISTON FROM THE CYLINDER. REMOVE ONLY TO A POINT TO GAIN ACCESS TO THE PISTON PIN. REMOVE THE PISTON PIN, THEN THE PISTON AND CYLINDER AS ONE UNIT.

B.

With cylinders and pistons removed, visually inspect the number 1, 2, 3, and 4 crankcase main bearings for any signs of bearing rotation within the case; bearing movement fore or aft within the case or crankcase material distress. Particular attention should be given to number 2 and 3. The crankshaft should be moved fore and aft while performing this inspection. The crankshaft will also require rotation to allow for unobstructed view of the bearings.

NOTE...The crankcase main bearings are numbered from number 1 in the rear of the engine and progressing forward. (Toward the propeller flange).

Figure A depicts how bearing should generally appear.

Figure B depicts a bearing that has shifted.

NOTE...Contact your local Teledyne Continental Motors representative (See Page 4) for disposition of any bearing appearing as in Figure B or with any signs of crankcase material distress.

C.

If no problems are detected during the inspection outlined in paragraph IIB, proceed with the installation of new piston pins P/N 630046 and the reassembly of the engine.

D.

The cylinders should be installed in sequence and torqued in sequence per the instructions in Figure C. New cylinder gasket sets should be used, 6 each P/N 646563A1. NOTE...Liberally apply clean 50 weight engine oil on the rod bushing, piston pin and valve mechanism during engine reassembly.

(Continued)

21 December 1987

III.

A.

Page 3

M87-26

Finalize reassembly of the cylinders to the point of rocker cover installation. At this point repeat paragraph IA above and record the pounds required to rotate the propeller. If the effort (pounds) to rotate the propeller has increased above that previously recorded in paragraph IC or there is no crankshaft end play, contact your local Teledyne Continental Motors representative (See page 4) for disposition. If no discrepancies are noted, finalize reassembly of the engine.

B. WARRANTY:

Perform appropriate testing, make appropriate log book entry stating compliance to this service bulletin and return the engine to service. The action to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. When submitting the warranty claim for compliance with this service bulletin, you must enter the pounds required to rotate the propeller as recorded in paragraph IA, IC, IIIA. It should be recorded in the CONDITIONS REPORTED SECTION of the warranty claim.

EXAMPLE:

Compliance with Service Bulletin M87-26 Paragraph IA - 12 pounds Paragraph IC - 12 pounds Paragraph IIIA - 14 pounds

TCM will allow 32 hours labor at current posted shop rates to comply with this service bulletin and the following parts: 6 each P/N 630046 piston pin 6 each P/N 646563A1 gasket set

21 December 1987

M87-26

Page 4

ADDRESS: Teledyne Continental Motors Attn: J. Black/C. McClellan P.O. Box 90 Mobile, AL 36601 (205) 438-3411

J. A. Buskirk 10014 Venetian Way Dallas, TX 75229 (214) 351-3149

R. W. Lambrix 3661 Duffer Court Zellwood, FL 32798 (305) 880-1221

Tom Thys/Tony Evanson Room 4, 19 The Square Sand Bach, CW11 OAT Chesire, ENGLAND 44 270 76-7339

David Blanchard P.O. Box 427 Scarborough, ME 04074 (207) 883-3150

R. A. Deets 14611 Chalet Lane Huntingdon Beach, CA 92647 (714) 895-5597

R. M. Robbins 11477 Wolftooth Pass Littleton, CO 80127 (303) 979-7923

Edgardo Martedi R Charles S Chaplin 85 Apartment #23 05642 Sao Paulo BRAZIL 55 11 299-2666

21 December 1987

Page 5

Figure B

(Continued)

M87-26

21 December 1987

28

32

34

30

9

13

M87-26

Page 6

15

11

1

5

7

17

3 17

CYL# 1 31

35

33

36 29 12

CYL# 3

16

14

37 10

4

CYL# 5

8

6

21

23

1

CYL# 6

38 2

19

5

7

CYL# 4

20

24

22

18

13

15

26 4

8

6

11 28

CYL# 2

25

20

9

3

2

12

27 16

14

10

31

CAUTION...Before proceeding note that the six nuts utilized with the seventh stud (positions 25, 26, 27, 36, 37, 38) have a conical seat and can only be used in these positions. NOTE...Nuts on both ends of thru bolts must be torqued and all studs and thru bolt threads are to be lubricated with clean 50 weight engine oil before installing nuts. ASSEMBLY AND PRELIMINARY TORQUE 1) Install cylinders 4 & 5. Tighten stud nuts (2, 3, 5, 6, 7, 8) and thru bolts (1 & 4) to 300-400 inch lbs. in sequence shown above. 2) Install cylinders 2 & 3. Tighten stud nuts (10, 11, 13, 14, 15, 16) and thru bolts (9 & 12) to 300-400 inch lbs. in sequence shown above. 3) Install cylinder #6. Tighten stud nuts (18, 19, 21, 22, 23, 24) and thru bolts (17 & 20) to 300400 inch lbs. in sequence shown above. 4) Install cylinder #1. Tighten stud nuts (29, 30, 32, 33, 34, 35) and thru bolts (28 & 31) to 300400 inch lbs. in sequence shown above. 5) Install 7th stud brackets & nuts (25, 26, 27, 36, 37, 38) and tighten to 300-400 inch lbs. (See Caution above). 6) Finish torquing thru bolts and stud nuts to their final torque values in sequence shown above. FINAL TORQUE VALUES INCH LBS. Thru Bolts

1, 4, 9, 12, 17, 20, 28, 31

690-710

Stud Nuts

2, 3, 5, 6, 7, 8, 10, 11, 13 Thru 16, 18, 19, 21 Thru 27, 29, 30, 32, Thru 38

490-510

NOTE...Repeat torquing sequence with final torque values to insure that all thru bolts and stud nuts have been torqued.

FIGURE C

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-6 Technical Portions Are FAA Approved

16 February 1987 SUBJECT: ROMEC SERVICE BULLETIN NO. 101SB015 FUEL PUMP P/N RR36090C (TCM P/N 643367) MODELS AFFECTED: COMPLIANCE:

GTSIO520-N ONLY See ROMEC Service Bulletin

Teledyne Continental Motors recommends that the attached ROMEC Service Bulletin No. 101SB015 be complied with as indicated with the following exceptions: Paragraph 2. Accomplishment Instructions:

Disregard step A and accomplish steps B thru D.

 TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M87-8 Technical Portions are FAA-DER Approved

26 February 1987 SUBJECT: EXHAUST VALVE INSPECTION MODELS AFFECTED:

Part I Rebuilt Engines Only Model

Serial Numbers

IO360B IO360C IO360D IO360G IO360GB IO360K TSIO360CB LTSIO360EB

235846 60566, 60567, 60568,60569, 60571, 60572, 60573 62861, 62862 244519, 244520, 244521, 244522, 244523, 244524 236630, 236631 240074, 240075,240076, 240077, 240078 236040 233931

PART II Exhaust Valve P/N 639283 purchased from TCM Atlanta Warehouse between March 15, 1985 and June 20, 1985 - This valve is used in 360 series engines. COMPLIANCE: Within the Next Five (5) Hours of Operation COMPLIANCE REQUIREMENT: Those engines listed in Part I and valves purchased per Part II with 250 hours or less operating time. 1.

Any valve inspected and not found to exhibit abnormal wear that has less than 100 hours operating time must be reinspected after 100 additional operating hours or at 150 hours operating time, whichever occurs first.

2.

Any valve inspected and not found to exhibit abnormal wear that has more than 100 hours operating time but less than 200 hours operating time must be reinspected in 50 hours.

3.

Any valve inspected and not found to exhibit abnormal wear that has 200 hours of operating time or more requries no further inspection.

TCM has received and verified a report of exhaust valve P/N 639283 coming loose from its retaining keys. This action was due to the valve tip not having the proper hardness. The reported valve has been traced to a limited number shipped from our vendor. Only a very small number of the valves shipped are suspected of improper hardness. This condition allows the valve tip to wear at an accelerated rate and could lead to valve failure and/or ultimate engine failure. The following action must therefore be taken.  TELEDYNE INDUSTRIES, INC. 1987

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

M87-8 Part I - Action The engines listed above in Part I were rebuilt by TCM using exhaust valve P/N 639283 from the suspect group. The following inspection is therefore required: 1.

Remove the exhaust rocker cover.

2.

Visually inspect the exhaust valve tip for abnormal wear. See Example A and B (abnormal wear). NOTE:

If wear is normal, the valve tip should appear similar to Example D (new, unused) or Example C (used, normal wear), depending on hours in use. Valves having improper hardened tips are very soft, so that abnormal wear is readily distinguishable.

3.

If a valve with abnormal wear is located, please contact Teledyne Continental Motors.

4.

If upon completion of the inspection or inspections explained in the COMPLIANCE REQUIREMENT section of this bulletin no valves with abnormal wear are noted, reinstall the rocker cover using a new gasket P/N 632310 and make appropriate logbook entry as to compliance with this service bulletin.

Part II - Action A quantity of exhaust valve P/N 639283 from the suspect group were sold from our Atlanta Warehouse to the aftermarket between March 15, 1985 and June 20, 1985; and therefore require the following action: 1.

Any exhaust valve P/N 639283 that was purchased from the TCM Atlanta Warehouse during the above dates and subsequently installed in an engine must be inspected per the COMPLIANCE REQUIREMENT section and the procedures outlined in the Part I - Action section of this service bulletin. NOTE:

2.

Only cylinders that had valves installed from this suspect group need to be inspected.

Any exhaust valve P/N 639283 that was purchased from the TCM Atlanta Warehouse during the above dates and is still in inventory must be returned to TCM for inspection. Please contact Teledyne Continental Motors.

WARRANTY: The action required to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. One-half hour of labor for a single cylinder with a maximum of two hours for a complete engine at current published shop rates will be allowed to comply with this service bulletin. ADDRESS:

Teledyne Continental Motors Aircraft Service Department P.O. Box 90 Mobile, AL 36601 (205) 438-3411

Page 2 of 3

M87-8

A

C

B

D

Page 3 of 3

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M88-10 Technical Portions Are FAA Approved

August 24, 1988

SUBJECT: MODELS AFFECTED: COMPLIANCE:

CONTAMINATED FUELS All As Required

It is the strong recommendation of Teledyne Continental Motors that any engine operated on fuel of lower grade than approved for the engine, especially fuel contaminated with kerosene, be completely disassembled for analytical inspection. The use of such fuel can result in internal damage which cannot be assessed by any other method. It is further recommended that during the course of teardown, any parts which show signs of detonation be scrapped. This would include the cylinders, pistons, piston pins, rods and crankshaft. The reason is that all parts exposed to the temperatures and excessive loads imposed by detonation are subject to the possibility of future failure and should be destroyed.

Member of GAMA

TELEDYNE CONTINENTAL MOTORS Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M88-12 Technical Portions Are FAA-DER Approved

September 9, 1988 SUBJECT: PIPER AIRCRAFT MANDATORY SERVICE BULLETIN NO. 892 MODELS AFFECTED:

COMPLIANCE:

TSIO520BE

New S/N

528005 through 528036 528038 through 528046 528048 through 528210 528212 through 528390 528392 through 528483

Rebuilt S/N

273500 through 273560

At the next scheduled inspection but not to exceed the next 25 hours of operation

We feel that the above referenced Piper Service Bulletin No. 892 requires your immediate attention and therefore have recommended a shorter compliance time than recommended by Piper Aircraft. Failure to comply with this bulletin could allow you to unknowingly operate your engine in excess of the maximum allowable temperatures as specified by Teledyne Continental Motors. Operating your engine at these extremely high temperatures could result in engine failure.

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M88-13 Supersedes M87-4 & M87-22 Technical Portions Are FAA Approved

September 26, 1988

SUBJECT: MODELS AFFECTED:

COMPLIANCE:

INDUCTION TUBE CRACKING TSIO360MB, S/N

317002 through 317044 317046 through 317069 317071 through 317170 317172 through 317177, 317179, 317181, 317182, 317186 and 317189

Within the next 50 hours of operation

Field reports indicate that previous service bulletins M87-4 and M87-22 have had positive effects but have not completely eliminated induction tube cracking; consequently TCM recommends the following procedure be performed on all of the above referenced engines. Modification Procedure 1.

Visually inspect cylinder #5 and #6 induction tubes for evidence of prior compliance with Service Bulletin M87-22. If tubes have been modified proceed to step #4. If tubes have not been modified continue to step #2.

2.

Gain access to the #5 and #6 induction tubes and remove from the engine.

3.

Modify the tubes per Figures 1 and 2. Note: Tubes should be cut using a hacksaw or bandsaw. Deburr modified tube ends.

4.

Remove the remaining tubes (including #5 and #6 if still installed).

5.

Remove the two brackets attaching the throttle body to the crankcase and discard.

6.

Install a new AN4-13A bolt in the vacated hole in the crankcase utilizing existing 20522 washers and 646605 nut. Torque nut to 180-220 in. lbs.

7.

Visually inspect all tubes at the flange radius where it attaches to the cylinder for cracks. If cracks are noted replace tube or tubes as required.

(continued)

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

26 September 1988

Page 2 of 4

M88-13

8.

Reinstall tubes 1 through 4. Torque flange nuts to 50/70 in. lbs.

9.

If Service Bulletin M87-22 tube modification was previously performed reinstall tube 5 and 6. Torque flange nuts to 50/70 in. lbs.

10.

If tubes 5 and 6 required modification then reinstall tubes with new hose P/N 639660-15 and new clamps P/N AN 737TW74 torque flange nuts to 50/70 in. lbs. Note: 2 ea. clamp P/N AN737TW74 and 1 ea. P/N 639660-15 required on each tube modified.

11.

Check all hoses for proper installation and verify that clamps are tight and secure.

12.

Make appropriate logbook entry of compliance to this service bulletin.

Warranty: The action required to comply with this service bulletin is covered by TCM Gold Medallion warranty subject to its terms and conditions. A labor allowance of two (2) hours per engine will be allowed if tube modification is required. If tube modification was previously complied with, then one (1) hour will be allowed for bracket removal only. Warranty claims may be filed through any TCM distributor.

(continued)

26 September 1988

Page 3 of 4

(continued)

M88-13

26 September 1988

Page 4 of 4

Figure 3

M88-13

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M88-14 Technical Portions Are FAA Approved

10 October 1988 SUBJECT: SLICK SERVICE BULLETIN SB1-88 MODELS AFFECTED: COMPLIANCE:

TSIO520 Series Incorporating Slick 6220 and 6224 Pressurized Magneto See Slick Bulletin

Teledyne Continental Motors recommends compliance with attached Slick Service Bulletin SB1-88. Teledyne Continental Motors does not supply internal magneto parts. Order parts required through any Slick Distributor.

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

SLICK

SB1-88 FAA APPROVED

SERVICE BULLETIN TO:

Aircraft Manufacturers, Aircraft Engine Manufacturers, Distributors, Engine Overhaul Facilities, Owners and Operators of Slick Aircraft Magnetos.

SUBJECT:

Periodic Inspection of Slick Models 6220 and 6224 Pressurized Magnetos.

MODELS AFFECTED:

BACKGROUND INFORMATION:

Slick Model 6220 and 6224 Magnetos installed on Cessna Models, P210, TU206, TP206, T207, T210, T303, T310, 320, 335, 340, 401, 402,414 Aircraft. Slick Model 6220 and 6224 pressurized magnetos are used on turbocharged engine that require very high altitude mission capability. Slick 6220 and 6224 magnetos are pressurized with air from the engine turbocharger. The pressurization system connecting the magnetos to the turbocharger, including all fittings, lines and filtration devices, is part of the aircraft engine and / or airframe. It is therefore important that in conjunction with the instructions contained in this bulletin, the engine and aircraft manufacturer’s service literature be consulted to insure the pressurization system is functioning properly and is in the proper condition. The operation of Slick pressurized ignition systems is similar to conventional magnetos with the exception that as the aircraft climbs, the air density inside the pressurized magneto decreases at a slower rate. The resulting air density at altitude improves the insulation properties of the air inside the magneto to reduce the likelihood of high altitude misfire. Field service reports of these installations indicate that the magneto pressurization systems installed on the above listed aircraft may be capable of depositing moisture inside the magnetos and may be incapable of maintaining magneto pressurization under some flight conditions. Similar to the ignition distributor on an automobile, an aircraft magneto will not operate properly when contaminated with water or other corrosives. In particular, the models of aircraft noted above will have a higher probability of developing moisture in the magnetos when they are flown in rain, for, or clouds. High altitude flying in such wet weather will increase the probability of moisture contamination and magneto malfunction even further.

ISSUED MO DAY 04 10

YR 88

MO -

REVISED DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

1 OF 11

NONE

SLICK Service Bulletin WARNING:

SB1-88 FAA APPROVED

MOISTURE IN MAGNETOS CAN LEAD TO SEVERE ARCING INSIDE THE MAGNETOS AND TOTAL MAGNETO FAILURE.

This bulletin describes increased inspection intervals as well as post flight magneto checks for Slick 6220 and 6224 magnetos installed in the specified aircraft. Pilots and mechanics should be aware, however, that the problems of moisture developing magnetos are most likely for aircraft flow into rain, for, or clouds. This Service Bulletin, in conjunction with Maintenance and Overhaul Manual L-1037, outlines the step-by-step procedures required to maintain and overhaul Slick Model 6220 and 6224 pressurized magnetos. This Service Bulletin supersedes and obsoletes Service Letter SL184A. This Bulletin and its procedures DO NOT replace Slick Maintenance and Overhaul Manual L-1037 and / or required 500 hour inspections. COMPLIANCE: Within next 50 hours of flight time and every 100 hours thereafter or annual inspection, whichever occurs first. (Also, pre-flight and postflight magneto checks.) PROOF OF COMPLIANCE: Appropriate logbook entries. PARTS REQUIRED PER BULLETIN: As required for proper overhaul and maintenance. TOOLS REQUIRED PER BULLETIN: Slick T-100 Timing and Assembly Tool Kit and standard shop tools. WEIGHT CHANGE: None. DETAILED INSTRUCTIONS: THIS SERVICE BULLETIN IS A SUPPLEMENT TO SLICK MAINTENANCE AND OVERHAUL MANUAL L-1037. CHECK WITH SLICK TO BE SURE YOU HAVE THE MOST CURRENT REVISION OF THIS MANUAL AND PERTINENT SERVICE BULLETINS AND LETTERS BEFORE PERFORMING MAINTENANCE OR OVERHAUL. NOTE:

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

The numbers in parentheses ( ) following the name of each part refer to the assembly drawing in Diagram 1.

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

2 OF 11

NONE

DIAGRAM 1 EXPLODED PARTS DIAGRAM

SB1-88

SLICK Service Bulletin REF NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

FAA APPROVED

DESCRIPTION

6220

6224

Cotter Pin Nut, Impulse Coupling Washer, Impulse Coupling Impulse Coupling Assy. Oil Seal Pressure Vent Frame Gasket Ball Bearing Rotor Bearing Cap Assy. Bearing Plate Clamp Screw Rotor Gear Contact Point Kit (includes Cam, Cam Grease, Screws, Lockwasher) Cam Woodruff Key Coil Wedge Screw Coil Screw Gasket (O-ring) Pressure Tube Fitting Screw Housing, Distributor Condenser Distributor Block & Gear Assy. Screw Carbon Brush Washer

M2540 M3019 M3172 M3050 M3175 M3179 M3248 M3176 M3006 M3047 M3485 M3018 M3221 M3057 M3081

M2540 M3019 M3172 M3089 M3175 M3179 M3249 M3176 M3006 M3093 M3485 M3018 M3221 M3057 M3081

QTY. USED 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1

M1522 M2536 M3040 M3020 M3525 M2555 M3177 M3180 M3015 M3002 M3183 M3122 M3021 M3215 M3489

M1522 M2536 M3040 M3020 M3525 M2555 M3177 M3180 M3015 M3002 M3183 M3122 M3021 M3215 M3489

1 1 2 2 1 1 4 1 3 1 1 1 2 1 1

DIAGRAM 1 CONTINUED PARTS LISTING

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

3 OF 11

NONE

SLICK Service Bulletin I.

SB1-88 FAA APPROVED

PREFLIGHT CHECK Mag Check – Perform mag check as described in the airframe operating manual. If the mag check is not within acceptable limits, the magnetos must be disassembled and checked according to the 100 hour inspection procedures stated in this bulletin and in Slick Maintenance & Overhaul Manual, Form L-1037. Also reference the engine and/or airframe manufacturer’s literature for pressurization system corrective action. NOTE: Many non-ignition system factors influence engine performance during a magneto check, and the replacement or repair of ignition components may not remedy problems in all cases. After verifying that all non-ignition system related causes for problems have been explored, proceed with inspection procedures as stated in this bulletin.

II. POST-FLIGHT CHECK Mag Check – After landing, perform mag check as described in the airframe operating manual. If the mag check is not within acceptable limits, the magnetos must be disassembled and checked according to the 100 hour inspection procedures stated in this bulletin and in Slick Maintenance & Overhaul Manual, Form L-1037. Also reference the engine and/or airframe manufacturer’s literature for pressurization system corrective action. NOTE: Many non-ignition system factors influence engine performance during a magneto check, and the replacement or repair of ignition components may not remedy problems in all cases. After verifying that all non-ignition system related causes for problems have been explored, proceed with inspection procedures as stated in this bulletin. III. 100 Hour Inspection The purpose of these instructions is to check the magneto for moisture contamination following procedures in Section A below. If moisture contamination is found, (1) clean affected parts following procedures in Section B, General Cleaning, and (2) check operation of engine pressurization system following instructions in Section C. Pressurization System Check. A. CHECK MAGNETO FOR MOISTURE CONTAMINATION 1. Check for rust and corrosion on screws (19, 21, 24, 28), bearing cap hold down clamps (12), rotor shaft (10), breaker point assembly (15), frame and coil laminations (20), etc. See figure 1. Rust and corrosion are signs of contamination and require component cleaning or replacement (reference Sections B and C of this Bulletin and Slick Form L-1037 Maintenance & Overhaul Manual).

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

4 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

FIGURE 1 2. Soft or sticky distributor and rotor gears (14, 27) indicate moisture contamination and require component replacement (reference Slick Form L-1037 Maintenance & Overhaul Manual). See Figure 2.

FIGURE 2 3. Gummy or sticky distributor gear oilite bearing (27) indicates contamination. Check distributor block assembly according to instructions in Slick Form L-1037 Maintenance & Overhaul Manual. See figure 3.

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

5 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

FIGURE 3 4. Traces of pooling water on the distributor bearing bar (27) in the vicinity of the carbon brush or other internal surfaces of the magneto indicates the presence of moisture. See Figure 4. Check distributor block assembly according to instructions in Slick Form L-1037 Maintenance & Overhaul Manual.

FIGURE 4 5. A yellow powder, yellow particulates, oxides or white chalky powder on the condenser housing (26) indicate moisture contamination. See Figure 5. Refer to Sections B and C of this Bulletin and Slick Form L-1037 Maintenance & Overhaul Manual.

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

6 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

FIGURE 5 6. A yellow powder, yellow particles, oxides or white chalky powder on the magneto frame (7) and housing (25) indicates moisture or corrosive contamination. See Figure 6. Clean or replace as necessary following procedures in Sections B and C of this Bulletin and Slick Form L-1037 Maintenance & Overhaul Manual.

FIGURE 6 7. White or gray chalky deposits around the electrodes inside the distributor block (27) indicates lack of pressurization. See Figure 7. Refer to Sections B and C of this Bulletin for cleaning and pressurization system check. Check distributor block assembly according to instructions in Slick Form L-1037 maintenance & Overhaul Manual.

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

7 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

FIGURE 7 8. Electrical tracking or arcing in the distributor block and bearing bar (27) indicates contamination or lack of pressurization. See Figure 8. Check distributor block assembly according to instructions in Sections B and C of this Bulletin and Slick Form L1037 Maintenance & Overhaul Manual.

FIGURE 8

9. Check inside of magneto for corrosion, oil and other turbocharger contaminants. Clean if necessary following instructions in Section B of this Bulletin. Check air lines accordingly.

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

8 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

10. Frame Gasket (8) – Check gasket M-3176 for wear and replace as necessary. Gasket M-3176 contains a metal mesh foundation insure proper ground between the magneto frame and the magneto housing. If replacement is required, use only Slick replacement M-3176 gasket. 11. Screw Gasket (22) – Check screw gasket M-3177 for wear and replace as necessary. For replacement, use only Slick M-3177 gaskets and Slick M-2555 and M-3015 mounting screws. 12. Harness Cap ‘O’ Ring (not shown in Fig. 2) – Check ‘O’ ring M-3184 for wear and replace as necessary. 13. Orifice Vent (6) – Check and clean orifice vent M-3179 to insure it is clean and free of obstruction. Reference Section B of this Bulletin. Maximum orifice diameter is .025 inch. See Figure 9.

FIGURE 9 14. Turbo Filter – Check for yellow or red color, condensation or free standing water or foreign matter in the filter element. See Figure 10. If the filter is contaminated, reference the engine and / or airframe manufacturer’s literature for pressurization system corrective action. Replace turbo filter.

FIGURE 10

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

9 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

15. Inlet Nozzle (23) – Check and clean inlet nozzle M-3180 to insure it is clean and free of obstruction. (Figure 11.) Reference Sections B and C of this Bulletin. Yellow or white contamination and possible lack of pressurization. Reference the engine and / or airframe manufacturer’s literature for pressurization system corrective action.

FIGURE 11 B. GENERAL CLEANING PROCEDURES 1. Metal Parts – use Stoddard Solvent, Varsol, or any standard evaporative non-filming solvent. 2. Plastic or nylon parts – use soapy water, rinse with clear water, and dry with lint free cloth. C. CHECK PRESSURIZATION SYSTEM To check for correct operation of the engine pressurization system, reference engine and / or airframe manufacturers’ literature. IV.

REASSEMBLY After any necessary maintenance has been performed, reassemble magneto using procedures outlined in Slick Form L1037 Maintenance & Overhaul Manual.

V.

POST – ASSEMBLY TESTING A. Perform testing procedures as outlined in Slick Form L-1037 4200/6200 Series Maintenance & Overhaul Manual, in addition to pressure testing outlined below.

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

10 OF 11

NONE

SLICK Service Bulletin

SB1-88 FAA APPROVED

B. Pressure Testing – After magneto reassembly, install a pressurized harness cap and apply 15 psi filtered air to the inlet nozzle of the magneto. Air flow at 15 psi is not to exceed 40 standard cubic feet per hour (SCFH). If flow is excessive, reposition gaskets and re-torque to 18-20 in. lbs. See Figure 12 for Test Apparatus details. Testing should be conducted with magneto at room temperature.

FIGURE 12 C. Perform mag check on engine as described in the airframe operating manual to ensure proper mag operation.

ISSUED MO DAY 04 10

YR 88

REVISED MO DAY YR -

Slick Aircraft Products

PAGE NO.

REVISION

A Division of Unison Industries, Inc. 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104

11 OF 11

NONE

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M88-15 Technical Portions Are FAA-DER Approved

10 October 1988 SUBJECT: Facet Service Bulletin A1-88 MODELS AFFECTED: COMPLIANCE: WARRANTY:

O-470-A, K, L, R, S, U See Facet Bulletin A1-88 TCM does not supply kits required to perform this bulletin. Order parts through Facet Aerospace Products.

Teledyne Continental recommends compliance of the attached Facet Service Bulletin A1-88 as published.

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M88-4 Technical Portions Are FAA Approved

15 January 1988

SUBJECT: MODELS AFFECTED: COMPLIANCE:

TCM PRO-TECH OIL FILTER P/N 649309, 649310 (Pro-Tech) Before Further Flight

We have verified field reports of oil leakage of the above part number filters. It is, therefore, required that any P/N 649309 or 649310 (Pro-Tech) filter installed on an engine be removed before further flight and replaced. NOTE...TCM recommends the P/N 649309 filter be replaced with a Champion filter P/N CH48109 (TCM P/N 649923) and the P/N 649310 filter be replaced with a Champion P/N CH48108 (TCM P/N 649922). It is also required that any P/N 649309 or 649310 (Pro-Tech) filter in parts inventory be removed and returned. Make appropriate logbook entry of compliance with this service bulletin. WARRANTY: The action required to comply with this service bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. FILTERS INSTALLED ON ENGINES One half (0.5) hours of labor at current posted shop rates will be allowed to comply with this service bulletin. An allowance of $12.37 for P/N 649309 and P/N 649310 filter will be allowed. FILTERS IN PARTS INVENTORY These filters should be returned for credit to TCM through the distributor where it was purchased.

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M88-5 Technical Portions Are FAA Approved

4 April 1988 SUBJECT: MODELS AFFECTED:

STARTER ADAPTER SHAFTS (Reference Service Bulletin M87-24) IO-520-BA, IO-520-BB, IO-550-B, TSIO-520BE, TSIO-520UB, TSIO-520LB, AND TSIO-520WB

Only those new and rebuilt serial numbers that were required to have their compressor drive belts cut in compliance with TCM Service Bulletin M87-24. COMPLIANCE:

As required.

On December 15, 1987 Teledyne Continental Motors issued Service Bulletin M87-24 requiring the deactivation (cutting the drive belt) of some air conditioning compressors as an interim measure until shaft redesign and testing were completed. TCM has available replacement starter drive assemblies for those engines that required deactivation (cutting the drive belt). The following action is therefore required: 1.

Replacement assemblies should be ordered through any Teledyne Continental Motors distributor per the following: ORDER REPLACEMENT STARTER DRIVE ASSEMBLY

FOR ENGINE MODEL IO-520-BA, IO-520-BB, AND IO-550-B TSIO-520-LB AND TSIO-520-WB TSIO-520-BE TSIO-520-UB

P/N 642087A23R P/N 642087A22R P/N 642087A24R P/N 646757A4R

2.

Any new or rebuilt TSIO-520-BE engine used on the Piper Malibu Aircraft and shipped from TCM as a replacement engine in conjunction with compliance to TCM Service Bulletin M87-25 should not order a replacement starter drive assembly. Those engines will have replacement starter drive assemblies shipped directly from the TCM factory.

3.

The replacement starter drive assembly is shipped without a drive sheave. You must remove the spacer adjacent to the 12 point lock nut to allow for installation of the drive sheave. Install the drive sheave from your existing unit. Then lubricate the threads of the 12 point lock nut P/N 649924 supplied on the replacement starter drive assembly with clean 50 weight engine oil and torque to 450 to 500 inch pounds. (continued)

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

4 April 1988

Page 2

M88-5

4.

When the replacement starter adapter assembly is installed the drive sheave and belt should be installed using proper torque, alignment and belt tension per TCM Service Bulletin M88-6 or subsequent revision.

5.

Make appropriate log book entry stating compliance to this service bulletin. WARRANTY: The action to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

The following exceptions apply: A.

TCM will supply replacement units on an exchange basis at no charge to the customer.

B.

TCM will pay up to five (5) hours labor at posted shop rates to install the replacement unit on the IO-520-BA, IO-520-BB, IO-550-B, TSIO-520LB, TSIO-520-WB and TSIO-520-UB. Eight (8) hours will be allowed on the TSIO-520-BE.

NOTE:

C.

Installation of the replacement unit on the Piper Malibu (TSIO-520-BE engine) does not require engine removal. Piper Aircraft Corporation Service Bulletin 876B gives detailed instructions on this subject. Exchange parts must be returned to TCM for credit and should accompany the warranty claim for expeditious processing.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M88-9 Technical Portions Are FAA Approved

August 24, 1988

SUBJECT: MODELS AFFECTED: COMPLIANCE:

LIGHTNING STRIKES All As Required

The following is Teledyne Continental Motors' recommendations concerning lightning strikes on aircraft incorporating our engines. Since it is impossible to assess internal damage that may have resulted from the high voltage discharge, we recommend a complete disassembly of the engine and a thorough inspection for arcing and heat damage to the crankshaft rod journals, main journals, counterweights, camshaft lobes, bearings, gear teeth and all other hardened surfaces. The steel parts of the engine should be magnafluxed and degaussed during this engine inspection.

 TELEDYNE INDUSTRIES, INC. 1988

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M89-14 Supersedes M89-11 Technical Portions Are FAA Approved

29 June 1989 TO: SUBJECT:

All Malibu Owners THRU BOLT TORQUE CHECK AND VISUAL INSPECTION #2 MAIN BEARINGS

MODELS AFFECTED: COMPLIANCE:

TSIO520BE, S/N 528001 thru 528337 Within Next 10 Hours of Operation

It has come to our attention that some engines may not have achieved the optimum compression load in the crankcase bearing boss during compliance with Service Bulletin M8725. It is, therefore, required that the above affected engines be inspected as follows: Section A.

Crankshaft end play checked within 10 hours and repeated every 25 hours of operation.

Section B.

Thru bolt torque check within 10 hours (one time inspection only).

Section C.

Visual inspection of #2 crankcase main bearing within 10 hours and repeated every 200 hours of operation.

The repetition of Section A crankshaft end play and Section C visual inspection will not be required once engine has been overhauled or crankcase has been split, inspected for fretting and bearings replaced. The inspection requirements should be accomplished in accordance with the following procedures: Section A. 1.

Crankshaft End Play

Allow the engine temperature to stabilize to ambient room temperature. Insure that the magnetos are properly grounded. Check crankshaft end play at eight positions starting at the 12 o'clock position and rotating propeller counter clockwise at 45 degree increments.

NOTE...If there is no crankshaft end play at any position, contact Teledyne Continental Motors for disposition. WARNING...USE EXTREME CAUTION IN THE AREA OF THE PROPELLER WHILE PERFORMING THIS CHECK. (continued)  TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

29 June 1989

Page 2

M89-14

Section B. Thru bolt Torque Check 1.

Allow the engine temperature to stabilize to ambient room temperature. Remove one spark plug (the most accessible) from each cylinder. Insure that the magnetos are properly grounded. Turn the engine with starter approximately 15 seconds to obtain positive lubrication to main bearings. Attach a spring scale to the propeller blade at the 36 inch station (4 inches in from prop tip). Rotate the propeller in normal direction of rotation via the attached scale and record the pounds required to rotate with the propeller in motion. Normal range is approximately 0 to 20 pounds.

NOTE...If the recorded pounds are not within the normal range, contact Teledyne Continental Motors for disposition. WARNING...USE EXTREME CAUTION IN THE AREA OF THE PROPELLER WHILE PERFORMING THIS CHECK. 2.

Remove the intercooler, peripheral baffle, cylinder drain tube and intercylinder baffles as required from the 1,3,5 cylinder side of the engine to gain access to the thru bolt nuts of the number 3 and 5 cylinders. The intercylinder baffle between number 3 and 5 cylinders must be disassembled in two pieces for ease of removal. The intercylinder baffle between number 1 and 3 cylinders is removed as a completed assembly. With a 5/8 inch cylinder base wrench, loosen the four (4) thru bolt nuts and back them away from the cylinder flange approximately 1/2 inch. Caution should be used so as not to remove the nuts from the thru bolts as accessibility to re-install the nuts is very restrictive without extensive engine disassembly. Assure the thru bolt threads are cleaned and liberally lubricate the exposed threads and the nuts with clean 50 weight engine oil. Torque the nuts to a preliminary torque to 350 inch pounds then repeat final torque to 700 inch pounds each. Make sure cylinder base wrench shank does not contact cylinder barrel and create false torque reading. It may be necessary to retain the opposite nuts to prevent thru bolt rotation.

NOTE... Torque should be with a calibrated torque wrench. 3.

Repeat paragraph B1 above and record the pounds required to rotate the propeller. If after torquing the thru bolts per paragraph B2, the effort (pounds) to rotate the propeller has changed from the previously recorded value by more than three pounds or the crankshaft has no end play, contact your local Teledyne Continental Motors representative (listed below) for disposition. If no special disposition is required, proceed to Section C.

(continued)

29 June 1989

Page 3

M89-14

Section C. Visual Inspection of #2 Crankcase Main Bearing 1.

Gain visual access to the #2 crankcase main bearing by removal of number three (3) cylinder.

NOTE...DO NOT REMOVE THE PISTON FROM THE CYLINDER. REMOVE ONLY TO A POINT TO GAIN ACCESS TO THE PISTON PIN. REMOVE THE PISTON PIN, THEN THE PISTON AND CYLINDER AS ONE UNIT. 2.

With cylinder and piston pin removed, visually inspect the number 2 crankcase main bearings for any signs of: a.

Bearing shift forward and aft within the crankcase. The back of the bearing shell will be shiny if there has been movement.

b.

Bearing contact with crankshaft fillet.

c.

Mismatch of bearing halves at case split line. The pattern has been for right bearing shell to move forward and the left bearing shell to move aft. The crankshaft should be moved fore and aft while performing this inspection. The crankshaft will also require rotation to allow for unobstructed view of the bearings.

NOTE...The crankcase main bearings are numbered from number 1 in the rear of the engine and progressing forward (toward the propeller flange). Figure A depicts how bearing should generally appear. Figure B depicts a bearing that has shifted. NOTE...Contact you local Teledyne Continental Motors representatives (see listing below) for disposition of any bearing appearing as in Figure B (Press F7 to see Figure B) or with any signs of distress as noted in paragraph C2. 3.

If no problems are detected during the inspection outline in paragraph C2, proceed with the installation of the #3 cylinder assembly and the reassembly of the engine. Assure that the cylinder thru bolts and deck studs are cleaned and oiled. Use clean 50 weight engine oil. Replace thru bolt nuts (P/N 634505) and cylinder base nuts (P/N 531001) if there are any signs of deterioration to threads or nut retention wrench flats.

(continued)

29 June 1989

M89-14

Page 4

4.

The cylinder should be installed and torqued with a calibrated torque wrench per the instructions in Figure C. New cylinder gasket sets should be used, P/N 646565A1.

5.

After cylinder installation, check for crankshaft end play and assure prop rotation is still within limits of Section B1.

6.

Finalize reassembly of the engine. Perform appropriate testing, make appropriate logbook entry stating compliance to this service bulletin with results of crankshaft end play and pounds required to rotate prop. Return the engine to service.

WARRANTY...The action to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. When submitting the warranty claim for compliance with this service bulletin, you must enter the pounds required to rotate the propeller as recorded in paragraph B1 and B3. It should be recorded in the CONDITIONS REPORTED SECTION of the warranty claim. EXAMPLE: Compliance with Service Bulletin M89-14 Paragraph B1 - 12 pounds Paragraph B3 - 12 pounds Man hours required to comply with this Service Bulletin: 10 man hours. Parts Required: 1 ea. P/N 646565A1 gasket set. Address: Teledyne Continental Motors Attn:J.Black/C.McClellan/D.Conrad P.O. Box 90 Mobile, AL 36601 (205) 438-3411

David Blanchard P.O. Box 427 Scarborough, ME 04074 (207) 883-3150

J.A. Buskirk 10014 Venetian Way Dallas, TX 75229 (214) 351-3149

R.A. Deets 14611 Chalet Lane Huntingdon Beach, CA 92647 (714) 895-5597

Tom Thys/Tony Evanson Room 4, 19 The Square Sand Bach, CW11 OAT Chesire, ENGLAND 44 270 76-7339

R. M. Robbins 11477 Wolftooth Pass Litteton, CO 80127 (303) 979-7923

(continued)

Edgardo Martedi R Charles S Chaplin 85 Apartment #23 05642 Sao Paulo BRAZIL 55 11 299-2666

29 June 1989

Page 5

Figure B (continued)

M89-14

29 June 1989

M89-14

Page 6

5

7

1

3

#3 Cylinder Deck

9

4

10

2

8

6

CAUTION...Before proceeding note that the nuts (P/N 646312) utilized with the seventh stud (positions 9 and 10) have a conical seat and can only be used in these positions. Assembly and preliminary torque: 1.

Install cylinder and tighten nuts (1 thru 10) to 300-400 inch pounds in sequence shown above.

2.

Finish torquing thru bolts and stud nuts to final torque in sequence shown above. Final torque values Thru bolts 1 & 4 690-710 inch pounds Stud nuts 2,3,5 thru 10 490-510 inch pounds

NOTE...Repeat final torque sequence

Figure C Cylinder Base Torque Sequence

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-15 Supersedes M87-9 Technical Portions Are FAA Approved

12 July 1989 SUBJECT: MODELS AFFECTED:

OVERSPEED LIMITATIONS All

Engine operation at speeds in excess of rated RPM (revolutions per minute) limitations can cause serious damage to the engine and can result in subsequent catastrophic engine failure. The following criteria is established as a guideline to be used when engines have inadvertently experienced some degree of overspeed for very limited periods of time:

RATED RPM LIMITATION

CAT. I TO

CAT.II TO

CAT.III OVER

GTSIO-520

3200-3400

3500

3700

3700

IO & L/TSIO-520 and IO & TSIO-550

2400-2850

3000

3300

3300

O, IO, & TSIO-470

2400-2625

2900

3200

3200

3200

3500

3700

3700

2500-2800

3000

3300

3300

IO-346

2700

3000

3300

3300

GO-300

3200

3500

3700

3700

0-300

2700

3000

3300

3300

2575-2750

3000

3300

3300

Tiara 6-285

4000

4100

4200

4200

Tiara 6-320

4400

4500

4600

4600

ENGINE

GIO-470 IO & L/TSIO-360

0-200, C-90, Etc.

(continued)

 TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

12 July 1989

Page 2

M89-15

CATEGORY I - RPM LIMITATIONS A.

Less than 10 seconds - No action required.

B.

More than 10 seconds - Proceed as follows: 1. Drain oil - inspect for contaminants in oil and screens and filters, where applicable. 2. Remove rocker covers and inspect valves, springs, rocker arms, tappets, spring retainers, pushrods, etc. 3. Check all accessory drives for excessive backlash. NOTE...If no secondary problems are indicated with above inspection, repeat item I after next five hours of flight time.

CATEGORY II - RPM LIMITATIONS A.

Less than 10 seconds - Same action required as for Category I.B.

B.

More than 10 seconds - In addition to action required for Category I.B., proceed as follows: 1. Remove all cylinder assemblies including rods and pistons. 2. Remove all counterweights (Tiara, inspect VTC unit). 3. Inspect and replace parts in accordance with published service manuals using new connecting rod bolts and nuts.

CATEGORY III Engines having experienced overspeeds of this magnitude considered "Excessive Overspeed" must be dealt with on an individual basis with the TCM Service Department in Mobile, Alabama, telephone (205) 438-3411, considering such factors as time at speed, engine age, engine type, application, and other related circumstances. In general, however, proceed as follows: 1. Remove engine and clearly identify (removal for excessive overspeed). 2. Engine and accessories should be completely overhauled and comply with appropriate overhaul instructions. 3. Critical to excessive overspeed loading components such as: Connecting Rods and Bolts All Valve Train Parts should be replaced without consideration of normal wear tolerance allowances or magnaflux inspection techniques.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-18 Supersedes M76-19 Rev. 1 Technical Portions Are FAA Approved

10 August 1989 TO:

Distributors, Dealers, Aircraft Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

SUBJECT:

EXHAUST GAS TEMPERATURE (E.G.T.) RECOMMENDATIONS FOR STANDARD ENGINES

The proper use of E.G.T. for assisting the operator with fuel management and as a diagnostic tool is considered by Teledyne Continental Motors as acceptable and often times desirable. The following is prepared as an instructional aid, (when specific airframe manufacturers instructions are not available) to assure that when such equipment is installed, it is properly used. A.

Take-off and climb power settings are normally performed at full rich mixture to enhance cylinder cooling compensating for limited available cooling air flow. The exception to this rule is in those cases where fuel systems are not adequately compensated for altitude. Some leaning is then permissible but only to avoid engine roughness or power loss while still keeping the fuel flow within rich limits.

B.

For cruise power settings, leaning is recommended to obtain optimum aircraft range at powers of approximately 75% or less. Best Power can be defined as that mixture setting that results in maximum indicated air speed, and which produces E.G.T. values from 100 to 150 degrees F. rich of peak at a given M.P. and R.P.M. Additional gains can be realized with fuel management below best power from the standpoint of fuel economy and extended aircraft range. This is the leaning area of most interest to the manufacturer and operator. Exhaust Temperature Sensing Equipment

Various types of equipment are available today and differ somewhat in their characteristics. The most significant difference appears to be whether they are sensing temperature in the exhaust system at one location (single point) or at several locations (multiple point). When specific installation instructions are not available from the airframe manufacturer, install E.G.T. systems in conformance with the following recommendations: A.

Single Point E.G.T. This unit is primarily useful for fuel management only and the location of the sensor in the exhaust system is of importance relative to recommended operational values of E.G.T. In general, the probe should be located in the exhaust of the leanest cylinder and approximately three inches from the cylinder exhaust flange.

(continued)  TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

10 August 1989

Page 2

M89-18

If the unit is located in the exhaust system sensing multiple cylinders, operation further from peak is required to avoid any one cylinder running too lean. This factor is of importance only on naturally aspirated engines (especially those with carburetor fuel systems). If more specific instructions on this point are not available from the aircraft owners manual, a further enrichment of 25 degrees F. for a probe sensing multiple cylinders over a probe installed in the leanest cylinder is advisable. For carburetor equipped engines, the exhaust gas temperature probe should be located in the exhaust stack of the leanest cylinder as determined with maximum cruise power at an altitude of 5000 feet or above. This must be established in the particular airframe installation. B.

Multiple Point E.G.T. This equipment has the advantage of performing engine diagnostic functions as well as being as asset in fuel management. It is often referred to as an engine analyzer. 1. For fuel management, a reference position should be established and used for adjustments of fuel at cruise conditions. Do not pick the cylinder that indicates the hottest E.G.T. at a given fuel flow; rather, by leaning progressively pick the reference cylinder as that one which reaches peak E.G.T. at the greatest fuel flow. 2. Cylinder malfunction can best be detected by an indication of a significant change in the normal temperature pattern between cylinders. Guidelines for Fuel Management Using E.G.T.

In specific installations where aircraft manufacturers have provided specific instructions, those instructions should be followed. A.

Take-off and Climb Power Settings. On normally aspirated engines, use full rich mixture. Lean only to avoid engine roughness or noticeable power loss, at elevated fields. Remember that a turbocharged engine is an altitude compensated engine, and can achieve full sea level power up to a very high critical altitude. Therefore, the mixture must be full rich at full throttle up to critical altitude.

B.

Maximum Cruise. (Approximately 75% Power). For economy of fuel and extended range, do not lean the mixture below 50 degress F. rich of peak. Note: All turbocharged engines are limited to 1650 degrees F. or 1750 degrees F. maximum Turbine Inlet Temperature (T.I.T.) Peak T.I.T. operation is allowed for 60 seconds to determine peak T.I.T.

C.

Economy Cruise. (Approximately 65% Power or Lower). Lean out to peak E.G.T. is approved at these low power settings as the value of peak E.G.T. is below that which is allowed at the corresponding propeller load maximum cruise power point at 50 degrees F. rich of peak E.G.T.

(continued)

10 August 1989

Page 3

M89-18

Remember, use of exhaust gas temperature indicators to monitor fuel mixture settings is recommended only at maximum cruise power settings and below. Mixture settings must be reestablished for any change in altitude or power settings. NOTE:

If doubts arise as to correct operation of engine, an operator's manual for every model engine is available from TCM Publications Department, P.O. Box 90, Mobile, Alabama 36601 or call (205) 438-3411, Ext. 298.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-19 Technical Portions Are FAA Approved

18 September 1989 TO: SUBJECT: MODELS AFFECTED: COMPLIANCE:

Beech Baron Owners RE-DESIGN OF LOWER THROTTLE BODY BRACKET IO520C, CB and IO550C At Owners Discretion Or At Overhaul

It has come to the attention of TCM that the upper throttle body support bracket P/N 631832, has prematurely broken in some installations. In an effort to alleviate this problem the lower throttle support bracket has been re-designed to provide positive support. This change has been incorporated on new IO-550-C engines beginning with Serial Number 676411 and on all re-manufactured and overhauled engines built after July 1, 1989. To accomplish this change remove the existing lower support bracket and related hardware: P/N P/N P/N

631840 631836 631837

Bracket Bushing Sleeve

Retain nuts and washers for installation of new support bracket: P/N P/N

652314 649290

Bracket Spacer

NOTE...See illustration for proper installation. The parts necessary to accomplish this change may be obtained through your TCM distributor.

(continued)

 TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

18 September 1989

Page 2

M89-19

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-23 Technical Portions Are FAA Approved

25 September 1989 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Continental Aircraft Engines

SUBJECT:

TSIO520CE LOWER THROTTLE BODY SUPPORT BRACKET AND LINKAGE

MODELS AFFECTED: COMPLIANCE:

TSIO520CE At Next 100 Hour Inspection

It has come to our attention through service tests conducted at Cessna Aircraft Corporation on the TSIO520CE engine that premature wear of the pin joints of the throttle and controller linkage has occurred. These pin joints should be inspected very carefully for wear and any necessary repairs be made. In order to alleviate this premature wear, remove and discard the lower throttle body support bracket, P/N 632750. See illustration on page 2. Removal of this support bracket will reduce the vibration levels exerted on the controller and throttle linkage, and will in no way be detrimental to the operation of your engine. NOTE...Lubrication of the linkage and controller cam must be accomplished at 100 hour inspections using clean 50 weight engine oil.

(continued)  TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

25 September 1989

Indicates areas to be lubricated.

Page 2

M89-23

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-5 Supersedes M79-11 and M87-10 Technical Portions Are FAA Approved

9 February 1989

SUBJECT: MODELS AFFECTED:

ALTERNATOR AND DRIVE COUPLING INSTALLATION IO/TSIO520, IO550, AND GTSIO520 Engines With Gear Driven Alternators

The gear driven alternators, which are not manufactured by TCM, used on subject engines are equipped with a drive coupling which has a spring assembly to help absorb torsional vibrations. This spring is wound in the opposite direction for the geared engines as compared to the direct drive engine. Coupling P/N 640933 is used on the geared engine and P/N 640934 is used on direct drive engines. Elastomer coupling P/N 646655 can be used as an option for 640933 or 640934. The gear driven TCM alternators P/N 642056 and 642055, and subsequent part numbers used on some of the affected engine models are equipped with a bi-directional drive coupling P/N 646655 which has an elastomer section to help absorb torsional vibrations and provide a "shear" section. The proper installation of the coupling is important and special attention should be given to the following items. Remove shipping spacer and washer from the alternator shaft and discard, if installed on TCM alternator. Follow vendor's instructions on alternators other than TCM. WARNING...Installation of the drive coupling assembly on TCM alternators with the shipping washer in place will cause interference with the face gear on the crankshaft and will result in damage to the engine and alternator. Install Woodruff key, coupling assembly and washer. The washer is a special thrust washer and must be installed with the bearing surface (copper color) toward the alternator. Install nut and tighten to 300 in. lbs. torque. If slots of nut do not align with the cotter pin hold in alternator shaft, the nut may be tightened further but not to exceed 450 in. lbs. Do not back off nut to align holes. alternator is installed in engine.

Install cotter pin as shown to insure clearance when

The elastomer coupling can be reused if a torque slippage check is completed. The torque required to slip the coupling elastomer when new must be 180 in. lbs. min. measured after 45 degrees of revolution at a rate of 1 to 2 degrees per second. Slippage must occur at O.D. of elastomer with no apparent damage to the elastomer for coupling in service more than 25 hours the slippage torque must not drop below 140 lbs.

(continued)

 TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

9 February 1989

Page 2

M89-5

Insure that the alternator slips into the crankcase without binding and that the mounting flange is properly seated against the crankcase. Do not force the alternator into position as damage to the alternator and drive gears could result. If there is stud interference with the mounting lug holes while mounting the subject alternators, do not force the alternator over the studs. Doing so could precipitate mount lug failure due to the resulting pre-load. If interference exists, it is permissible to enlarge the mount lug stud holes by drilling or reaming (as necessary) up to a maximum diameter of .387. Standard hole size is .337-.347. Care must be taken during installation to assure that the alternator pilot enters the crankcase pilot bore squarely. Forcing entry with the attaching nuts may pre-stress the lugs to cause cracking and failure. Install alternator gasket and alternator onto the engine. With the alternator pilot properly engaged in the pilot bore, run the attaching nuts up to the lug contact surfaces evenly and snug. Torque the nuts to 150-180 in. lbs. in diagonally opposite pairs.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE M89-6 Supersedes M88-6

service bulletin

Technical Portions Are FAA Approved

10 March 1989

SUBJECT: MODELS AFFECTED: COMPLIANCE:

COMPRESSOR BELT SHEAVE ALIGNMENT AND BELT TENSIONING

IO-520-BA, BB; TSIO-520-L, LB, WB, UB, BE; IO-550-B When a replacement starter drive assembly, idler sheave or compressor is installed or when premature belt replacement is experienced.

Premature belt replacement on the above engines can usually be attributed to improper alignment of the sheaves and/or improper belt tensioning. The problem of improper alignment and/or improper belt tensioning can be corrected per the following instructions: 1.

Place the alignment bar (Borroughs Tool Number 8082) around the driver sheave causing the extended end to overlay the upper portion of the compressor outer sheave. When the alignment is correct, the extended end will fall within 0.020 of the center of the bottom of the sheave groove. If the alignment bar does not fall within 0.020 of the center of the bottom of the sheave groove, remove the driver sheave and place as many (up to the maximum of 5) 0.020 inch shims, P/N 646064-20, on the starter shaft as are required to achieve the correct alignment between the driver sheave and compressor sheave. Remove the alignment bar. Lubricate the threads of the 12 point self-locking nut with clean 50 weight engine oil and torque to 450-500 inch pounds and recheck sheave alignment.

CAUTION...Prevent engine from turning during torquing. NOTE 1:

Borroughs Tool 8082 should be checked for flatness prior to each use. This can be done by laying it on a surface table or similar flat surface.

NOTE 2:

If the driver sheave retaining nut is anything other than a 12 point self-locking nut P/N 649924 it should be replaced and torqued per Paragraph 1.

2.

Place the alignment bar around the idler sheave causing the extended end to overlay the lower portion of the compressor outer sheave. When the aligment is correct the extended end of the alignment bar will fall within 0.020 inch of the center of the bottom of the sheave groove. If the alignment bar does not fall within 0.020 inch of the center of the bottom of the sheave groove, remove the idler sheave and place as many (up to maximum of 5) 0.020 shims, P/N 643956-20, between the idler spacer and the bearing as are required to achieve the correct alignment between the idler sheave and compressor sheave. Remove the alignment bar. Tighten the screw to a torque value of 800 to 850 inch pounds and recheck the sheave alignment. (continued)

 TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

10 March 1989

Page 2

M89-6

3.

BELT TENSIONING:

A.

Loosen the jam nut on the adjusting bolt and the idler pulley slide nut. The idler pulley slide nut should be loosened only enough to allow the slide to move freely. The adjusting bolt should be turned out far enough to allow installation of the belt.

B.

Install the belt.

C.

Slide the idler pulley snugly against the belt and tighten the adjusting bolt finger tight into its socket. At this stage, the idler pulley should be rotatable by hand under the belt.

D.

Tighten the adjusting bolt two full turns. Secure the adjusting bolt jam nut (275-325 inch pounds) and the idler pulley slide nut (300-350 inch pounds).

E.

Confirm that the belt tension is 50-70 lbs by one of the following methods:

1.

Use a direct reading belt tension gage such as Burroughs tool No. BT-33-73F.

2.

Measure belt deflection under a 5 lb load at the center of the longest belt span, correct deflection is .3 - .4 in.

F.

If belt tension is not within the above tolerance, loosen the adjusting screw jam nut and the idler pulley slide nut and readjust the tension, one full turn of the adjusting screw results in about a 10 pound change in belt tension. W A R N I N G: DO NOT OVER TIGHTEN BELT

After approximately five (5) hours of operation, recheck belt tension, and adjust as required to maintain 50-70 pounds belt tension.

(continued)

10 March 1989

Page 3

M89-6

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-7R1 Supersedes M89-7 Technical Portions Are FAA Approved

4 August 1989

SUBJECT: MODELS AFFECTED:

ENGINE OPERATION AFTER CYLINDER REPLACEMENT AND/OR MAJOR OVERHAUL All Models (Steel, Nitrided or Chrome Cylinders)

Proper operation of the engine following cylinder replacement or major overhaul is extremely important. The following procedures should be followed to insure that adequate lubrication is being provided to newly installed components and that the piston ring seating will occur as soon as possible. I.

Operation After Major Overhaul Utilizing an Engine Test Cell A.

Servicing and Pre-starting Procedures 1.

Service the lubricating system with mineral oil of the appropriate grade depending on ambient temperature.

NOTE...Corrosion preventive mineral oil MIL-C-6529 Type II can be used but must not be used after the first 25 hours, or six months, whichever occurs first as this oil can cause coking with extended use.

B.

2.

Rotate the propeller by hand through several cycles with the spark plugs removed.

3.

Pre-oil the lubrication system using an external pre-oiling pressure system.

4.

Install the spark plugs and ignition harness.

Test Cell Operational Procedures 1.

II.

Consult the applicable TCM Overhaul Manual recommended test cell operational procedures listed.

and

follow

the

Operation After Major Overhaul Utilizing The Aircraft in Lieu of an Engine Test Cell A.

The aircraft can be considered a suitable test stand for running-in overhauled engines contingent on the following conditions: 1.

Install engine cowling.

(continued)

 TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

4 August 1989

Page 2

2.

M89-7R1

Each cylinder should be equipped with a temperature sensing device to monitor the head temperature. If the aircraft cylinder head temperature gauge monitors one cylinder, the following precaution must be adhered to: During ground runs do not permit monitored head temperatures to exceed 400 degrees f or oil temperature to exceed 200 degrees f.

B. III.

3.

The flight propeller may be used contingent on careful observation of cylinder temperatures. Head the aircraft into the wind for this test.

4.

Calibration of the aircraft engine instruments must be performed.

Prepare and test the engine per the procedures outlined in Paragraph I above.

Engine Operation After Cylinder(s) Overhaul or Installation of New Cylinder(s) A.

Engine Starting and Ground Operation 1.

Service the engine with mineral oil of the appropriate grade depending on ambient temperature.

NOTE...Corrosion preventive mineral oil MIL-C-6529 can be used but must not be used after the first 25 hours, or six months, whichever occurs first as this oil can cause coking with extended use. 2.

Assure that all engine and cylinder bafflings is properly installed and in good condition.

3.

Cowl the engine. Start the engine and assure that oil pressure rises to within the specified limits within 30 seconds.

4.

Operate the engine at 750 RPM for one minute, gradually increasing toward 1000 RPM in three minutes. Check the magneto circuit for grounding prior to a normal shut-down. Allow the engine to cool adequately and then make a visual inspection for any irregularities.

(continued)

4 August 1989

Page 3 5.

B.

M89-7R1

Start the engine again and operate it at 750 RPM gradually increasing to 1500 RPM over a period of four minutes. If the engine is equipped with a controllable pitch propeller, cycle the propeller allowing only a 100 PRM drop. Return to the idle range and make adjustments to the idle mixture and RPM as required on carburetor engines and to the low unmetered fuel pressure, idle RPM and mixture on fuel injected engines. Position the throttle to 1200 RPM to smooth the engine. Then do an idle mixture check. Refer to the appropriate service information for these fuel system adjustments. Run engine up to full power for a period not to exceed 10 seconds. Visually inspect and correct any discrepancies. Check the oil quantity. Re-cowl the engine in preparation for test flight.

Test Flight 1.

Ambient air and engine operation temperatures are of major concern during this test flight. Do a normal pre-flight run-up in accordance with the aircraft flight manual. Conduct a normal take-off with full power and monitor the fuel flow, RPM, oil pressure, cylinder head temperatures and oil temperatures. Reduce to climb power in accordance with the flight manual and maintain a shallow climb attitude to gain optimum airspeed and cooling. Rich mixture for all operations except lean for field elevation where applicable and lean to maintain smoothness during climb in accordance with airframe manufacturer's operating instructions.

2.

Level flight cruise should be at 75% power with best power or richer mixture for the first hour of operation. The second hour power settings should alternate between 65% and 75% power with the appropriate best power mixture settings. Engine controls or aircraft attitude should be adjusted as required to maintain engine instrumentation within specifications.

3.

The descent should be made at low cruise power settings, with careful monitoring of engine pressures and temperatures. Avoid long descents with cruise RPM and manifold pressure below 18" hg.; if necessary decrease the RPM sufficiently to maintain manifold pressure.

4.

Any discrepancies detected during test flight or any final adjustments necessary should now be made. The engine can be operated in normal service in accordance with the aircraft flight manual.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M89-9 Technical Portions Are FAA Approved

21 April 1989 SUBJECT: MODELS AFFECTED: COMPLIANCE:

EXCESSIVE CRANKCASE PRESSURES All Information Only

The following trouble shooting test is recommended when excessive crankcase pressures are suspected. For some time we have been recommending the use of an airspeed indicator as a substitute for a water manometer. The indicator can be plumbed into a field modified oil cap, dipstick housing or timing plug, depending on engine model, to determine excessive crankcase pressure. The engine with timing plugs can be modified or use P/N 630415 plug which is already drilled for attachment of the fitting for the airspeed indicator. On engines that incorporate a separate dip stick tube, the rubber hose to the airspeed indicator can be connected directly to this tube and secured with a clamp. By the use of the following table it will be possible to obtain actual water pressure (in H20) when checking a suspect engine. Run engine on the ground at full power to check for excessive pressure. If the pressures are excessive, then check the system with crankcase breather system disconnected from the engine vent standpipe. If the pressure then drops appreciably the breather system should be checked for possible blockage caused by, but not limited to, the air oil separator, collapsed lines, sludge build up, wet vacuum pump, etc. After disconnecting the breather system if the pressure is still high, the cylinders should be checked for blow-by. If the aircraft has an air oil separator installed in the breather system it will cause a higher airspeed reading when connected because of the back pressure. When the ground run has been finished and no excessive pressures are found the breather system should be reinstalled. NOTE:

Excessive crankcase pressure in flight can be induced by ram air entering through an improper fitting oil cap seal and/or defective crankshaft nose seal. If the problem occurs on turbocharged engines only at higher altitudes, then it is possible that the turbocharger is suspect.

(continued)

 TELEDYNE INDUSTRIES, INC. 1989

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

21 April 1989

M89-9

Page 2

AIRSPEED VERSUS WATER PRESSURE (INCHES H20)

40MPH= 44MPH=

.79 1.00

H20 H20

LIMITS FOR A-65, C-75, C-85, C-90, 0200, C-145, 0300, GO300, IO346

44MPH - Maximum limit on ground 50MPH= 60MPH= 70mph= 80MPH= 90MPH=

1.23 1.77 2.42 3.16 4.00

H20 H20 H20 H20 H20

LIMITS FOR IO360, TSIO360, 0470, IO470, TSIO470, IO520, TSIO520, GTSIO520, 6-285, IO550

90MPH - Maximum limit on ground 100MPH= 120MPH= 140MPH= 150MPH=

4.94 7.131 9.729 11.18

Reference:

1 PSI=2" Hg. 1"Hg=13.6" H20

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY

M90-10

service bulletin 11 April 1990 SUBJECT: MODELS AFFECTED: COMPLIANCE:

Standby Vacuum Pump Oil Leak Check/Inspection All TSIO520BE Engines Installed in Piper Malibu PA46-310P Aircraft Prior to Further Flight and After Every Ten Hours of Operation Thereafter

An oil leak between the standby vacuum pump adapter plates, manufactured by Parker-Hannifin Corporation, Airborne Division, and the engine accessory drive pad on the TSIO520BE engine has been confirmed to have been the cause of numerous incidents of loss of engine oil. Recent inspections of over one hundred (100) installations indicate that oil leaks have occurred from the standby vacuum pump adapter plate joint on at least forty-seven (47) of these installations. Because of the potential that such an oil leak will develop into a serious loss of engine oil, the following action is required on the above referenced engines prior to further flight and every ten hours thereafter. 1.

Remove upper engine cowl. Inspect underside of upper cowl for any oil deposits, especially that area of the cowl immediately above the standby vacuum pump.

2.

Using a bright light, visually inspect the back right side of the engine accessory case in the area immediately adjacent to and below the standby vacuum pump, noting any and all traces of oil. Use a mirror to inspect all areas not otherwise directly visible.

3.

Inspect all components in the vicinity of the standby vacuum pump in a similar manner, noting any evidence of oil deposits.

4.

With a dry clean rag wipe the bottom of the standby vacuum pump itself in the area of the gasket between the adapter plate and the accessory drive pad noting any and all oil deposits.

5.

If oil deposits are revealed in or around the standby vacuum pump, on the rear of the engine accessory case or any component in the vicinity of the standby vacuum pump, immediately contact Teledyne Continental Motors at (205) 4383411, Ext. 305.

WARNING...UNDER NO CIRCUMSTANCES SHOULD THE AIRCRAFT BE FLOWN IF OIL IS FOUND IN THE AREA OF THE STANDBY VACUUM PUMP. (continued)

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

11 April 1990

Page 2

M90-10

6.

If no oil deposits are revealed by the above inspection, reinstall the engine cowl.

7.

Make appropriate logbook entry of compliance with this service bulletin.

NOTE...The above inspection procedures are supplemental to and not intended to replace normal preflight inspections. If any evidence of an oil leak or abnormal oil consumption is noted during preflight procedures, the inspection required by this Service Bulletin should be conducted prior to further flight.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-13 Technical Portions Are FAA Approved

16 July 1990 TO: SUBJECT: COMPLIANCE:

Aircraft Manufacturers, Distributors, Dealers, F.B.O.’s, Overhaul Facilities, Owners and Operators of Aircraft Engines EXHAUST VALVE STEM CORROSION/EROSION When performing cylinder/exhaust system maintenance or repair

TCM cylinders are equipped with solid stem exhaust valves made of an exotic alloy, Nimonic 80A. Service history of these valves has been excellent and unparalleled in the industry. TCM Service Bulletin M87-11 recommends 100% replacement at overhaul due to stem wear and/or stem to head corrosion/erosion, or pitting. TCM has become aware that occasionally this condition has progressed at the time of overhaul to the extreme example shown in Figure 2, which undetected could lead to valve failure.

Figure 1. Normal Wear

Figure 2. Excessive Corrosion/Erosion

(Continued)  TELEDYNE INDUSTRIES, INC. 1990 Member of GAMA

General Aviation Manufacturer’s Association

TELEDYNE CONTINENTAL MOTORS

Aircraft Products PO Box 90 Mobile Alabama 36601

16 July 1990

Page 2

M90-13

Laboratory tests conducted by the valve manufacturer have shown the condition is caused by chemicals that exist in the exhaust gases while the valves are at operating temperature. The source of the chemicals is a product of combustion of the fuels and oils being used; however, we have not established any correlation between the valve environment of an operating engine and the stem corrosion that resulted in laboratory tests.

It is strongly recommended, therefore, that at any time cylinder/exhaust system maintenance is performed prior to major overhaul, the exhaust valves be examined through the exhaust port for excessive corrosion/erosion or pitting in the head to stem area. If a stem diameter reduction of 10% or more is evident, replacement should be considered prior to major overhaul.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-14 Technical Portions Are FAA- Approved

7 August, 1990 SUBJECT: MODELS AFFECTED: COMPLIANCE:

CHAMPION AVIATION ACTION ALERT 360, 470, 520, 550 Model Engines See Attached Alert

Teledyne Continental Motors recommends compliance with the attached Aviation Action Alert 90-1.

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

July 2, 1990

90-1

SUBJECT:

OIL FILTER RECALL

AFFECTED PART NUMBERS:

CH48108 (TCM 649922) AND CH48109 (TCM 649923)

PART IDENTIFICATION:

All filters having Champion bow-tie logos printed in red (see below) and having no TCM part number on the exterior.

CHAMPION ®

AFFECTED DATE CODES:

+ Date codes 1AO and 2AO. + All date codes having “9” as the third digit. (See example below) + All previously recalled date codes: 1K8, 2K8, 3K8, 1M8, 3J8, 4K8, 2L8, 3M8, 4J8.

2B9A EXAMPLE THIRD DIGIT

ENGINE APPLICATIONS:

Various models of the following TCM engines: IO-520, TSIO-520, GTSIO-520, IO-550, O-470, TSIO-360, LTSIO-360, LTSIO-520, IO-360.

PROCEDURE:

All shelf stock should be returned to your distributor for credit or replacement. Filters currently installed on engines should be removed at next regular oil change interval, but no later than September 15, 1990. All affected filters must be replaced by the start of winter flying season, September 15, 1990.

REPLACEMENT:

All recalled parts should be replaced with product having date codes other than those listed above or with new CH48108 and CH48109 product. New product may be identified by the following: a two color (black & red) Champion logo (see below) and the appropriated TCM part number will be present on the exterior.

We do not anticipate any difficulty in supplying replacement product. We sincerely apologize for any inconvenience this recall may cause you.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-15 Technical Portions Are FAA- Approved

21 August, 1990 SUBJECT:

ROCKER ARM AND PUSHROD INSPECTION

MODELS AFFECTED: NEW ENGINES TSIO520BE

528487-528494, 528498, 528500, 528501

GTSIO520M 613027-613032 REBUILT ENGINES TSIO520BE

273562, 273565-273579, 273582-273585, 273593-273596, 273599, 273601, 273607, 273608, 273612, 273632

GTSIO520C

155555, 155556

GTSIO520D

219442, 219443

GTSIO520H

267116, 267128, 267129, 267131-267143, 267145, 267146

GTSIO520L

272194, 272195, 272197-272235, 272237, 272238, 272239, 272241

GTSIO520M 276068-276070, 276072, 276078-276102, 276104-276119 GTSIO520N COMPLIANCE: WARRANTY:

277020, 277022-277039

Within the next 100 hours or at annual inspection The action required to comply with this Service Bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

It has come to TCM's attention that rocker arms on the above referenced engines may have been improperly machined. This condition can cause unusual wear on the push rods. It is, therefore, required that an inspection of the rocker arms and push rods be performed per the guidelines of this bulletin. The inspection should be performed as follows: 1.

Remove the engine cowling, gain access to the valve cover and remove all 12.

2.

Inspect just below the rocker arm socket for any sign of a groove worn into the push rod as depicted in Figure 1. (continued)

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

21 August 1990

Page 2

M90-15

3.

If a groove exists, remove and replace both the push rod and rocker arm. Use new tab washers (P/N 501868) under the hold down bolts. Torque rocker shaft hold down bolts to 190-210 in. lbs. If no groove exists, continue to Step #5.

4.

Check the clearance between the rocker foot and valve tip with the hydraulic lifter deflated. This should be .060" to .200".

5.

Replace the valve covers using new gaskets (P/N 632459), torque screws to 4555 in. lbs.

6.

Ground run and check rocker covers for oil leaks.

7.

Return aircraft to service and make logbook entry showing compliance of this bulletin.

FIGURE 1

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-16 Technical Portions Are FAA-Approved

22 August, 1990 TO: SUBJECT: MODELS AFFECTED: COMPLIANCE:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Continental Aircraft Engines 7TH STUD IMPROVEMENT ON TCM CRANKCASES IO520, TSIO520, GTSIO520, IO550 At time of installation of 7th stud crankcases

TCM has incorporated into its engine crankcases an additional stud adjacent to each cylinder. This 7th stud improvement reduces stresses and increases crankcase durability. When installing the new 7th stud crankcase on any of the above referenced engines, it will be necessary to change and/or modify certain parts. The following is a listing of these kit and parts requirements. NOTE...If the crankcase being replaced already incorporates this 7th stud feature, the requirements of this bulletin will not be necessary. For:

IO520C, CB, M, MB TSIO520B, BB, E, EB, J, JB, K, KB, L, LB, N, NB, VB, WB Use Kit P/N 649406-1A1

For:

IO520BA, BB, N, NB IO550B TSIO520D, DB, UB Use Kit P/N 649406-3A1

For:

IO520A, D, E, F, J, K, L TSIO520C, G, H, M, P, R, T, AF, AE Use Kit: 652657A1 (For engines with Standard Oil Cooler) 652618A1 (For engines with Non-Congealing Oil Cooler)

NOTE...Kit part numbers 652657A1, 652618A1 contain oil cooler modification information. This modification will require detailed machining by an experienced machine shop. Should this modification prove unfeasible, it will then become necessary to replace the oil cooler. The following are replacement parts numbers:

For:

Existing Cooler P/N

Replacement Cooler P/N

626189

652671

639151

652660

639152

652759

639171

652661

All GTSIO520 Series Engines Use Kit P/N ALT01800

 TELEDYNE INDUSTRIES, INC. 1990

(continued)

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products Division

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

22 August 1990

M90-16

Page 2

NOTE...Slight modifications will be required on certain airframe supplied baffling components. Contact the manufacturer of the airframe in question to determine whether airframe modifications are required and to obtain further information and instructions regarding any such modification. In conjunction with these kits, the following engines will require dipstick replacement: ENGINE

DIPSTICK P/N

IO520BA, BB

652171-15

IO520C, CB, L/H

652171-18

IO520C, CB, R/H

652171-16

IO520M, MB, L/H

652171-19

IO520M, MB, R/H

652171-14

TSIO520B, BB, L/H

652171-17

TSIO520B, BB, R/H

652171-12

TSIO520D, DB

652171-15

TSIO520E, EB, L/H

652171-17

TSIO520E, EB, R/H

652171-12

TSIO520J, JB, L/H

652171-17

TSIO520J, JB, R/H

652171-12

TSIO520K, KB, L/H

652171-17

TSIO520K, KB, R/H

652171-12

TSIO520L, LB, L/H

652171-11

TSIO520L, LB, R/H

652171-16

TSIO520N1, NB1, L/H

652171-17

TSIO520N2, 4, 6, 8, NB2, 4, 6, 8

652171-12

TSIO520N5, NB5

652171-13

TSIO520VB, L/H

652171-13

TSIO520VB, R/H

652171-12

TSIO520WB, L/H

652171-11

TSIO520WB, R/H

652171-16

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-17 Supersedes M83-10R.1 and M77-14R.1 Technical Portions Are FAA Approved

23 August, 1990 TO: SUBJECT: MODELS AFFECTED: COMPLIANCE:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines CRANKCASE INSPECTION CRITERIA All At 100 hour inspection

Teledyne Continental Motors has incorporated Engineering and Manufacturing improvements into crankcases installed on many engine models. These new crankcases incorporate improved casting methods which reduce material porosity and increase thickness in certain areas to improve structural integrity. The changes should significantly reduce the rate of crack incidence in all areas. All new and factory rebuilt engines currently being produced have the crankcases identified below, or a higher number, installed at the time of assembly at no additional cost to the customer. Current prices for new and factory rebuilt engines can be obtained from your Teledyne Continental Motors distributors. It is strongly recommended that the crankcases be replaced at the time of major overhaul if they do not have the number identified in Table 1, or a higher number, cast into the case: Casting Number

Year Casting Production Released

O-200

All casting numbers acceptable

N/A

O300

530836/530837

1948

360

640432/640433

1973

470

All casting numbers acceptable

N/A

520 Sandcast

640960/640961

1974

*520 Permold

642000/642001

1977

GTSIO520

642080/642081

1977

Engine Model

Table 1 Refer to the current parts catalog for the correct P/N crankcase service assembly. *Direct drive 520 permold crankcases have the alternator pad on the right front of the crankcase. (continued)

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

23 August,1990

Page 2

M90-17

Critical (gray) and non-critical (dark gray) areas are illustrated in Figures 2,3,4,5,6 & 7. If a crack is observed in any of the non-critical (dark gray) areas less than two (2) inches in length, the crack should be scribe marked at its extremities and re-inspected for crack progression at the next 50 hours of operation, see Figure 1. If no crack progression is observed and no additional cracks are found, continue to re-inspect at regular intervals not to exceed 100 hours duration. If a crack is observed in any of the non-critical (dark gray) areas more than two (2) inches in length or if a previously observed crack has progressed to two (2) or more inches in length, repair or replace the crankcase or engine prior to further flight. If any crack is observed in a critical (gray) area, repair or replace the crankcase or engine prior to further flight. SUMMARY - Reasons for Crankcase Repair or Replacement A.

Any crack in the critical (gray) area.

B.

Any crack two (2) inches or more in length in the non-critical (dark gray) area.

C.

Any size crack that is leaking oil (not seeping).

D.

Major overhaul with crankcases having lower numbers than set forth in Table 1.

Teledyne Continental Motors has established that welding of crankcases is an acceptable repair process. The weld procedure must conform to approved FAA repair standards, and dimensional integrity of the crankcase must be maintained. Make an appropriate log book entry indicating compliance with this bulletin. Include engine total time in service, method of compliance (visual, Zyglo, dye penetrant, other) and date.

(continued)

23 August,1990

M90-17

Page 3

When replacing a crankcase not listed in Table 1 with the later improved crankcase it is necessary to order and install on certain engine models an EQ Kit which includes longer bolts, wider manifold valve bracket, 2 studs used at the starter adapter where necessary, and information required for installation. The EQ kits and corresponding engine models are listed in Table 2.

EQ Kit

Applicable Engine Model

EQ 6530

IO520B, BA TSIO520B, D, E, J, K, L, N

EQ 6531

IO520C, M

EQ 6533

*GTSIO520C, D, F, H

*P/N 641407 lifting eye must be ordered separately for the GTSIO520C model engine.

Table 2

Figure 1

(continued)

23 August,1990

Page 4

FIGURE 2 O-200 CASE

FIGURE 3 O-300 CASE (continued)

M90-17

23 August,1990

Page 5

FIGURE 4 360 CASE

FIGURE 5 DIRECT DRIVE SANDCAST 470 AND 520 CASE

(continued)

M90-17

23 August,1990

Page 6

FIGURE 6 DIRECT DRIVE PERMOLD 520 CASE

FIGURE 7 GEARED DRIVE 520 CASE

M90-17

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-19 Technical Portions Are FAA Approved

16 October 1990 SUBJECT: MODELS AFFECTED: COMPLIANCE:

FUEL INLET TEE TSIO-52O-BE At Next 100 Hour or Annual Inspection

Teledyne Continental Motors (TCM) has received reports of fractures occurring in the brass fuel inlet tee (P/N 627642) of the metering unit at the throttle body on the TSIO-520-BE model engine. These fractures are believed to have been caused by improper tightening procedures being utilized while attaching the fuel line and/or the fuel pressure gage to this tee. A fracture in this tee could cause fuel leakage and create the possibility of engine compartment fire. TCM is now incorporating a steel fuel inlet tee (P/N 634195) of its new and rebuilt engines in place of the brass tee. TCM recommends that the brass fuel inlet tee (P/N 627642) be replaced by the steel fuel inlet tee (P/N 634195) on all TSIO-520-BE engines at the time of the next 100 hour inspection or annual inspection, whichever occurs first. The fuel inlet tee must be supported with the proper wrench when removing and installing fuel lines. WARRANTY: The action required to comply with this service bulletin is covered by the Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any Teledyne Continental Distributor.

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-20 Technical Portions Are FAA Approved

12 December 1990 SUBJECT:

LEAR ROMEC CORPORATION, SERVICE BULLETIN NO. 101SB019

TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines

MODELS AFFECTED:

GTSIO520N

COMPLIANCE:

See Lear Romec Bulletin

WARRANTY:

See Lear Romec Bulletin

Teledyne Continental Motors recommends compliance with the attached Lear Romec Service Bulletin, No. 101SB019. Refer to appropriate Aircraft Manuals and Service Bulletins for removal and installation of fuel pumps.

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-4 Supersedes M89-20 Technical Portions Are FAA Approved

1 February 1990

TO: SUBJECT: MODELS AFFECTED:

All Owners and Operators Conversion of Rolls Royce Engines TSIO360D

Service Bulletin M89-20 issued September 18, 1989 has been made obsolete. Teledyne Continental Motors will not re-issue a data plate for conversion of TSIO360D Rolls Royce engines.

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-6 Technical Portions Are FAA Approved

26 February 1990 SUBJECT: MODELS AFFECTED: COMPLIANCE:

INSPECTION AND REPLACEMENT OF SCAVENGE PUMP GEARS P/N 635334 AND 639388 TSIO520B, BB, D, DB, R, RB, J, JB, K, KB, N, NB, UB, VB At TCM recommended overhaul time, discovery of metal contamination in the engine, or removal of the scavenge oil pump gears prior to major overhaul.

This service bulletin calls for the replacement of scavenge pump gears 635334 and 639388 which were installed in scavenge pumps at TCM prior to April of 1985. At that time these gears were superseded by p/n 649157 and 649159. These superseding gears are carburized in order to extend their service life. Scavenge pumps which contain the new gears and engines equipped with an air conditioner drive pulley on the starter adapter are excluded from the requirements of this service bulletin. Listed below are the part numbers and serial numbers of starter adapter/scavenge pump assemblies and engines which are excluded. All other affected models must have their scavenge pumps disassembled and the scavenge pump gears replaced with the 649157 and 649159 gears. Components and engines which are excluded from the requirements of this service bulletin: 1. Starter adapters with ink stamped part numbers 642085A4 and 642085A5. (These contain the new gears 649157 and 649159 and do not need to be disassembled.) 2. The following serial numbered engines. (These engines contain the new gears and do not need to be disassembled.) TSIO520B NEW

N/A

REB

N/A

TSIO520BB NEW

526027 - AND SUBSEQUENT

REB

236969 - AND SUBSEQUENT

TSIO520D-DB NEW D

N/A

REB D 180083 - AND SUBSEQUENT NEW DB

N/A

REB DB

242005 - AND SUBSEQUENT (continued)

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

26 February 1990

Page 2

M90-6

TSIO520E-EB NEW E

N/A

REB E

275045-275134, 275141-275156 - AND SUBSEQUENT

NEW EB

510818 - AND SUBSEQUENT

REB EB

271058, 271061-271130, 271135-271137 - AND SUBSEQUENT

TSIO520J-JB NEW J

N/A

REB J

218937-218942, 218944 - AND SUBSEQUENT

NEW JB

N/A

REB JB

237135 - AND SUBSEQUENT

TSIO520K-KB NEW K

N/A

REB K

224588 - AND SUBSEQUENT

NEW KB

531000

REB KB

245705 - AND SUBSEQUENT

TSIO520N-NB NEW N

N/A

REB N

228549 - AND SUBSEQUENT

NEW NB

521630 - AND SUBSEQUENT

REB NB

276619, 276626, 276629, 276630, 276634 - 273636, 276638 276770, 276772, 276773, 276777 - AND SUBSEQUENT

TSIO520U-UB NEW U

N/A

REB U

N/A

NEW UB

527114 - AND SUBSEQUENT

REB UB

248887-248889, 248893, 248895, 248898 - 248926, 278202, 278203 AND SUBSEQUENT

TSIO520VB NEW VB

529072 - AND SUBSEQUENT

REB VB

266975, 266898, 266990, 266991, 278008-278144, 278147 - 278201 278204 - 278241 - AND SUBSEQUENT

3. Starter adapters equipped with a pulley for an air conditioner compressor drive. (These contain a different set of scavenge pump gears which do not need replacement) (continued)

26 February 1990

Page 3

M90-6

If an affected model engine does not fall into one of the above categories, then the scavenge pump must be removed and the scavenge pump gears replaced with p/n 649157 and 649159. It may be that p/n 649157 and 649159 have been previously installed in the pump during an overhaul or other servicing. Gears removed from a pump may be inspected to determine if they are 649157 and 649159. Prior to inspection, the scavenge pump gears should be cleaned with an approved carbon cleaner and thoroughly rinsed with a mineral spirit solvent. 649157 and 649159 gears can be identified by a drill point on the end of one gear tooth as shown in figure 1. 1. Gears so identified may be reused in the scavenge pump after the visual and dimensional inspection outlined below. Some earlier 649157 and 649159 gears do not have the drill point marking but may be identified by means of a hardness test. The hardness test must be performed in a Rockwell tester with the test point in the same location as the drill point shown in figure 1. If the gears test above 56 Rc or 79 Ra, then the gears are 649157 and 649159. (Rockwell A scale testing is recommended in order to minimize the test indentation.) Gears intended for reuse should be visually inspected for uneven wear, pitting or excessive galling. A light amount of polishing is normal and acceptable. If the gears pass this visual inspection then they should be inspected to the dimensions specified in the Table of Limits and Magnaflux procedures found in the TSIO520 Permold Series Overhaul Manual X30574A. If the gears pass all of these test they may be reused. All other affected model scavenge pump gears must be replaced with serviceable 649157 and 649159 gears.

CAUTION...Do not abrasive blast gears. This may remove surface hardness which can cause excessive wear in service.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

M90-8 Supersedes M85-15 Rev. 1 Technical Portions Are FAA Approved

service bulletin 22 March 1990 SUBJECT: MODELS AFFECTED: COMPLIANCE: WARRANTY:

EXHAUST SYSTEM INSPECTION TSIO-520-BE new S/N 528003 thru 528195 (In The Piper Malibu Aircraft) Next Scheduled Maintenance The action required to comply with this service bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

At the next scheduled maintenance a complete inspection of the exhaust system is recommended. The following procedure is required: 1. Remove the engine cowling. 2. Loosen the 1-3-5 side exhaust risers to cylinder attachment nuts. 3. Remove the by-pass assembly to #1 cylinder tee assembly tie rod. 4. Remove the ducting and obstructions from the vicinity of the 90 degree bend on the bypass assembly on the 1-3-5 side in accordance with the Piper Malibu Maintenance Manual. 5. Separate the by-pass assembly from the tee assembly and slide the tube and shroud assembly out of the aft expansion connection by-pass tube. 6. Remove shroud covering the by-pass assembly and inspect the tube in its entirety for leaks, cracks or distortion. 7. Visually inspect the entire exhaust system for leaks, cracks or distortion. Pay particular attention to the tee assembly under the #1 cylinder in the bracket area. Repair or replace components as required. NOTE...Minor weld repairs in accordance to the practices and procedures of FAR Part 43.13-1A are acceptable. Weld per Spec. MIL-W-8611. Weld wire to be used is AMS5786 Hastalloy W. Before any weld repair is to be accomplished, it is extremely important that the crack and/or area to be repaired is thoroughly cleaned. It may be necessary to grind the cracked area out to attain a quality weld repair. The repair should be accomplished with the part secured in a fixture to hold the end points in place and then let the part cool in the fixture after welding.

(continued)

 TELEDYNE INDUSTRIES, INC. 1990 Member of GAMA General Aviation Manufacturer’s Association

TELEDYNE CONTINENTAL MOTORS

Aircraft Products

PO Box 90 Mobile Alabama 36601

22 March 1990

Page 2

M90-8

8. Assemble the by-pass assembly slip joint to the by-pass tube assembly. The total slip clearance of this connection must be .006 to .012 inches on the diameter. It may be necessary to clean the assembly with coarse valve lapping compound or expand the female section to obtain this clearance. 9. Reinstall all airframe components in accordance with the Piper Malibu Maintenance Manual. 10. Loosen the left by-pass to wastegate attachment bolts and loosely assemble components in their respective positions including the tie rods. Evenly torque all exhaust flange and wastegate attachments with particular attention given to alignment to prevent binding of components. Apply P/N 646943 Anti-Seize lubricant to all slip connections during assembly. 11. Prior to return to normal service, visually reinspect the system after test flight. 12. Make Engine Log Book notation indicating method of compliance.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M90-9 Supersedes M89-21 Technical Portions Are FAA Approved

20 April 1990 TO: SUBJECT:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Continental Aircraft Engines NEW TCM MAGNETO AND HARNESS APPLICATIONS

The following table lists part numbers of TCM Ignition Systems products which have been approved for the corresponding engine models. TCM part numbers are given in parentheses. NEW MAGNETO AND HARNESS APPLICATIONS MAGNETO P/N

HARNESS P/N

TCM ENGINE MODEL

MODEL S4LN-21, QTY. 2: 10-51360-37 (646968) |

10-720325-4 (652197)

0-200-A

MODEL S6LN-21, QTY. 2: 10-51365-39 (646964) |

10-720640-1 (652198)

0-300-C, D

MODEL S6RN-1225, QTY. 1 EACH: LEFT: 10-349350-4 (646958) RIGHT: 10-349350-5 (646957)

10-720095-108 (636951)

MODEL S6RN-1225, QTY. 1 EACH: LEFT: 10-349350-4 (646958) RIGHT: 10-349350-5 (646957)

10-726814-1 (652150)

TSIO-520-CE { 

MODEL S6LSC-25P, QTY. 1 EACH: LEFT: 10-500556-901 (652466) RIGHT: 10-500556-101 (652465) }

10-726714-2 (652464)

TSIO-520-BE { ~

MODEL S6LN-1225 QTY. 1 EACH: LEFT: 10-349350-6 (652233-1) RIGHT: 10-349350-7 (652233-2)

10-720095-108 (636951)

LTSIO-520-AE { 

0-470-R, S, U IO-470-F, J, K, L, N, S IO-520-A, BA, BB, C, CB, D, F, J, L IO-550-B,C TSIO-520-AE, AF, C, D, DB, G, H, M, P, R, T, UB { 

{ This bulletin provides authority for noted conversions until revision of type certification data sheet No. E8CE-21 can be revised to clearly show magneto eligibility. | Requires qty. 2 P/N 10-52305 terminal kit and qty. 8 P/N 10-35937-12 screw. } Requires qty. 2 P/N 10-357520 gasket and qty. 8 P/N 10-35937-12 screw. ~ Upon installation with TCM magneto, use pointed tool to remove screen and cotton filter in B & D tachometer sensor P/N 0402-102 or P/N 0406-003.  When initially changing from Slick pressurized magnetos to TCM Ignition System magnetos (non-pressurized) remove hoses, filter and clamps. Plug or cap pressurization source located in the throttle body with a MS20913 pipe thread plug or equivalent. If more information is needed refer to airframe manufacturing service information.

 TELEDYNE INDUSTRIES, INC. 1990

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M91-10 Rev. 1 Supersedes M91-10 Technical Portions Are FAA Approved

27 November 1991 SUBJECT: MODELS AFFECTED:

INSPECTION FOR CORRECT OIL PICK-UP TUBE INSTALLATION TCM REBUILT ENGINES: O470-L, S/N 069735-R through 069738-R; O470-R, S/N 321195-R through 321198-R, 321200-R through 321203-R, 321205-R; O470-S, S/N 269190-R through S/N 269194-R; O470-U, S/N 273495-R, 273496-R, 286506-R, 286507-R, 286514-R, 286518-R, 286519-R, 286522-R, 286524-R, 286526-R, 286527-R, 286530-R, 286531-R, 286532-R, 286534-R through 286537-R; IO470-E, S/N 088739-R; IO470-F, S/N 089833-R; IO470-L, S/N 272812-R through 272821-R; IO470-S, S/N 109923-R; IO470-V, S/N 171034-R through 171037-R; IO520-A, S/N 112640-R; IO520-D, S/N 282642-R, 282644-R, through 282646, 282649-R through 282660-R, 282663-R, 282665-R, 282666-R, 282668-R through 282674, 282677-R, 282679-R; IO520-E, S/N 215763-R, 215764-R, 215767-R; IO520-F, S/N 286078-R through 286081-R, 286084-R through 286090-R, 286092-R through 286099-R, 286101-R through 286104-R, 286106-R through 286110-R, 286112-R through 286115-R, 286120-R through 286124-R, 286126-R through 286128-R, 286133-R, 286136-R, 286138-R; IO520-K, S/N 224069-R; TSIO520-C, S/N 178355-R, 178356-R, TSIO520-G, TSIO520-M, S/N 283078-R, 283081-R through 283087;

S/N

216039-R;

IO550-D, S/N 284008-R, 284009-R; IO550-E, S/N 283271-R, 283272-R; IO550-F, S/N 284511-R, 284512-R, 284514-R, 284515-R, 284517-R, 284518-R; TCM OVERHAUL ENGINES: O470-L, S/N 069478-H; O470-R, S/N 226637H, 238135-H, 238357-H, 451691-H; O470-U, S/N 249979-H, 467302-H, 467315-H; IO470-V, S/N 170747-H, 170762-H; IO520-A, S/N 110159-H; IO520-D, S/N 175072-H, 175165-H, 175398-H, 175529-H, 552121-H, 566511-H; TSIO520-T, S/N 515042-H, 515355-H, 515357-H

COMPLIANCE:

WITHIN THE NEXT 25 HOURS OF OPERATION (continued)

 TELEDYNE INDUSTRIES, INC. 1991

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

27 November 1991

Page 2

M91-10

Some Teledyne Continental Motors rebuilt and overhaul engines of the affected models may have been assembled using an improper oil pick-up tube, P/N 637813. The oil pick-up screen of this tube will make contact with the oil sump and make an imprint on the bottom surface. If your engine is affected, the following steps should be taken to ascertain if oil pick-up tube, P/N 637813 was installed: 1.

Inspect the oil sump of your engine for an imprint of the oil pick-up tube screen, approximately 2" in diameter.

2.

Using a Snap-On PR28D, 2 lb. pull magnet or equivalent, at the oil pick-up tube screen location a strong pull will be evident if the oil screen is in contact with the oil sump. Only a very light pull will be evident if the proper oil pick-up tube was installed.

3.

Using a small rubber mallet tap on the sump, a hollow sound will be produced. If the oil pick-up tube screen is contacting the sump, a solid sound will be produced at that location. (See Fig.#1).

If steps #1, 2 or 3 give indications that the oil pick-up tube screen is contacting the oil sump, remove the oil sump and oil pick-up tube and replace with oil pick-up tube P/N 625207 and appropriate oil sump. If steps #1, 2 or 3 give no indication of oil screen contact with the oil sump, make a log book entry of compliance with this service bulletin and return aircraft to service. The action required to comply with this service bulletin is covered by the Gold Medallion Warranty, subject to its terms and conditions. Teledyne Continental Motors will allow one (1) hour at posted shop rate to perform this inspection. Warranty claims may be filed through any Teledyne Continental Motors Distributor.

27 November 1991

Page 3

FIGURE 1.

M91-10

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M91-12 Supersedes M89-16 Rev. 1 Technical Portions Are FAA Approved

11 December 1991 SUBJECT: MODELS AFFECTED:

NEW OIL GAUGE ROD HOUSING TSIO520CE New S/N

Rebuilt S/N COMPLIANCE:

530002 through 530100 530102 through 530122 530124 through 530127 530131 through 530140 530143 through 530151 268501 through 268506

When Cessna SEB91-14 is complied with (Removal of Air/Oil Separator).

On December 19, 1989, Teledyne Continental Motors issued Service Bulletin M89-16 Rev. 1 announcing a new oil gauge rod housing on the TSIO-520-CE engines. Since the release of this bulletin it has been determined that the Air/Oil Separator should be removed from these installations per Cessna SEB91-14. When the Air/Oil Separator is removed, the oil gauge rod housing will have to be replaced. Aircraft which have complied with SB M89-16 or M89-16 Rev. 1 only need the outer housing P/N 652016 replaced with housing P/N 631915 in accordance with steps 1 through 3 and 7 through 10 listed below. The installations which have not complied with SB M89-16 or M89-16 Rev. 1 can be accomplished in accordance with steps 1 through 10 listed below. Parts required:

1 ea. 631915 - oil gauge rod housing (outer) 1 ea. 631927 - oil gauge rod housing (inner) 1 ea. 631928 - hose 646941 - Loctite sealant (Loctite 271) 646944 - Loctite primer (Locquic Primer "T")

Tools required:

1/2 inch diameter x approximately 2 inch long bolt 5 inch and 8 inch length Vice-Grip type pliers .040 inch diameter safety wire Installation drift

1.

Allow sufficient time for engine oil to drain from engine to sump. Remove oil gauge rod. Note crankcase oil level. Oil level must be accurately recorded for reference after new parts are installed.

2.

After gaining access to the oil gauge rod housing, remove all securing clamps and drain lines. These parts should be retained for installation of the new oil gauge rod housing.

(continued)

 TELEDYNE INDUSTRIES, INC. 1991

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

11 December 1991 3.

Page 2

M91-12

Remove and discard the outer portion of the housing and rubber connecting hose. Retain oil gauge lock ring P/N 537299 and clamps for installation of new parts. NOTE...Care should be exercised to prevent foreign object contamination of the engine. This can be accomplished by putting heavy grease into the lower tube.

4.

Reference Figures 1 & 2. To remove the inner portion of the oil gauge rod housing, place the 1/2 inch bolt in the existing inner housing. Clamp the 5 inch size vice-grip type pliers onto the housing in the area where bolt was placed. It is recommended that the handle end of the pliers be placed in approximately the 8 o'clock position. Rotate the pliers/inner housing clockwise or counterclockwise to break loose the housing to crankcase Loctite sealant joint. Place a loop of safety wire around pliers/housing area and make the loop long enough to insert a rod or screwdriver. Rotate the pliers back and forth and pull on the safety wire at the same time to pull inner housing from engine crankcase. After pulling the housing out approximately 3 inches, it may be necessary to slightly bend the housing aft to clear the cylinder and baffle. Remove the 5 inch pliers and clamp on the 8 inch pliers from above in a straight/parallel direction with the housing. Continue to rotate, bend and pull on the housing until it is removed from the crankcase.

5.

To ensure a proper seal of the new housing thoroughly clean and apply Locquic primer "T" (P/N 646944) to crankcase and housing.

6.

Using installation drift fabricated as illustrated in Figure 3 install the inner portion of the oil gauge rod housing, P/N 631927, using Loctite 271, (P/N 646941), as a sealant. Care should be taken to ensure proper extension of the oil gauge rod housing. A reference mark of 1.25" made on inner housing P/N 631927 will aid in proper installation, as shown in Figure 4. Improper installation will result in inaccurate crankcase oil level readings. NOTE...Installation drift should be fabricated from aluminum rod stock. The angle of bend should be approximately the same as the outer housing.

7.

Install the new design outer housing, P/N 631915 into the inner housing, up to the bead on the outer housing. Secure using the new connecting hose (P/N 631928) and clamps retained from old installation.

8.

Secure new housing to engine. Install oil gauge lock ring P/N 537299 on new outer housing.

9.

Insert dip stick, insure oil level matches oil level noted prior to housing change. If a discrepancy is noted, adjust the outer housing to obtain the proper oil level readings.

10.

Make appropriate logbook entries and return aircraft to service.

(continued)

11 December 1991

Page 3

FIGURE 1 ACCESS TO INNER HOUSING

FIGURE 2 INNER HOUSING REMOVAL (continued)

M91-12

11 December 1991

Page 4

M91-12

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M91-4 Supersedes M85-8 Technical Portions Are FAA Approved

11 February 1991 SUBJECT: MODELS AFFECTED:

PISTON IDENTIFICATION AND PISTON RING APPLICATION BULLETIN

ALL INSTRUCTIONS

The objective of the Piston Identification and Piston Ring Application Bulletin is to simplify the task of correctly identifying pistons to enable the selection of the appropriate piston ring set for both steel, chrome and Cermicrome(TM). WARNING...Refer to SB M90-5R1, or subsequent revision as applicable for proper cylinder choke dimensions. HOW TO USE THE GUIDE 1. Select the engine model from the first column 2. Second column is the finished piston. 3. Third column is the casting or forging number cast into the piston. Do not utilize this casting number as the finished piston part number. Several finished pistons can be machined from one casting or forging. 4. Fourth column is the actual number of ring grooves in the piston. 5. Fifth column is the overall or total height of the piston. 6. Sixth column is the measurement from the top of the piston to the center line of the pin and plug hole. 7. Seventh column is piston ring set numbers for STEEL cylinders. (Caution...Do Not use in chrome cylinders). 8. Eighth column is individual piston ring part numbers, listed in order from top to bottom of piston in their order. This column is for steel cylinders. 9. Ninth column is piston ring set numbers for chrome and Cermicrome(TM) cylinders. 10. Tenth column is individual piston ring part numbers, listed in order from the top to bottom of piston in their order. This column is for chrome cylinders. 11. Sub-notes appearing after part numbers indicates a notation applicable to that individual part. 12. **Cast inserted. If it is not feasible to replace the forged pistons with cast inserted pistons as a complete engine set; it is mandatory that the cast inserted pistons be installed in opposing bays, e.g. 1,2; 3,4 etc. Cermichrome is a Registered Trademark of Engine Components, Inc.

(continued)

 TELEDYNE INDUSTRIES, INC. 1991

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

11 FEBRUARY 1991 PISTON ENGINE MODEL A65

A75

C15 C75 C85 C185 C90-16F O200A, B O300A, B C, D GO300A, C, D, E, F

IO346A

IO360, A, C, D, G, J, K

M91-4

Page 1 STEEL CYLINDER

CASTING OR FORGING NO. 4557

NO. OF RING GROOVES 3

OVERALL HEIGHT 2.984

HEIGHT CENTER OF PIN HOLE TO TOP 1.796

646295 Supersedes 40731

4557

3

2.984

1.796

640157A2P005

40577

4957

3

2.984

1.796

640157A2

646287 (Supersedes 40327)

4940

4

2.895 2.885

1.708 1.698

649632A1

646255 (Supersedes 530348)

530348

4

2.743 2.738

1.596 1.591

649632A1

646279 (Supersedes 626146)

530348

4

2.763 2.758

1.616 1.611

649632A1

4 (Top 2 Tapered)

3.350

1.752 1.748

649227

PISTON NUMBER 40731

646063**

SINGLE CYL. RING SETS 640157A2P005

633109 (Superseded by 646063)

628909

4 (Top 2 Tapered)

3.55

1.752 1.748

646625A4

648049** (Supersedes 642647 & 630687)

649388

4 (Top 2 Tapered)

3.24

1.5954 1.5904

649225

642619F 630687F

* Not SOLD SEPARATELY. ** CAST INSERTED. See item # 12, cover page.

RING ORDER TOP TO BOTTOM 1) 640157P005* 2) 640158P005* 3) 640159P005* 1) 640157P005* 2) 640158P005* 3) 640159P005* 1) 640157* 2) 640158* 3) 640159* 1) 649632 2) 638110 3) 638110 4) 638111 1) 649632 2) 638110 3) 638110 4) 638111 1) 649632 2) 638110 3) 638110 4) 638111 1) 648005 2) 648006 3) 648007 4) 648008 1) 648005 2) 648006 3) 632496 4) 648008 1) 648039 2) 648040 3) 648041 4) 648042

CHROME CYLINDER

SINGLE CYL. RING SETS N/A

RING ORDER TOP TO BOTTOM N/A

N/A

N/A

N/A

N/A

652978

652978

652978

649227CP

639744

649225 CP

1) 2) 3) 4) 1) 2) 3) 4) 1) 2) 3) 4) 1) 2) 3) 4) 1) 2) 3) 4) 1) 2) 3) 4)

638110 638110 638110 640298 638110 638110 638110 640298 638110 638110 638110 640298 648005 CP 648006 CP 648007 CP 648008 648005 CP 648006 CP 632496 648008 CP 648039 CP 648040 CP 648041 CP 648042

11 FEBRUARY 1991

M91-4

Page 2 PISTON

STEEL CYLINDER HEIGHT CENTER OF PIN HOLE TO TOP

CHROME CYLINDER

ENGINE MODEL

PISTON NUMBER

CASTING OR FORGING NO.

NO. OF RING GROOVES

OVERALL HEIGHT

IO360A, AB, C, CB, D, DB, G, GB, H, HB, J, JB,K, KB

626247 (Supersedes 642229)

642619F

4 (Top 2 Tapered)

3.24

1.5954 1.5904

649225

TSIO360 A,B,C,D,E,F, G,H

648048 (Supersedes 646743**, 633428, 642230)

646743

4 (Top 2 Tapered)

3.41

1.68

649225

1) 2) 3) 4)

648039 648040 648041 648042

649225 CP

1) 2) 3) 4)

648039 CP 648040 CP 648041 CP 648042

L/TSIO360 ALL MODELS EXCEPT LB

648048 (Supersedes 646743**, 642230)

646743

4 (Top 2 Tapered)

3.41

1.68

649225

648048 (Supersedes 646743**, 633428, 642230)

646743

4 (Top 2 Tapered)

3.41

1.68

649225

648039 648040 648041 648042 648039 648040 648041 648042

649225 CP

TSIO360 LB & MB

1) 2) 3) 4) 1) 2) 3) 4)

1) 2) 3) 4) 1) 2) 3) 4)

648039 CP 648040 CP 648041 CP 648042 648039 CP 648040 CP 648041 CP 648042

646710**/**** (Supersede by 646743)

646710

4

3.248

1.68

649225

649044** (Supersedes 534895)

649044

4

3.370

534895 (Superseded by 649044)

534895

3

3.370

1) 2) 3) 4) 1) 2) 3) 4) 1) 2) 3)

648039 648040 648041 648042 648009 648010 648011 648012 639567 639568 639768

1) 2) 3) 4) 1) 2) 3) 4) 1) 2) 3)

648039 CP 648040 CP 648041 CP 648042 648010 CP 648010 CP 648011 CP 648012 640299 640299 639768

4

3.370

1) 2) 3) 4)

648009 648010 648011 648012

1) 2) 3) 4)

648010 CP 648010 CP 648011 CP 648012

E-185-225 O470A, E, J, IO470J, K

0470-11 0470-7B

649044

649044

1.7709

1.7729 1.7689

1.7709

SINGLE CYL. RING SETS

649226

639567A9

649226

** CAST INSERTED. See item #12, cover page. *** WHEN REPLACING 646455 WITH 646743 PISTON, 6492285P005 RING SET MUST BE USED. **** WHEN THE 646282 CYLINDER IS USED, THE 639570A7P005 RING SET IS USED WITH THE 646743 PISTON.

RING ORDER TOP TO BOTTOM 1) 648039 2) 648040 3) 648041 4) 648042

SINGLE CYL. RING SETS 649225 CP

649225 CP

649225 CP

649226 CP

639723

649226 CP

RING ORDER TOP TO BOTTOM 1) 648039 CP 2) 648040 CP 3) 648041 CP 4) 648042

11 FEBRUARY 1991

M91-4

Page 3 PISTON

ENGINE MODEL O470-11 O470-7B

O470-4 –13/13A

O470K,L,R, S,-4,-13,-13A

PISTON NUMBER

CASTING OR FORGING NO

STEEL CYLINDER

NO. OF RING GROOVES

OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

SINGLE CYL. RING SETS

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

534895 (Superseded by 649044)

534895

3

3.340

1.792

639567A9

1) 2) 3)

639567 639567 639768

639723

1) 2) 3)

640299 640299 639768

531510 (Superseded by 534895)

531510

3

2.824 2.814

1.792 1.788

639567A9

1) 2) 3)

639567 639567 639768

639723

1) 2) 3)

640299 640299 639768

646263

632932

4

3.79

1.981 1.977

649226

1) 2) 3) 4)

648009 648010 648011 648012

649226

1) 2) 3) 4)

648009 CP 648010 CP 648011 CP 648012

535133 (Superseded by 646263 in engine sets)

535133

3

3.544 3.540

1.999 1.995

639567A9

1) 2) 3)

639567 639567 639768

639723

1) 2) 3)

640299 640299 639768

646263

632932

4

3.79

1.981 1.977

649226

1) 2) 3) 4)

648009 648010 648011 648012

649226

1) 2) 3) 4)

648009 CP 648010 CP 648011 CP 648012

3

3.552 3.542

2.004 2.000

639567A9

1) 2) 3)

639567 639567 639768

639723

1) 2) 3)

640299 640299 639768

Use: 649226 for steel barrels 649226 CP for chrome barrels. O470K,L

RING ORDER TOP TO BOTTOM

CHROME CYLINDER

539614 (Superseded by 646263)

539614

11 FEBRUARY 1991

M91-4

Page 4 PISTON

ENGINE MODEL O470K,L,R

PISTON NUMBER

CASTING OR FORGING NO

626992 (Superseded by 646263)

626992 632932

STEEL CYLINDER

NO. OF RING GROOVES 4

OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

3.52

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

1.981 1.977

639567A10

1) 2) 3) 4)

639567 639568 639768 648012

639734

1) 2) 3) 4)

640299 640299 639768 648012

1.981 1.977

639567A13

1) 2) 3) 4)

639567 639568 648011 648012

652433

1) 2) 3) 4)

640299 640299 639768 CP 648012

1.981 1.977

649226

1) 2) 3) 4)

648009 648010 648011 648012

649226 CP

1) 2) 3) 4)

648009CP { 648010CP { 648011CP 648012

649226

1) 2) 3) 4)

648009 648010 648011 648012

649226 CP

1) 2) 3) 4)

648009CP { 648010CP { 648011CP 648012

NOTE: Oil control groove is 5/32”. Top 2 ring grooves are rectangular. 632932 (Superseded by 646263)

4

3.79

NOTE: Oil control groove is 3/16”. Top 2 ring grooves are rectangular. O470K,L,R,S

640518 (Superseded by 646263)

632932

4

3.79

NOTE: Oil control groove is 3/16”. Top 2 ring grooves are semi-keystone O470B,G,M,P

648028

IO470C,G,P,R,T { Ring set may contain 648009 rings.

648028

4 (Top 2 Tapered)

3.6177

2.0157 2.0197

11 FEBRUARY 1991

M91-4

Page 5 PISTON

ENGINE MODEL LIO470A, O470G,M, IO470C

O470U IO470D,E,F,H,L,M, N,S,U,V

PISTON NUMBER

CASTING OR FORGING NO

STEEL CYLINDER

NO. OF RING GROOVES

539814 (Superseded BY 648028)

535133 537883

3 (Top 2 Tapered)

646772 Cast Insert (Superseded by 648028)

646772

4

537883 (Superseded by 539814)

535133 537883

648029**

OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

2.085 2.081

639566A1

1) 2) 3)

648010 648010 639768

639726

1) 2) 3)

648010CP { 648010CP { 639768

3.6177

2.0177

649226

1) 2) 3) 4)

648009 648010 648011 648012

653433

1) 2) 3) 4)

648010CP { 648010CP { 648011CP 648012

3

3.360 3.526

2.085 2.081

639567A9

1) 2) 3)

639567 639568 639768

639723

1) 2) 3)

640299 640299 639768

648029

4 (Top 2 Tapered)

3.823

2.146

649226

1) 2) 3) 4)

648009 648010 648011 648012

653433

1) 2) 3) 4)

648010CP { 648010CP { 648011CP 648012

646280 (Superseded by 648029)

646280 Cast Insert

4 (Top 2 Tapered)

3.823

2.146

649226

1) 2) 3) 4)

648009 648010 648011 648012

653433

1) 2) 3) 4)

648010CP { 648010CP { 648011CP 648012

631481 (Superseded by 648029)

631481F

4 (Top 2 Tapered)

3.93

2.136 2.132

649226

1) 2) 3) 4)

648009 648010 648011 648012

653433

1) 2) 3) 4)

648010CP { 648010CP { 648011CP 648012

4 (Top 2 Tapered)

3.682 3.678

2.137 2.133

639565A5

1) 2) 3) 4)

648009 648010 648011 648012

639729

1) 2) 3) 4)

648010CP { 648010CP { 639768 648012

3.360 3.526

NOTE: Oil Control Ring is 3/16 627738 (Superseded by 648029)

627738F

{ Ring set may contain 648009 rings. **CAST INSERTED. See item #12, cover page.

11 FEBRUARY 1991

M91-4

Page 6 PISTON

ENGINE MODEL TSIO470 B,C,D

IO520, ALL MODELS

TSIO520 ALL MODELS Except T, UB, VB,WB,BE,AE

PISTON NUMBER

CASTING OR FORGING NO

STEEL CYLINDER

NO. OF RING GROOVES

OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

631540

631481F

4

3.84

2.046 2.042

649226

1) 2) 3) 4)

648009 648010 648011 648012

649226 CP

1) 2) 3) 4)

648010CP { 648010CP { 648011 648012

629185 (Superseded BY 631540)

631481F

4 (Top 2 Tapered)

3.591 3.587

2.046 2.042

639565a5

1) 2) 3) 4)

648009 648010 639768 648012

639729

1) 2) 3) 4)

648010CP { 648010CP { 640301 648012

648045**

648045

4 (Top 2 Tapered)

3.520

1.918 1.922

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

648013** (Superseded BY 648045)

646072

4 (Top 2 Tapered)

3.519

1.919

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

631475 (Superseded BY 648045)

631892

4 (Top 2 Tapered)

3.88

2.086 2.082

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

646072 (Superseded BY 648045)

646072

4

3.519

1.919

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

648044**

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

632585 (Superseded BY 648044)

4 (Top 2 Tapered)

3.73

1.929 1.925

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

{ Ring set may contain 648009 rings. **CAST INSERTED. See item #12, cover page.

11 FEBRUARY 1991

M91-4

Page 7 PISTON

ENGINE MODEL TSIO520 ALL MODELS Except BE,AE

PISTON NUMBER

CASTING OR FORGING NO

L/TSIO520 AE

OVERALL HEIGHT

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

642761** Cast Insert (Superseded BY 648044)

642761

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

646303** (Superseded BY 648044)

642761

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

648033** (Superseded BY 648044) L/TSIO520 ALL MODELS Except AE

NO. OF RING GROOVES

STEEL CYLINDER HEIGHT CENTER OF PIN HOLE TO TOP

648044**

648044

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

648033** Cast Insert (Superseded BY 648044)

648033

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

643619** Cast Insert (Superseded BY 648044)

642761

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

648037**

648037

4 (Top 2 Tapered)

3.337

1.779 1.775

649227

1) 2) 3) 4)

648005 648006 648007 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

1.779 1.775

640625A6

1) 2) 3)

648005 648006 641303*

1) 2) 3)

648005CP 648006CP 636144

Used in engine sets, 630046 pin must be used. 646311** 5122-N 3 3.337 (Superseded by 648037 in engine sets 630046 pin must be used.) *648007 and 648007 CP rings cannot be used on 646311 and 643735 piston. **CAST INSERTED. See item #12, cover page.

11 FEBRUARY 1991

M91-4

Page 8 PISTON

ENGINE MODEL

PISTON NUMBER

CASTING OR FORGING NO

STEEL CYLINDER

NO. OF RING GROOVES

OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM 1) 2) 3)

648005CP 648006CP 636144

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

649227CP

1) 2) 3) 4)

648005CP 648006CP 648007CP 648008

L/TSIO520 AE

*643735** (Superseded by 648037 in engine sets

5122-N

3

3.337

1.779 1.775

640625A6

1) 2) 3)

648005 648006 641302*

IO550 B,C,D,E,F,L

648046**

648046

4 (Top 2 Tapered)

3.337

1.779 1.775

649227

1) 2) 3) 4)

648005 648006 648007 648008

646533** (Superseded by 648046)

646533

4 (Top 2 Tapered)

3.337

1.779 1.775

649227

1) 2) 3) 4)

648005 648006 648007 648008

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

GTSIO520 C,D,G,H CAUTION: TCM does note recommend oversize boring of cylinders beyond 0.005 on GTSIO520’s.

GTSIO520 F,K

648044**

648033** (Superseded by 648044)

NONE

4 (Top 2 Tapered)

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

632491 (Superseded by 648044)

632491F 631392

5 (Top 2 Tapered)

3.64

1.844 1.840

642602A3

1) 2) 3) 4) 5)

648005 648006 640627 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

648044**

648044

4 (Top 2 Tapered)

3.337

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

648033** NONE 4 3.437 Cast Insert (Top 2 Tapered) (Superseded by 648o44) *648007 and 648007 CP rings cannot be used on 646311 and 643735 pistons. **CAST INSERTED. See item #12, cover page.

11 FEBRUARY 1991

M91-4

Page 9 PISTON

ENGINE MODEL GTSIO520 F,K CAUTION: TCM does note recommend oversize boring of cylinders beyond 0.005 on GTSIO520’s. GTSIO520 C,D,FG,H,K

GTSIO520 C,D,FG,H,K,L,M

GTSIO520 All Models

PISTON NUMBER

CASTING OR FORGING NO

NO. OF RING GROOVES

STEEL CYLINDER OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

5 (Top 2 Tapered)

3.64

1.844 1.840

642602A3

1) 2) 3) 4) 5)

648005 648006 640627 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

641883 (Superseded by 648044)

4 (Top 2 Tapered)

3.64

1.844 1.840

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

648044**

4 (Top 2 Tapered)

3.377

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

635141 (Superseded by 648044)

635141

640945 (Superseded by 648044)

640945 632491F

4 (Top 2 Tapered)

3.64

1.844 1.840

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

641350 (Superseded by 648044)

641350

4 (Top 2 Tapered)

3.63

1.844 1.840

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

641782** Cast Insert (Superseded by 648044)

641782

4 (Top 2 Tapered)

3.64

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

4 (Top 2 Tapered)

3.377

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 648007 648008

TCM does not recommend chrome cylinder be used on GTSIO520.

648044**

**CAST INSERTED. See item #12, cover page.

11 FEBRUARY 1991

M91-4

Page 10 PISTON

ENGINE MODEL GTSIO520 All Models CAUTION: TCM does note recommend oversize boring of cylinders beyond 0.005 on GTSIO520’s.

PISTON NUMBER

CASTING OR FORGING NO

648033 (Superseded by 648044) 642761** Cast Insert (Superseded by 648044)

NO. OF RING GROOVES (Top 2 Tapered)

642761

646303 646303** Cast Insert (Superseded by 648044) **CAST INSERTED. See item #12, cover page.

(Top 2 Tapered)

(Top 2 Tapered)

STEEL CYLINDER OVERALL HEIGHT

HEIGHT CENTER OF PIN HOLE TO TOP

SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

CHROME CYLINDER SINGLE CYL. RING SETS

RING ORDER TOP TO BOTTOM

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 640627 648007

TCM does not recommend chrome cylinder be used on GTSIO520.

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 640627 648007

TCM does not recommend chrome cylinder be used on GTSIO520.

3.437

1.839 1.835

649227

1) 2) 3) 4)

648005 648006 640627 648007

TCM does not recommend chrome cylinder be used on GTSIO520.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M91-6 Supersedes M90-21 Technical Portions Are FAA Approved

20 March 1991 SUBJECT:

CYLINDER BARREL INSPECTION

MODELS AFFECTED:

IO520, TSIO520, GTSIO520, IO550

COMPLIANCE:

Within the next 35 hours and then at intervals not exceeding 35 hours.

Affected Cylinder Part Numbers: 639272, 639272CP, 639272CE, 639274, 639274CP, 639274CE, 642320, 642320CP, 642320CE, 642594, 642594CP, 642594CE, 642691, 642691CP, 642691CE, 643771, 643771CP, 643771CE, 643985, 646100, 646101, 646652, 646652CP, 646652CE, 646657, 646657CP, 646657CE, 649162, 649162CP, 649162CE, 649169, 649169CP, 649169CE and all "A" dash numbers (example 646657CP-A3) Recent information has necessitated the re-evaluation of the inspection criteria called for in the previous M86-7 R6 and M87-19 service bulletins. As a result the following information should be noted and checked for compliance. Part I. A.

Any cylinder of the above listed part numbers that were manufactured by Teledyne Continental Motors on or after January 1, 1981 are affected by this bulletin. (1)

If a cylinder has a part number listed above and was purchased on or after January 1, 1981, remove the rocker cover/covers and determine the date of manufacture stamped on the rocker shaft boss, (i.e. 1-85 is January 1985). Any cylinders with1-81 (January 1981) or subsequent date must be inspected per part II below.

(2)

Any cylinder in A. (1) that has complied with Service Bulletin M87-19 and has the new part number piston installed (see chart below), must comply with inspections per Part II until the cylinder has a total operating time of 300 consecutive hours with the new piston.

(3)

If the cylinder has not been installed on an engine and is identified as described in the paragraph above, notify Teledyne Continental Motors for disposition.

 TELEDYNE INDUSTRIES, INC. 1991

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

20 March 1991

M91-6

Page 2

Part II. A.

Visually inspect all cylinders for oil stains or leakage between the first and second barrel fins from the bottom of the head casting. The area of concern on direct drive engines is at the 12 o'clock position on the 1-3-5 cylinder side and the 6 o'clock position on the 2-4-6 side. On the GTSIO series engine, the area of concern is at the 6 o'clock position on the 1-3-5 cylinder side and the 12 o'clock position on the 2-4-6 cylinder side.

B.

Pressurize each cylinder using a differential compression tester. The piston should be as close to BDC (Bottom Dead Center) as possible with both valves closed and maintaining pressure in the cylinder. NOTE...The pressure is checked at BDC to assure the piston and rings are below the inspection area specified in paragraph A. With 80 PSIG (Pounds Per Square Inch Gauge) air pressure in the cylinder, check the area specified in, Part II, paragraph A with a soap/water solution and inspect for any leakage. WARNING...Use extreme caution in the area of the propeller while performing this inspection.

C.

If any leakage is noted from the above inspection, the cylinder must be changed. Notify TCM immediately if any evidence of leakage is detected. (Service Department: 205-438-3411.)

Part III. The inspection requirements for cylinders listed in Part I is eliminated by the installation of cylinders P/N 649315, 649316, 649317, 649317CE, 649317CP, 649318, 649318CE, 649318CP, 649329, 649357, 649357CE, 649357CP, 649358, 649358CE, 649358CP and all "A" dash numbers appropriate for that model engine. New pistons have been developed with skirt contours which reduce cylinder barrel stress levels. These pistons supersede previous design pistons. The superseded pistons should be removed from stock. Current pistons have been superseded as follows: Engine Series

Superseded and No Longer Available

New Piston

IO550

646533 S/S by

648046

IO520

646072, 648013 S/S by

648045

TSIO520, GTSIO520

641782, 642761, 646303 and 648033 S/S by

648044

20 March 1991

Page 3

M91-6

Part III. (cont’d) Teledyne Continental Motors is developing an alternative testing procedure for the cylinder. When this procedure has been finalized a revision to this bulletin will be issued. WARRANTY If, as a result of this inspection, a cylinder must be changed, it will be covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. Make appropriate Engine Log Book entry upon completion of each inspection.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M91-7 Technical Portions Are FAA Approved

20 March 1991 SUBJECT: MODELS AFFECTED: COMPLIANCE:

CYLINDER BARREL ULTRASONIC INSPECTION IO520, TSIO520, GTSIO520, IO550 Prior to reconditioning (Chroming or Oversizing) of Affected Cylinders (WARNING...This service bulletin does not alter or modify manufacturer's specification regarding oversizing or chromeplating of cylinders. See applicable overhaul manuals for this information.)

Affected Cylinder Part Numbers: 639272, 639272CE, 639274, 639274CE, 642320, 642320CE, 642594, 642594CE, 642691, 642691CE, 643771, 643771CE. 643985, 646100, 646101, 646652, 646652CE, 646657, 646657CE, 649162, 649162CE, 649169, 649169CE AND ALL "A" DASH NUMBERS (Example: 646657CE-A3) An alternate method of inspection has been developed to detect discrepancies in TCM manufactured cylinders between the first and second cylinder barrel fins from the bottom of the head casting. The areas of concern are the 12 o'clock and 6 o'clock positions. Compliance with this inspection will be required only once and will relieve the inspection requirements of Service Bulletin M91-6, as long as the new piston as described in Service Bulletin M91-6 is utilized and the piston to cylidner fit is as specified by TCM. WARNING...This inspection cannot be performed satisfactorily on Channel Chrome Cylinders. The equipment used to perform this inspection can be purchaed from: Krautkramer-Branson, Inc. P. O. Box 350 Lewistown, PA 17044 Telephone (717) 242-0327 Training will be provided by TCM at no charge, but you must supply your own equipment. Contact TCM Service Department, (205) 438-3411, Ext. 305, to schedule training sessions or for locations of facilities that are equipped to perform the inspection. Inspection Equipment: Flaw Detector Fixture Transducer Cable

Karutkramer-Branson USL-42 or equivalent Krautkramer-Branson P/N 291-678-000 60" axial Krautkramer-Branson 5.0 MHz, .125 diameter SMSWS, P/N 113-214-585 6' MMD to BNC Krautkramer-Branson P/N C-047

 TELEDYNE INDUSTRIES, INC. 1991

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

20 March 1991

Page 2

M91-7

Inspection Equipment: (cont’d) Filter Reference Standard Couplant

1.5 Microhenry BNC to BNC Krautkramer-Branson, P/N 281-678-200 Purchase from TCM at the time of training Engine Oil SAE 30 to SAE 50 weight

NOTE...The Wheel Fax Jr. Mark IV Model O instrument is not suitable for performing this inspection. Identification: Identify affected cylinders which have complied with this inspection by steel stamping the letter "T" at the cylinder head rocker cover flange. See Figure A. WARRANTY If, as a result of this inspection, a cylinder must be replaced, it will be covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. Make appropriate engine logbook entry upon completion of each inspection.

Figure A

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M91-9 Technical Portions Are FAA Approved

9 August 1991 SUBJECT: MODELS AFFECTED: COMPLIANCE:

Cam and Lifter Lubrication During Engine Build All TCM Models During Engine Build-up

Teledyne Continental Motors will incorporate the following change to the next revision of each of its engine overhaul manuals concerning the lubrication of the cam and lifters before installation. During engine assembly, the cam lobes and lifter faces must be coated with a molybdenum disulfide grease, such as Dow Corning Molykote G-n paste or equivalent, so as to provide enhanced lubrication upon initial start-up of the engine.

 TELEDYNE INDUSTRIES, INC. 1991

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-10 Technical Portions Are FAA Approved

14 August 1992 SUBJECT: MODELS AFFECTED: COMPLIANCE:

STARTER ADAPTER Sandcast 470's, 520's, 550's, O-300-D, all 360's and all GTSIO-520's. As Required

TCM is currently producing an improved starter adapter for the engine models listed above. These adapters include a new style shaft gear, clutch spring, worm wheel gear and no longer utilize the adapter housing sleeve. These changes improve the adapters resistance to slippage during starting and increase its wear resistance. Applicable parts catalogs are currently being revised to reflect all of the parts which will go into effect with the improved adapters. The new part numbers are ink stamped on the adapter housing and can be identified by the part numbers listed below which includes all "A" suffix numbers such as 643259A4.

BASIC PART NO.

ENGINE MODEL

643259

ALL 470's IO-520-A, D, E, F, J, K & L IO-550-D, E, F & L TSIO-520-C, G, H, M, P, R, T, AF & CE ALL GTSIO-520's

643147

TSIO-520-AE

643152

L/TSIO-520-AE

646220

O-300-D IO-360-A, C, D, ES, G, H, J, JB, K & KB L/TSIO-360-A, B, C, CB, D, DB, E, EB, F, FB, G, GB, H, HB, K, KB & LB

653074

TSIO-360-MB

NOTE...These new adapters will exhibit varying degrees of resistance to propeller rotation in the direction opposite of normal engine cranking rotation. This is caused by the light friction which is required to initiate clutch engagement in the cranking mode and is considered normal. Contact your local TCM Distributor for the latest starter adapter assembly part number for your particular engine model and specification.

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-11 Technical Portions Are FAA Approved

24 August 1992 SUBJECT: MODELS AFFECTED: COMPLIANCE:

LIQUID COOLED CYLINDER ASSEMBLY, SPARK PLUG AND SPARK PLUG HELI-COIL TSIOL-550-A At Spark Plug Replacement

TCM has incorporated a change in the spark plug and spark plug helicoil utilized in the TSIOL550-A liquid cooled engine cylinder assembly. All TSIOL-550-A liquid cooled engine cylinder assemblies, P/N 652944, manufactured by TCM with a cylinder head manufacture date of May 1992 and subsequent are fitted with a new spark plug, P/N 652361 (RHU32E) and a new spark plug helicoil P/N 520112-1. NOTE...The cylinder head manufacture date code is stamped into the top of the rocker shaft boss indicating month and year of manufacture. Example: A date code of 5-92 would indicate a cylinder head manufacture date of May 1992. Liquid cooled cylinder assemblies manufactured prior to May 1992 are fitted with heli-coil, P/N 520112-2, which is longer than the heli-coil, P/N 520112-1, now being utilized. At the time of spark plug replacement, this longer heli-coil may cause an interference fit with the shoulder at the threaded end of the spark plug when replacement spark plug P/N 652361 is utilized. If an interference is noted, both heli-coils must be replaced with P/N 520112-1. This shorter heli-coil must be installed to a depth of .195 - .215 inch from the spark plug seat and must not extend into the combustion chamber. If no interference is noted, no further action is required. Care should be taken to insure the spark plug is properly seated to the cylinder head, torqued to 300/360 inch lbs. Failure to do so could result in engine damage. WARRANTY: The action required to comply with this service bulletin is covered by the Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. NOTE... Make a log book entry of compliance with this bulletin.

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-12 Technical Portions Are FAA Approved

27 August 1992 SUBJECT:

MODELS AFFECTED: COMPLIANCE:

NEW AND REBUILT ALTERNATOR THRU-BOLT TORQUE INSPECTION, P/N's 649304, 649305 (with drive coupling), 649304R and 649305R (with drive coupling) IO-520, IO-550, TSIO-520, TSIOL-550 and GTSIO-520 engines with gear driven TCM 24 Volt 100 AMP alternators. Within the next 50 hours of operation.

TCM gear driven, 24 volt, 100 AMP alternators, P/N's 649304, 649305 (with drive coupling), 649304R and 649305R (with drive coupling) built between January 1, 1988 and April 1, 1991 may have inadequate torque on the housing thru-bolts. Refer to Figure 1 below for an interpretation of the serial number appearing on the alternator data plate from which the build date can be determined. Remove the safety wire from the housing thru-bolts and torque the thru-bolts to 100 to 105 in. lbs. Reference Alternator Service Instructions Manual (Form No. X30531-3 dated July 1989) Figure 33, Item 34. Install new safety wire in the fashion illustrated in Figure 2. The safety wire diameter must be .030 to .040 in. Whenever the alternator is dismantled for service or overhaul, 100-105 in-lb torque must be applied to the thru-bolts during re-assembly. NOTE...Subject alternators with S/N D0191010 & D0191010R and subsequent are not affected by this bulletin. Example: A018801OR A

Month A: January B: February C: March D: April E: May F: June G: July H: August I: September J: October K: November L: December

01

88

Day of Month

Year (1988)

01

Sequential Number for Unit. Begins With 01 Each Day

O

R

Product Code: O: Alternator

Factory Rebuilt (No Letter for New)

FIGURE 1. SERIAL NUMBER INTERPRETATION (continued)  TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

27 August 1992

Page 2

M92-12

FIGURE 2. SAFETY WIRE CONFIGURATION

WARRANTY STATEMENT: The action required to comply with this service bulletin is covered by the Gold Medallion Warranty, subject to its terms and conditions. Teledyne Continental Motors will allow (1) hour labor at the posted shop rate to perform this inspection. Warranty claims may be filed though any Teledyne Continental Motors distributor.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M92-14 Technical Portions Are FAA Approved

9 September 1992 SUBJECT: MODELS AFFECTED:

COMPLIANCE:

NEW MODINE OIL COOLERS, P/N 635996, 646685, 649479 and 652759 New, Rebuilt, and TCM Overhaul Engines; IO-520-B, BA, BB, CB, M & MB; IO-550-A, B, C; TSIO-520-BB, D, DB, K, KB, UB; TSIO-520-BE, E, EB, J, JB, L, LB, N, NB, VB, WB; GTSIO-520-H, K, L, M, N; IO-470-U, V. Within The Next 50 Hours Of Operation.

TCM has received notification from Modine Manufacturing Company that during a routine air underwater leak test, a leaking tube on one oil cooler was detected. An examination by Modine of the tubes used in the construction of the subject TCM oil coolers revealed a visible score mark in the leading edge of some tubes. The part number of the oil cooler is ink stamped on the assembly along with the date code. (Example: P/N 635996 / 12-91). The ink stamp is located on the top flange of P/N's 635996, 646685, 652759 cooler and on the outer end for the P/N 649479 cooler. The affected part numbers are as follows: TCM

MODINE

DATE CODE

635996

1E-1774

12/91 thru 4/92

646685

1E-2860

2/92 thru 5/92

649479

1E-3132

12/91 thru 5/92

652759

1E-3431

3/92 thru 3/92

It is mandatory to replace these affected oil coolers installed on TCM engines shipped December 1991 through May 24th 1992 and new oil coolers sold to the aftermarket during the period specified by the date code on the cooler. Only the coolers with affected dates need to be replaced. Contact your local TCM Distributor to order the replacement coolers. WARRANTY...The action required to comply with this service bulletin is covered by the Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M92-4R1 Supersedes M92-4 Technical Portions Are FAA Approved

5 February 1992 TO:

SUBJECT: MODELS AFFECTED:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Products engines IO AND L/TSIO360 ROCKER SHAFT STUD INSPECTION New and rebuilt IO and L/TSIO 360 engines with the below listed serial numbers which have less than 50 hours of operation time. IO and L/TSIO 360 engines with new service cylinder assemblies and uninstalled new service cylinder assemblies with cylinder assembly dates of 6-91 through 12-91 with less than 50 hours of operation time. Cylinder part numbers affected are: 646924, 649484, 652955, 653098 and all A suffix numbers of these base part numbers. Cylinder assembly dates are stamped on the cylinder head between the two rocker shaft pockets. NEW: TSIO360-KB, 320109 through 320117. LTSIO360-KB, 319109 through 319117. IO360-E, 357000. IO360-HB, 353390, 353391, 353394, 353395, 353397 through 353399, 358000 through 358010. IO360-JB, 359000, 359001. IO360-KB, 356743. REBUILT: R-TSIO360-A, 197103. R-TSIO360-CB, 236149 through 236156, 236158 through 236165. R-TSIO360-C, 283511 through 283513. R-TSIO360-EB, 265801 through 265814. R-TSIO360-FB, 281069, 281070, 281072 through 281078, 281080 through 281088. R-TSIO360HB, 239967 through 239969. R-TSIO360-KB, 268118, 268122 through 268130. R-TSIO360-LB, 247192 through 247197. R-TSIO360-MB, 279224, 279225. R-LTSIO360-EB, 266337 through 266351, 266353. RLTSIO360-KB, 268357 through 268369. R-IO360-C, 060609 through 060612. R-IO360-DB, 239684 through 239688, 239690, 239691, 239693 through 239700. R-IO360-D, 062945 through 062951. R-IO360-G, 244559 through 244564. R-IO360-HB, 265172 through 265178. R-IO360H, 226548 through 226550. R-IO360-KB, 235989 through 235996. RIO360-K, 240110, 240111.

COMPLIANCE: Before next flight for affected engines. Before installation for uninstalled new service cylinder assemblies.

(continued)  TELEDYNE INDUSTRIES, INC. 1992 Member of GAMA

General Aviation Manufacturer’s Association

TELEDYNE CONTINENTAL MOTORS

Aircraft Products PO Box 90 Mobile Alabama 36601

5 February 1992

Page 2

M92-4 Rev. 1

Introduction: There is a possibility that some affected model engines and cylinder assemblies may have an interference between the cylinder head casting and the rocker shaft. This interference can cause improper seating of the rocker shaft which can lead to breakage of the rocker shaft hold down stud and consequent engine stoppage. Required inspection: On affected models, remove the exhaust side valve cover, rocker shaft and rocker arm assembly. Place the removed rocker shaft on the hold down studs and press the shaft against the cylinder head. The flat seating surface of the shaft should seat against the head with no clearance and no perceptible rocking. There must be at least .02 inches clearance between the rocker shaft and the inner cast surfaces of the cylinder head rocker pocket. If the cylinder head meets these tests, the rocker shaft and rocker arm assembly may be reinstalled. New lock tab washers part number 501867 must be used. Tighten the stud nuts to the overhaul manual specified torque of *110-120 inch pounds. After torquing the nuts, bend the washer tabs into position. Install the valve covers with new part number 632310 gaskets. Record this inspection in the engine log book. If insufficient clearance is found, rework the cylinder per the instructions in this bulletin. Uninstalled cylinder assemblies must be inspected using rocker shaft part number 648002 in the manner described in Required inspection prior to assembly on an engine. If sufficient clearance is found, the cylinder may be installed on an engine. If insufficient clearance is found, rework the cylinder per the instructions in this bulletin except that new studs need not be installed. Record compliance in the engine logbook. Required rework: If an interference is found, remove sufficient material from the cylinder head rocker shaft pocket to provide at least .02 inches clearance for the rocker shaft. Do not remove more than .06 inches from the side of the pocket to provide this clearance. The material removal must not exceed .37 inches depth from the rocker shaft seating surface or .37 inches distance from the centerline of the rocker shaft. Care must be taken to assure that the removed material does not enter the engine. Both rocker shaft studs must be removed and replaced with new part number 401852. Coat the new studs with engine oil and install them to an extension of .81/.75 inches . Re-install the rocker shaft and rocker arm assembly. New lock tab washers part number 501867 must be used. Assure that the rocker shaft flats fit tightly against the seating surface with no evidence of interference with the head casting. Tighten the stud nuts to 110-120 inch pounds. After torquing the nuts, bend the washer tabs into position. Install the valve covers with new part number 632310 gaskets. Record compliance in the engine logbook. Warranty: The action required to comply with this Service Bulletin is covered by the Gold Medallion Warranty, subject to it's terms and conditions. Warranty claims may be filed through any Teledyne Continental Motors Aircraft Product Distributor. *NOTE...Service Bulletin M92-4 rocker shaft stud nut torque is incorrect. Rocker shaft stud nuts must be torqued to 110-120 inch pounds. If M92-4 has been previously complied with and nuts torqued to 75-85 inch pounds then the nuts must be re-torqued before next flight.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-5 Technical Portions Are FAA Approved

28 February 1992 TO:

Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT:

PRECISION AIRMOTIVE CORPORATION MANDATORY SERVICE BULLETINS #MSA-1 REV. 1 AND MSA-2 REV.2

MODELS AFFECTED: COMPLIANCE:

MSA-1 Rev. 1: A-65, C-75-85-90, O-200, C-145, O-300-A-C-D, GO-300A-C-D-E, O-470-A-J-K-L-R-S-U. MSA-2 Rev.1: A-65, C-75-85-90, O-200, C-145, O-300-A-C-D See Precision Airmotive Corporation Bulletins.

Teledyne Continental Motors requires that the attached Precision Airmotive Corporation Service Bulletins MSA-1 Rev. 1 and MSA-2 Rev. 1 be complied with.

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

MANDATORY service bulletin

M92-6 Technical Portions Are FAA Approved

28 February 1992 SUBJECT: MODELS AFFECTED:

COMPLIANCE:

ROCKERSHAFT RETENTION IMPROVEMENT FOR INCLINED VALVE CYLINDER O470, IO470, IO520, IO550, TSIO520 AND TSIOL550 WITH THE EXCEPTION OF O470 A, E, & J, IO550G, L/TSIO520AE AND TSIO520BE AT NEXT COMPLETE TOP OR ENGINE OVERHAUL

Teledyne Continental Motors has incorporated into the inclined valve cylinder an improved method of rocker shaft retention. It is required that at next complete top or engine overhaul this improved rocker shaft retention be implemented on all affected cylinders now in service. The latest cylinder assembly part numbers that are not required to comply with the cylinder modification instructions and have had this operation performed are: A.

Cylinder assembly part numbers: 652944, 652953, 652954, 653040, 653041, 653142, 653148 and 653149. This would also include any of these numbers which have a letter or number suffix such as 652944A1.

B.

Any cylinder assemblies which are identified with the letter "B" stamped on the cylinder rocker cover flange. See Figure 2. NOTE...THE CYLINDER ASSEMBLIES AS IDENTIFIED ABOVE INDICATE THAT THE CYLINDER HEAD HAS HAD THE MACHINING MODIFICATION PERFORMED. THIS DOES NOT MEAN THAT THE NEW SOLID BEVEL ROCKER SHAFT AND ITS ATTACHING HARDWARE ARE BEING UTILIZED. IN CASES OF UNCERTAINTY, THE ROCKER COVER MAY BE REMOVED TO INSPECT FOR THE INSTALLATION OF THE NEW SHAFT.

The following engine models and their subsequent, (higher) serial numbers have had the complete modification performed, including new shafts and attaching hardware, and therefore are not affected by this service bulletin.

(continued)

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

28 February 1992 ENGINE MODEL O470G O470K O470L O470M O470R O470S O470U IO470C IO470D IO470E IO470F IO470H IO470L IO470M IO470N IO470S IO470U IO470V IO520A IO520B IO520BA IO520BB IO520C IO520CB IO520D IO520E IO520F IO520J IO520K IO520L IO520M IO520MB TSIO520AF TSIO520B

M92-6

Page 2 SERIAL NUMBER NEW REMAN 85028 70694 48999 49435 67473 69745 54025 54148 466710 321266 464585 269208 470739 286557 463009 242134 456012 105620 452001 88741 453052 89834 N/A 87337 48575 272849 94565 94589 458152 96557 460002 109337 457010 118427 455777 171043 550035 112653 N/A 234762 569649 280747 578833 285605 571232 267999 576306 282175 575890 282705 556628 215774 579200 286186 558005 216519 557541 224072 577211 270291 N/A 270775 575054 277394 525099 245216 500714 176594

Parts Required: For One (1) Cylinder: Tools Required:

TSIO520BB TSIO520C TSIO520CE TSIO520D TSIO520DB TSIO520E TSIO520EB TSIO520G TSIO520H TSIO520J TSIO520JB TSIO520K TSIO520KB TSIO520L TSIO520LB TSIO520M TSIO520N TSIO520NB TSIO520P TSIO520R TSIO520T TSIO520UB TSIO520VB TSIO520WB IO550A IO550B IO550C IO550D IO550E IO550F IO550L

SERIAL NUMBER NEW REMAN 526038 236998 501626 178360 530157 268534 505009 180094 505015 242009 510476 275220 510835 271198 507068 216042 506888 217271 503613 218953 503628 237154 504317 224602 531001 245709 508734 241935 508730 237275 520990 283119 514820 228589 521653 276924 513920 278594 522655 269810 515432 239378 527171 248981 529093 278429 518927 274215 677006 280326 675729 281646 676623 271719 680009 284015 681006 283277 679508 284522 680003 N/A

Helicoil, 2 ea. MS21209C4-15, 1/4"-20 Bolt, 2 ea. MS90725-12 Flat Washer, 2 ea. 652947 Rockershaft, 2 ea. 652984 Drill, .266 (H) Helicoil Installer, 1/4"-20 *Drill Guide Kit P/N 8181 Tap, 1/4"-20 Helicoil Chamfer Tool, .339 Drill and "T" Handle Drive.

*Drill guide kit P/N8181 includes: 1 each drill guide P/N 8181-1 and 1 each drill guide pilot P/N 8181-2. Drill guide kit may be purchased from Borroughs Tool Co. Ph. 1-800-253-0138. (continued)

28 February 1992

Page 3

M92-6

Prior to performing the modification, clean the rocker shaft bosses and inspect for cracks using an approved method of dye penetrant inspection. 1.

Remove the existing rocker shafts and attaching hardware and inspect shaft bores for proper size .7495 - .7510.

2.

Install drill guide kit, P/N 8181 into rocker boss using the existing screw bore as shown in figure 1.

3.

Using a .266 drill, drill to a depth of 1.820 - 1.850 as measured from the top of the drill guide as illustrated in figure 1, in two places.

4.

Remove the drill guide and chamfer each bore 120", .34 - .31 diameter by hand using a .339 drill and "T" handle drive. Deburr as necessary.

5.

Turn drill guide pilot 90þ from original position and tap hole using a 1/4" - 20 helicoil tap, .430 deep.

6.

Remove helicoil installation tool body and use its threaded portion only. Install P/N MS21209C4-15, 1/4" - 20 self locking helicoil per MS33537 using the helicoil installation tool. Insure that the helicoil is installed below the surface of the rocker shaft bore. Break and remove the helicoil tang.

7.

Insure that the rocker shaft bore is clean and free of any burrs. Clean the entire cylinder assembly using an approved method to remove all of the shavings and foreign material.

8.

Install existing rocker arms and thrust washers using new rocker shafts, P/N 652984. Rocker shaft, P/N 652984 must be installed with the beveled side facing toward the cylinder base. Install washers, P/N 652947, bolts, P/N MS90725-12 and torque bolts to 90 - 100 in/lbs.

9.

Identify cylinder with steel stamp letter "B" as indicated in figure 2. Make a log book entry as to compliance with this service bulletin.

(continued)

28 February 1992

Page 4

FIGURE 1.

FIGURE 2.

M92-6

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-7 Supersedes M80-15 Technical Portions Are FAA Approved

26 May 1992 SUBJECT: MODELS AFFECTED: COMPLIANCE:

CRANKCASE CYLINDER DECK STUDS ALL - EXCEPT O-200, O-300 AND "C" SERIES AT OVERHAUL

Unlike other crankcase studs, "deck" studs are installed with a light interference fit, sealed and held in position with the use of Loctite at assembly. The following information is provided to familiarize you with current manufacturing practice, as it relates to this subject.

ENGINE MODEL

STUD PART NO.

LOCATION

360

643651-1

1, 2, 3, 4, 5, 6

470, 520, GTSIO520, 550, (Sandcast)

646140-1 646140-2

1, 2, 3, 6 4, 5, 

346, 520 550 (Permold)

646140-1 646140-2

1, 2, 3, 4, 5, 6 

Note…  "Seventh Stud" installed on 520 and 550 models reference SB M90-16 or current revision as applicable.

(continued)

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

26 May 1992

Page 2

M92-7

CYLINDER DECK STUD LOCATIONS The following procedure is specified for installing cylinder deck studs. 1. Studs and tapped holes must be clean and dry. 2. Apply "Lockquick Primer Grade N" to stud and cylinder deck threads and allow to dry. 3. Apply "Loctite Grade 271" to both threads. 4. Install studs to proper height. 5. Wipe away excess "Loctite". 6. Allow two hours minimum setting time before assembling cylinders.

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-8 Supersedes M85-5 Technical Portions Are FAA Approved

29 May 1992 SUBJECT: MODELS AFFECTED:

APPLICATION OF 4-1/6" DIAMETER CYLINDER ASSEMBLIES C-Series, O200, O300, GO300

INTRODUCTION: It has been brought to our attention that SB M85-5 has created some confusion regarding the restricted application of the subject cylinders. This revision is being published to provide the latest information about the cylinders and their applications. TEXT: C-75, 85, 90, O200, O300 may use all airworthy 4 1/16" diameter cylinders regardless of part number. GO-300 may NOT use 641916, 639702 and A50222 cylinder assemblies, all of which were manufactured prior to August 1976. The visual distinction between these cylinders is shown in Figures 1 and 2. To comply with the current specifications, cylinders must be reworked with the following upgraded parts in accordance with applicable instructions and specifications. Intake Valve

Valve Seat ................ 641793 Guide ........................ 24024 Valve ......................... 641792

Exhaust Valve

Valve Seat ................ 3923 Guide ........................ 628309 Valve ........................ 646612

Valve Springs as Follows: C75, C85

Inner ......................... 24029 Outer ........................ 24030 C90 Inner .................. 24031 Intermediate ............. 24029 Outer ........................ 24030 O200,O300 Inner ...... 24031 Intermediate ............. 24029 Outer ........................ 625958 GO300 Inner ............. 625957 Outer ........................ 625958 (continued)

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

29 May 1992

Page 2

FIGURE 2.

M92-8

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M92-9 Technical Portions Are FAA Approved

29 May 1992 SUBJECT:

FLANGED .500 THRU BOLT NUT, P/N 652541

MODELS AFFECTED:

All 470's, All 520's and All 550's

COMPLIANCE:

At Overhaul or When Necessary

Teledyne Continental Motors has released an improved twelve point flanged, .500 thru bolt nut, P/N 652541 superseding the six point thru bolt nuts, P/N's 634505 and 649496. All factory new, rebuilt and overhaul engines of the affected models incorporate the new twelve point thru bolt nut, torqued to 790 - 810 inch lbs. At engine overhaul this new twelve point nut must be used in a complete set per engine and torqued to 790 - 810 inch lbs. The twelve point nuts torqued to 790-810 in lbs. must be installed on the engine crankcase when measuring the crankcase main bearing bores during overhaul inspection and any necessary line bore of the crankcase. When replacing less than a full set of six point nuts prior to overhaul, this twelve point nut may be used and torqued to the values as stated in the applicable engine overhaul manual. CAUTION...All thru bolt threads and thru bolt nut threads must be lubricated with clean 50 weight engine oil prior to installation. See applicable overhaul manual for correct torquing sequence.

 TELEDYNE INDUSTRIES, INC. 1992

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M93-10 Technical Portions Are FAA Approved

1 March 1993 SUBJECT: MODELS AFFECTED: COMPLIANCE:

TCM IGNITION SYSTEMS SERVICE BULLETIN NO. 639 All Models that utilize TCM/Bendix magnetos with impulse couplings. See TCM Ignition Systems Service Bulletin No. 639

Teledyne Continental Motors requires that the attached TCM Ignition Systems Service Bulletin No. 639 be complied with as indicated.

 TELEDYNE INDUSTRIES, INC. 1993

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TCM IGNITION SYSTEMS

TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

SERVICE BULLETIN NO.639  TELEDYNE INDUSTRIES, INC. 1993

SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED:

COMPLIANCE:

Printed March 1993 Page 1 of 2 Engineering Portions are FAA Approved

Proper installation of impulse couplings To modify, confirm and stress the importance of proper installation procedures of impulse coupling assemblies All TCM & Bendix S-20, S-1200, D-2000 and D-3000 series magnetos with impulse couplings as installed on TCM, Lycoming, Franklin and other manufacturer’s engines.

MANDATORY AT TIME OF INSTALLATION OF ANY BENDIX/TCM IMPULSE COUPLING ASSEMBLY

General Information:

WARNING...Use of unapproved hardware and/or lubrication of threads will produce inaccurate torque values and increased stress on the impulse coupling during assembly.

Field reports indicate that there have been instances in which the impulse coupling cam assemblies have cracked upon installation. See Figure 1. Cracking can be caused by improper installation procedures which may result in coupling assembly damage or potential engine failure.

4. Using a CALIBRATED torque wrench, tighten nut to 180 in-lbs. Install and secure new cotter pin. If unable to install pin, increase torque gradually to align the first available slot in the castellated nut.

Detailed Instructions: The following instructions pertain to installation of new impulse coupling assemblies as well as those that are being reinstalled after scheduled magneto maintenance. 1. Clean impulse coupling assembly and magneto drive shaft using standard cleaning solvent. 2. Apply a light coating of TCM P/N 646943 anti-seize lubricant to the tapered section of the magneto drive shaft. This prevents seizure of the cam assembly to the shaft and avoids damage during disassembly. Do not apply lubricant to shaft or nut threads. See Figure 2.

WARNING...Under no circumstances should you exceed 300 in-lbs. torque. Any impulse coupling that is damaged in any way during installation must be replaced. The preceding information will be incorporated into the next revision of the TCM Master Service Manual form No. X40000.

3. Install woodruff key in tapered portion of the shaft. Install coupling assembly, washer(s) and thread nut onto shaft. Use approved hardware specified in the appropriate TCM Ignition Systems parts manual. (continued)

TCM IGNITION SYSTEMS SERVICE BULLETIN NO.639 Printed March 1993 Page 2 of 2 Engineering Portions are FAA Approved

FIGURE1

FIGURE 2 Apply P/N 646943 Anti Seize Lubricant to Magneto Shaft

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M93-4 Supersedes M90-7 Technical Portions Are FAA Approved

12 February 1993 SUBJECT: MODELS AFFECTED:

CRANKSHAFT COUNTERWEIGHTS IO-360, L/TSIO-360, E-185, E-225, O-470, IO-470, TSIO-470, IO-520, IO-550, L/TSIO-520, TSIO-550 AND TSIOL-550.

The purpose of this service bulletin is to stress the importance of thorough inspection and proper assembly of crankshaft counterweights and their associated parts. COMPLIANCE:

At overhaul or when the crankshaft is removed from the engine.

Remove the counterweights from the crankshaft, clean, and press the old bushings from the counterweight bores and the crankshaft hanger flange. Removing and replacing bushings with makeshift tools can result in damage to the crankshaft and counterweights. A special tool for removing and replacing the bushings is supplied by Borroughs Tool and Equipment Corp., 2429 North Burdick, Kalamazoo, Michigan, 49007. WARNING...Improper installation of the bushings, retaining plates or retaining rings will cause engine failure. Carefully inspect the counterweight bores for signs of wear. Special attention should be given to the wear area shown in Figure 1. Measure the counterweight bores. Counterweight bores which exceed the dimension shown in Figure 1 must be discarded. Oversize counterweight bushings are NOT permitted. Opposing pairs of counterweights must match in weight within two grams. If either counterweight is worn or damaged, it will be necessary to discard both on that cheek and procure a matched pair for replacement. Check the retaining ring groove in each counterweight for wear, damage, distortion or other improper conditions. Any of these conditions would require replacement of the counterweight. All counterweight and crankshaft blade bushings, pins, retaining rings and plates must be replaced 100% at overhaul. The counterweight plates have a small protruded point, (.001-.007) which provides an interference fit, (see Figure 2). Upon installation, check the counterweight plates for an actual interference fit in the bushing bore. DO NOT USE PLATES WHICH HAVE A LOOSE FIT. Proper installation of the retaining rings is very important. Make sure the rings are seated fully in the bushing bore grooves with the sharp edge side of the retaining ring facing outboard. Assure that the proper pins and plates are installed. Reference TCM Service Bulletin M89-24 or current revision as applicable.

(continued)

 TELEDYNE INDUSTRIES, INC. 1993

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

12 February 1993

M93-4

Page 2

ENGINE MODEL

DIAMETER “A”

All “E” Series, 470, 520 and 550

.8745 - .8755

All 360

1.000 – 1.001 FIGURE 1

FIGURE 2

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M93-5 Technical Portions Are FAA Approved

19 February 1993 SUBJECT: MODELS AFFECTED:

COMPLIANCE:

CHAMFER OF CRANKCASE MAIN BEARING OIL FEED HOLES IO-520B,BA,BB,C,CB,M,MB; IO-550A,B,C,G; TSIO-520B,BB,BE,D,DB,E,EB,J,JB,K,KB, L,LB,N,NB,UB,VB,WB; TSIO-550A,B; TSIOL-550A At time of engine overhaul or anytime the crankcase is disassembled

A proper chamfer at the crankcase main bearing oil feed holes must be maintained to reduce the possibility of crankcase cracking in that area. The following instructions must be performed at time of engine overhaul or any time the crankcase is disassembled. INSTRUCTIONS: 1.

Inspect the number one, two and three main bearing oil feed passages and determine if they conform to the illustration in Figure 1. The subject passages are located in the left (2,4,6) case half and begin in the rear main bearing saddle, counting forward.

2.

Any of the above mentioned oil feed passages which do not conform to the illustration in Figure 1 must be modified to conform. Deburr sharp edges after modification for smooth transition.

3.

After the modification has been accomplished, clean crankcase as outlined in the appropriate overhaul manual.

FIGURE 1

 TELEDYNE INDUSTRIES, INC. 1993

TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

service bulletin

M93-8 Technical Portions Are FAA Approved

19 February 1993

SUBJECT: MODELS AFFECTED: COMPLIANCE:

ROCKER ARM TO ROTOCOIL CLEARANCE E-185, E-225, IO-346, IO-360, L/TSIO-360, O-470, IO-470, IO-520, IO-550, L/TSIO-520, GTSIO-520, TSIO-550 AND TSIO-550.

MANDATORY AT TIME OF ENGINE OR CYLINDER OVERHAUL

To prevent mechanical interference which could cause rocker arm and/or valve failure, a minimum clearance of .020 inch must be maintained between the rocker arm and rotocoil. This clearance must be checked with the valve in the closed position and the foot of the rocker in contact with the valve stem tip. (See Figure 1.) It is permissible to smoothly grind across the forging flash line on the underside of the rocker arm to obtain the specified clearance, if necessary. The grind must not exceed the width illustrated in Figure 2. If the required clearance cannot be obtained without exceeding this grind width, the rocker arm must be replaced. The grind must be smooth and uniform. All the ground surface must be polished to remove all grind marks. The rocker arm must be magnetic particle inspected for cracks following the polishing operation. CAUTION...The presence of grinding marks or cracks in the rocker arm can result in rocker arm failure.

FIGURE 1

 TELEDYNE INDUSTRIES, INC. 1993

FIGURE 2 TELEDYNE CONTINENTAL MOTORS

Member of GAMA

Aircraft Products

General Aviation Manufacturer’s Association

PO Box 90 Mobile Alabama 36601

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB 00-1

SERVICE BULLETIN Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

CAMSHAFT PACKAGING

PURPOSE:

To advise Distributors, FBO’s and Engine Overhaul Facilities of possible shipping damage to camshafts.

COMPLIANCE:

Prior to installation of camshafts

MODELS AFFECTED:

All

Teledyne Continental Motors has received reports of camshafts that have been damaged during shipping. Damage has occurred to camshafts that were packaged using paper or paper by-products as a protective barrier between the cardboard box and the camshaft. TCM advises any distributor, FBO or Engine Overhaul Facility to inspect all camshafts packaged in cardboard boxes where paper or paper by-products were used as a protective barrier. The camshafts should be inspected visually for nicks, dents and deep scratches. Additionally, perform a run-out inspection of the camshafts as specified in the applicable engine overhaul manual. Camshaft run-out must be within the minimum and maximum new limits specified in the applicable engine overhaul manual table of limits. If not, contact your TCM Distributor or Teledyne Continental Motors Customer Service at 251-4383411.

ISSUED

TCM is now wrapping camshafts with a plastic protective cover and then placing them in a foam filled cardboard box. This method provides adequate protection against in-transit shipping damage. We recommend that any Distributor, FBO or Engine Overhaul Facility that ships engine parts review its packaging process and materials to insure that adequate protection from in-transit shipping damage is being provided.

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

01

14

2000

MO

DAY

YEAR

CONTINENTAL MOTORS

© 2000 TELEDYNE TECHNOLOGIES INCORPORATED

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

1 of 1 SB00-1

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB 00-10

Compliance will Enhance Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

FUEL PUMP SEAL P/N 649198

PURPOSE:

To provide installation instructions for fuel pump seal P/N 649198

COMPLIANCE: At fuel pump repair or overhaul MODELS AFFECTED:

IO-240, IO-360, IO-346, O-470-G7, O-470-G10, O-470-GCI, IO-470, GIO-470, IO-520, LIO-520, IO-550, GIO-550, LTSIO-360, TSIO-360, TSIO-470, TSIO-520, TSIO-550, TSIOL-550, GTSIO-520 TCM Fuel Injected Engines.

This service bulletin provides instructions for installation of fuel pump seal P/N 649198. NOTE: Use only P/N 649198 seals that do not have any coating on the outside diameter of the seal. Earlier production seals were coated with Boretite (a green colored material) on the seal outside diameter. If you have any P/N 649198 seals with Boretite in your inventory, contact your TCM Distributor for replacement seals. OD not to exceed 1.062 after installation of seal

.8756 - .8763 ID

.877 - .881 OD

P/N 643932- 1, 2, 3 & 4 & P/N 655244- 1, 2, 3 & 4 Fuel Pump Housing

P/N 649198 Seal

FIGURE 1

FIGURE 2

Prior to installation of seal P/N 649198, thoroughly clean seal bore ID using an approved solvent and 180 to 220 grit emery paper. Measure fuel pump seal bore ID. If seal bore ID is not within the minimum and maximum dimensions listed in Figure 1, it must be scrapped. Measure OD of seal P/N 649198, refer to FIGURE 2 for dimensions. Clean fuel pump housing seal bore and OD of seal with TCM P/N 653693 (loctite 7649) Primer. Then lightly coat seal, P/N 649198, OD and fuel pump housing seal bore with TCM P/N 654562 Retaining Adhesive (Loctite 609). Do not allow Loctite on pump shaft bushing or rubber portion of seal. Press seal into fuel pump housing seal bore using appropriate sized seal driver. Allow sealant to set for 1 hour. Full strength cure time is 24 hours. ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

12

19

YEAR 00

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

 2000 TELEDYNE TECHNOLOGIES INCORPORATED

1of 1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB 00-12

SERVICE BULLETIN

TECHNICAL PORTIONS FAA APPROVED

Compliance Will Enhance Safety SUBJECT:

SERVICE PUBLICATIONS FOR ROLLS ROYCE MANUFACTURED ENGINES

PURPOSE:

To provide maintenance, overhaul and parts information for Teledyne Continental Motors engines manufactured under license by Rolls Royce Motors.

COMPLIANCE: MODELS AFFECTED:

As required during maintenance or overhaul of affected engines.

All Rolls Royce Motors manufactured C-90; O-200; O-240; O-300; IO-360-A, C, D, G, H and J; TSIO-360-A, B, C, D

Beginning in August of 1982 Teledyne Continental Motors became responsible for providing service support for the all Teledyne Continental Motors engines manufactured under a licensing agreement by Rolls Royce. Maintenance, overhaul, illustrated parts breakdown (parts catalogs), operators manuals and instructions for continued airworthiness for the Rolls Royce manufactured engines listed in the models affected section of this service bulletin are contained in the Maintenance, Overhaul and Parts Catalogs, Service Bulletins and other Service Documents published by Teledyne Continental Motors for these engine models.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

12

19

YEAR 00

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

 2000 TELEDYNE TECHNOLOGIES INCORPORATED

1of 1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB 00-2

Compliance Will Enhance Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

IO-346 REPLACEMENT CYLINDER ASSEMBLY KIT

PURPOSE:

To notify owners, operators, maintenance facilities and distributors of new cylinder

COMPLIANCE: MODELS AFFECTED:

At next cylinder replacement or engine overhaul IO-346

Teledyne Continental Motors announces the availability of a new cylinder kit for the IO-346 engine model. Kit P/N EQ6657,{ includes four (4) cylinders and all components necessary for installation of the new cylinders. Figure 4 provides cylinder and component illustration and parts break down.

2. Verify that cadmium plating is present on cylinder deck stud threads, thru bolt threads and flanged nut threads. Absence of cadmium plating requires replacement of the stud, thru bolt or nut. Cylinder deck stud nuts and thru bolt nuts must be replaced at engine overhaul, reference the latest revision on TCM SB97-6.

NOTE: This EQ kit must be installed as a complete unit. Do not utilize any component parts or cylinder assemblies contained in this EQ kit with earlier cylinders or cylinder components.

3. Lubricate cylinder deck stud threads and through bolt threads with clean 50 weight engine oil prior to assembly.

Refer to the IO-346 Overhaul Manual, Form X30027, for cylinder removal and installation instructions. Additionally, the following installation instructions must be followed. NOTE: Prior to installation perform a complete dimensional inspection of the cylinder, pistons and piston rings. Dimensional fits and limits are provided in TABLE 2, on page 6. 1. Visually inspect cylinder deck stud threads and thru bolt threads for mechanical damage. Replace any cylinder deck stud or thru bolt that exhibits any mechanical damage. CAUTION DO NOT ATTEMPT TO RESTORE DAMAGED THREADS. CYLINDER DECK STUDS AND THRU BOLTS HAVE ROLLED THREADS.

ISSUED

4. Install piston rings, piston and cylinder in accordance with the instruction provided in the IO-346 Engine Overhaul Manual, Form X30027. 5. Install cylinder deck stud nuts and thru bolt nuts. 6. Initially torque the 7/16-20 cylinder deck stud nuts to 245 – 255 inch lbs. in the numerical sequence shown in Figure 1. 7. Torque the 7/16-20 cylinder deck stud nuts and the ½-20 thru bolt nuts to 490-510 inch lbs. in the sequence shown in Figure 2. 8. Torque the ½-20 thru bolt nuts to their final torque specified in Table 1 in the sequence shown in Figure 3.

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

02

02

2000

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

 2000 TELEDYNE TECHNOLOGIES INCORPORATED

1 of 6 SB 00-2

9. Install inter-cylinder baffles, induction system, exhaust system and peripheral baffles in accordance with the engine overhaul manual Form X30027 and the aircraft manufacturer’s maintenance manual.

noted before releasing aircraft and engine for test flight. Make a logbook entry. 12. Perform a test flight in accordance with the latest revision of TCM Service Bulletin M897R1.

10. Perform a complete ground run up in accordance with the aircraft manufacturer’s instruction.

{To order cylinder kit P/N EQ6657 contact a TCM Distributor.

11. Inspect the engine and nacelle for evidence of fuel and oil leaks. Correct any discrepancies

FIGURE 1 Initial Cylinder Installation Torqueing Torque Cylinder deck stud nuts: 245 to 255 inch lbs. in the numerical sequence shown.

FIGURE 2 Intermediate Cylinder Installation Torqueing Torque Cylinder deck stud nuts and thru bolt nuts: 490 to 510 inch lbs. in the numerical sequence shown. Thru bolt nuts number 1, 4, 9, 12, 17 and 20 must be torqued simultaneously from both sides of engine.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

02

02

2000

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

2 of 6 SB 00-2

FIGURE 3 Final Cylinder Installation Torqueing Torque Cylinder Thru Bolt Nuts to the appropriate value specified in Table 2. TABLE 1 SIZE .44-20 .50-20 .50-20

.50-20

FASTENER

TORQUE VALUE IN/LB. FT/LB.

Nut, cylinder deck stud Nut, 6 point flanged (P/N 538969) ½-20. Used with P/N 539050-10.75 thru-boltNut, 6 point flanged (P/N 634505) ½-20. Use with P/N 641930-10.75 thru-bolt Nut,12 point flanged (P/N 652541) ½-20. Use with P/N 641931-10.75 thru bolt

MODELS AFFECTED

490-510

40.8-42.5

IO-346

640-660

53.3 –55.0

IO-346- originally installed thru bolt and nut. {

690-710

57.5-59.2

790-810

65.8-67.5

IO-346- P/N 634505 superseded P/N 538969. P/N 641930-10.75 superseded P/N 539050-10.57 | IO-346- P/N 652541 superseded P/N 634505. P/N 641931-10.75 superseded P/N 641930-10.75 }

NOTE: {P/N 539050-10.75 thru bolt has a smooth machined dowel section. |P/N 641930-10.75 thru bolt has “O” ring grooves machined in center dowel section only. }P/N 641931-10.75 thru bolt has “O” ring grooves machined in center dowel section and machined identification grooves at either or both ends of the bolt. Final thru bolt torque value is determined by thru bolt and nut application: P/N 539050-10.75 thru bolt. Torque nut to 640-660 inch lbs. P/N 641930-10.75 thru bolt. Torque nut to 690-710 inch lbs. P/N 641931-10.75 thru bolt. Torque nut P/N 634505 to 690-710 inch lbs. Torque nut P/N 652541 to 790-810 inch lbs. When using P/N 641930-10.75 or 641931-10.75 thru bolt, do not install “O” ring seals on thru bolt unless Service Bulletin M 77-9 has been complied with.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

02

02

2000

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

3 of 6 SB 00-2

MO 02

ISSUED DAY 02

YEAR 2000

MO

YEAR

REVISED DAY

FIGURE 4

TM

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

CONTINENTAL MOTORS

PAGE NO REVISION

4 of 6 SB 00-2

FIGURE & INDEX 1 N/A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 N/A 25 26 27 28 29 30 31 32 33 34 N/A 35 36 37

PART NUMBER

DESCRIPTION

QUANTITY

KIT – CYLINDER TOP OVERHAUL 1 . CYLINDER & VALVE ASSY ............................................. 4 . . CYLINDER ASSY-MACH (ref. Only) .............................. 1 . . . INSERT-INTAKE VALVE SEAT ................................... 1 . . . INSERT-EXH. VALVE SEAT ......................................... 1 . . . INSERT-HELICOIL, SPARKPLUG ............................... 2 . . . GUIDE-INTAKE VALVE ................................................ 1 . . . GUIDE-EXHAUST VALVE ............................................ 1 . . . STUD RING LOCKED..................................................... 2 . . . INSERT-HELICOIL ........................................................ 2 . . VALVE-INTAKE ............................................................... 1 . . SEAL- VALVE GUIDE, INTAKE .................................... 1 . . VALVE-EXHAUST............................................................ 1 . . RETAINER-INTAKE VALVE SPRINGS ......................... 1 . . RETAINER-ROTOCOIL, EXHAUST VALVE................. 1 . . SPRING-VALVE INNER................................................... 2 . . SPRING-VALVE OUTER.................................................. 2 . . SEAT-VALVE SPRING ..................................................... 2 . . KEY VALVE SPRING ....................................................... 4 . ROCKER ASSY-INT. VALVE ............................................ 4 . ROCKER ASSY-EXH.VALVE............................................ 4 . . BUSHING-INT. & EXH.VALVE ROCKER ..................... 1 . . SCREW-DRIVE #2............................................................. 1 . SHAFT-VALVE ROCKER .................................................. 4 . SCREW – SHAFT RETAINER ............................................ 4 . GASKET KIT-SINGLE CYLINDER .................................. 4 . . WASHER-TAB................................................................... 1 . . PACKING-CYL HD BASE ................................................ 1 . . GASKET-ROCKER COVER ............................................. 1 . . GASKET-EXH FLANGE ................................................... 1 . . SEAL-INTAKE MANIFOLD ............................................ 1 . . PACKING- PUSH ROD HOUSING TO C/C .................... 2 . . PACKING- PUSH ROD HOUSING TO CYL .................. 2 . LIFTER ASSY INTAKE-HYDRAULIC.............................. 4 . LIFTER ASSY EXHAUST-HYDRAULIC .......................... 4 . PISTON ................................................................................ 4 . RING SET-SINGLE CYL. ................................................... 4 . . RING-#1 ............................................................................. 1 . . RING-#2 ............................................................................. 1 . . RING ASSY.-#3 ................................................................. 1 (P/N 654718 expander and 649250-1 ring) 38 648008 . . RING-#4 ............................................................................. 1 39 630046 . PIN & PLUG ASSY.-PISTON ............................................. 4 40 643230 . BAFFLE ASSY. ................................................................... 2 41 641106 . BOLT-8.5” ............................................................................ 2 42 AN960-10L . WASHER-PLAIN ................................................................ 2 43 22022 . NUT-EXHAUST .................................................................. 8 44 634675 { . SPARK PLUG-(RHB32E) ................................................... 8 45 MS9021-210 . O-RING ............................................................................... 1 46 649965 . GASKET, BREATHER/OIL FILLER NECK ..................... 1 Use only P/N 634675 (RHB 32 E) long reach spark plugs in cylinder P/N 654974A1 and subsequent.

{

EQ6657 654974A1 654974 643130 654567 520112-3 643766 643767 643804-1 MS122121 646283 646985 652956 35971 652112 654442 654441 625393 24802 646088 646086 530367 21007 653824 654589 646564A2 501868 641066 653193 652459 646103 534610 536410 653888 653877 654867 654716 648005 654719 654717

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

02

02

2000

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

5 of 6 SB 00-2

TABLE 2 CYLINDER DIMENSIONS DESCRIPTION

New Min.

New Max.

5.252 .000

5.254 .002

CYLINDER AND HEAD ASSEMBLY Cylinder bore................................................................................................................Diameter: Cylinder bore out-of-round ........................................................................................................ : Cylinder bore ............................................................................ Maximum Allowable Oversize: Cylinder bore surface roughness- (new cylinder with phosphated cylinder bore) Cylinder bore Cross Hatch - Wet Honing ...........................................Angle off Horizontal {: Microfinish (measured in direction of piston travel after honing, no phosphate) ............ ..Ra |: Intake valve seat insert in cylinder head ......................................................................Diameter: Exhaust valve seat insert in cylinder head ...................................................................Diameter: Intake valve guide in cylinder head .............................................................................Diameter: Exhaust valve guide in cylinder head...........................................................................Diameter: Intake valve in guide ....................................................................................................Diameter: Exhaust valve in guide .................................................................................................Diameter: Intake valve face (to stem axis).........................................................................................Angle: Exhaust valve face (to stem axis)......................................................................................Angle: Intake valve stem .........................................................................................................Diameter: Exhaust valve stem.......................................................................................................Diameter:

.015 30 Ra - 60 Ra 22° - 32° 30 Ra - 50 Ra .0090 T .0120 T .0070 T .0100 T .0010 T .0025 T .0010 T ,0025 T .0010 L .0042 L .0035 L .0062 L 59°-45' to 60°-15’ 45°-00' to 45°-30’ .4335 .4340 .4333 .4340

ROCKER ARMS AND SHAFTS Rocker shaft .................................................................................................................Diameter: Rocker boss (inside)..........................................................................................Finish Diameter: Rocker shaft in rocker boss..........................................................................................Diameter: Rocker shaft in rocker arm bushing .............................................................................Diameter: Rocker arm in support bosses ............................................................................ Side Clearance: Rocker arm foot-to-valve stem tip(lifter deflated) Int. and Exh..................................Clearance: Rocker arm to valve spring retainer ............................................................................Clearance: Rocker shaft Retainer Screw...........................................................................................Torque:

.7172 .7182 .0002 L .0012 L .0015 L .060

.7180 .7192 .0020 L .0030 L .0020 L .200

.020 45 in. lbs 55 in. lbs

PISTONS, RINGS AND PINS Piston skirt in cylinder ( Moly Coated) perpendicular to pin bore...............................Diameter: .005 .009 Top piston ring in groove................................................................................... Side Clearance: .0015 .008 Second piston ring in groove ............................................................................ Side Clearance: .0015 .008 Third piston ring in groove ............................................................................... Side Clearance: .0035 .0055 Fourth piston ring in groove............................................................................... Side Clearance: .006 .008 .028 .044 Top ring gap at 1.00 ± .50 inches from open end of barrel..................................................Gap: .034 .050 Second ring gap at 1.00 ± .50 inches from open end of barrel.........................................Gap }: .020 .036 Third ring gap at 1.00 ± .50 inches from open end of barrel ...............................................Gap: .015 .031 Fourth ring gap at 1.00 ±. 50 inches from open end of barrel..............................................Gap: Piston pin in piston: ....................................................................................................Diameter: .0001 .0007 Piston pin ....................................................................................................................Diameter: 1.1243 1.1245 { Hone turn around areas up to .5 inch from the bottom of the cylinder skirt and the cylinder head barrel stop are exempt from the cross hatch angle requirement. |

Whenever cylinder barrels are honed measure barrel surface finish using Hommel Tester T500 P/N 191800 prior to returning cylinder to service. Tester and Software may be purchased from Hommel America New Britain, Ct.

}

Second ring gap must be at least .006 larger than Top Ring gap.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

02

02

2000

MO

DAY

YEAR

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

6 of 6 SB 00-2

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB00-3A

Compliance Will Enhance Safety

Supercedes SB00-3, SIL98-7, M 89-24 And M 90-12 TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

CRANKSHAFT, COUNTERWEIGHT AND CONNECTING ROD REPAIR INFORMATION

PURPOSE:

Provide information that may be required by the mechanic during replacement or overhaul.

COMPLIANCE: MODELS AFFECTED:

Next Overhaul or anytime crankshaft, counterweights or connecting rods are removed. ALL

This Service Bulletin contains:

Crankshaft Counterweight Hanger Blade And

Table 1. Engine Power Train, a list of all engine models and their major power train components.

Counterweight Inspection/Repair and Connecting Rod Inspection/Repair.

Table 2. A history of crankshaft part numbers.

Use the first Table to find the crankshaft and the following tables to reference components. Use the crankshaft, counterweight and connecting rod procedures during replacement or overhaul.

Table 3. A list of all crankshaft assemblies and their counterweight components. Table 4. Specifications for non-current production “wide rod” crankshafts. Table 5. Connecting Rod Specifications.

ISSUED

Refer to the latest revision of TCM Service Bulletin SB96-7 for assembly torque values.

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

02

2000

10

29

2004

 2004 Teledyne Continental Motors, Inc.

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

1 of 35 SB 00-3

A

TABLE 1. ENGINE POWER TRAIN ENGINE MODEL A-65

C/S ASSEMBLY 530199A1

{ CONROD A35160A2

CONROD BEARING 639640

BEARING SET 627246A2

A-75

530199A1

A35159A2

639640

C-75

}530196A1 ~530199A1 }530196A1 ~530199A1

A35160A2

639640

A35160A2

639640

C-90

˜530182

654795

639640

C-145-2

530860

654795

639640

652152A1

C-145-2H

531113

654795

639640

530516A2

E-165

352174A2

A36121

530383

646149A1

E-185-1,3,8,9,

537561

A36121

530383

646149A1

E-185-1,3,8,9,

352174

A36121

530383

646149A1

E-225-4,8

537561

A36121

530383

0-200-A

653012

654795

639640

0-200-B

653012

654795

639640

646149A1 627246A2 | 530058A6 627246A2

0-240

637069

654794

639640

637062A2

0-300-A

530860

654795

639640

652152A1

0-300-B

531113

654795

639640

530516A2

0-300-C

653382

654795

639640

652152A1

0-300-D

653382

654795

639640

652152A1

OIL CONTROL COLLAR

|530058A6 627246A2

|530058A6

C-85

530058A4 530058A5 530058A4 530058A5 530058A4 530058A5

0-470-2

No Longer Serviced

0-470-4

No Longer Serviced

0-470-7

No Longer Serviced

0-470-11

No Longer Serviced

0-470-13A

No Longer Serviced

0-470-15

|530058A6

No Longer Serviced

0-470-A

649141

655910

630826

 537401A3 € 646589A1  646590A1

0-470-C

649141

655910

630826

0-470-E

649141

655910

630826

 537401A3  537401A3 € 646589A1  646590A1

0-470-B

653697

655910

630826

 537401A3 € 646589A1

0-470-N

653697

655910

630826

 537401A3 € 646589A1

0-470-G

652005

655910

630826

 646591A3 € 646588A1 ƒ 646807A1 ‚ 627795A3

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

626739

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

2 of 35 SB 00-3

A

TABLE 1. ENGINE POWER TRAIN (continued) ENGINE MODEL

C/S ASSEMBLY

{ CONROD

CONROD BEARING

BEARING SET

OIL CONTROL COLLAR

O-470-J

649141

655910

630826

 537401A3 € 646589A1  646590A2

O-470-K

652039

655910

630826

 537401A3 € 646589A1  646590A2

O-470-L

652039

655910

630826

 537401A3 € 646589A1  646590A2

O-470-M

652039

655910

630826

 646807A1 € 646589A1  646590A2

O-470-P

652011

655910

630826

 646591A3 € 646588A1 ‚ 627795A3

O-470-R

649141

655910

630826

 537401A3 € 646589A1  646590A2

O-470-S

649141

655910

630826

€ 646589A1  646590A2

O-470-U

649138

655910

630826

€ 646589A1  646590A2

GO-300-A,C,D,E GTSIO-520-C GTSIO-520-D GTSIO-520-H GTSIO-520-K GTSIO-520-L GTSIO-520-M GTSIO-520-N IO-240-A IO, IOF-240-B, IO-346-A IO-360-A IO-360-AB IO-360-C IO-360-CB IO-360-D IO-360-DB IO-360-ES IO-360-G IO-360-GB IO-360-H IO-360-HB IO-360-J IO-360-JB

627822 653020 653020 653020 653020 653020 653020 653020 653164 653164 630778 653138 653129 653138 653129 653138 653129 653129 653139 653129 653139 653129 653139 653129

654794A1 655910 655910 655910 655910 655910 655910 655910 654793A1 654793A1 655910 654794A1 654793A1 654794A1 654793A1 654794A1 654793A1 654793A1 654794A1 654793A1 654794A1 654793A1 654794A1 654793A1

639640 630826 630826 630826 630826 630826 630826 630826 642338 642338 630826 639640 642338 639640 642338 639640 642338 642338 639640 642338 639640 642338 639640 642338

626943A1 633024A2 633024A2 633024A2 633024A2 633024A2 633024A2 633024A2 637062A3 637062A3 646594A1 646595A1 646597A1 646595A1 646597A1 646595A1 646597A1 646597A1 646595A1 646597A1 646595A1 646597A1 646595A1 646597A1

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

3 of 35 SB 00-3

A

TABLE 1. ENGINE POWER TRAIN (continued) ENGINE MODEL

C/S ASSEMBLY

{ CONROD

CONROD BEARING

IO-360-K IO-360-KB IO-470-C

653139 653129 652011

654794A1 654793A1 655910

639640 642338 630826

IO-470-D

649133

655910

630826

IO-470-E

649133

655910

630826

IO-470-F

649133

655910

630826

IO-470-H

652011

655910

630826

IO-470-J

652009

655910

630826

IO-470-K

652009

655910

630826

IO-470-L

652010

655910

630826

IO-470-M

649133

655910

630826

IO-470-N

652011

655910

630826

IO-470-R

630977

A36121

530383

IO-470-S

649133

655910

630826

IO-470-U

649135

655910

630826

IO-470-V

649135

655910

630826

IO-520-A

649134

655910

630826

IO-520-B IO-520-BA IO-520-BB IO-520-C

649895 649896 649898 649895

655910 655910 655911 655910

630826 630826 642398 630826

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

BEARING SET

646595A1 646597A1  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3  627795A3 € 646588A1  646591A3 € 646588A1  646591A3 646593A2 646593A2 646592A2 646593A2

OIL CONTROL COLLAR

626739

626739

626739

626739

626739

626739

626739

626739

626739

626739

626739

626739

626739

626739

626739 629680 629680 629680 629680

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

4 of 35 SB 00-3

A

TABLE 1. ENGINE POWER TRAIN (continued) ENGINE MODEL

C/S ASSEMBLY

{ CONROD

CONROD BEARING

IO-520-CB IO-520-D

649898 649134

655911 655910

642398 630826

IO-520-E

649134

655910

630826

IO-520-F

649134

655910

630826

IO-520-J

649134

655910

630826

IO-520-K

649134

655910

630826

IO-520-L

649134

655910

630826

IO-520-M „ IO-520-MB IO-520-P IO-550-A IO, IOF-550-B IO-550-B29, B33, B37 IO, IOF-550-C IO-550-C25, C29, C30 IO, IOF-550-D IO, IOF-550-E IO, IOF-550-F IO, IOF-550-G IO, IOF-550-L IO, IOF-550-N IO, IOF-550-P IO, IOF-550-R LIO-520-P LTSIO-360-E LTSIO-360-EB LTSIO-360-KB LTSIO-360-RB LTSIO-520-AE TSIO-360-A TSIO-360-AB TSIO-360-B TSIO-360-C TSIO-360-CB TSIO-360-D

649895 649898 649144-1 649900 649900 649900

655910 655911 655910 655911 655911 655002

649900 649900 646623 646623 646623 649900 646623 649900 649900 649900 649144-2 653137 653136 653136 653136 649144-2 653138 653129 653138 653139 653129 653139

MO 02

ISSUED DAY YEAR 02

2000

MO 10

OIL CONTROL COLLAR

629680 626739

630826 642398 630826 642398 642398 642398

646592A2 € 646588A1  646591A3 € 646588A1  646591A3 € 646588A1  646591A3 € 646588A1  646591A3 € 646588A1  646591A3 € 646588A1  646591A3 646593A2 646592A2 646591A4 646592A2 646592A2 646592A2

655911 655002

642398 642398

646592A2 646592A2

629680 629680

655911 655911 655911 655911 655911 655911 655911 655911 655000 654794 654793 654793 654793 655000 654794 654793 654794 654794 654793 654794

642398 642398 642398 642398 642398 642398 642398 642398 630826 639640 642338 642338 642338 630826 639640 642338 639640 639640 642338 639640

646592A2 646592A2 646592A2 646592A2 646592A2 646592A2 646592A2 646592A2 646591A4 646596A1 646597A1 646597A1 646597A1 646591A4 646595A1 646597A 646595A1 646595A1 646597A1 646595A1

626739 626739 626739 629680 626739 629680 629680 629680 626739

REVISED DAY YEAR 29

BEARING SET

2004

626739 626739 626739 626739 626739 629680 629680 626739 629680 629680 629680

626739

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

5 of 35 SB 00-3

A

TABLE 1. ENGINE POWER TRAIN (continued) ENGINE MODEL

C/S ASSEMBLY

{ CONROD

CONROD BEARING

TSIO-360-DB TSIO-360-E TSIO-360-EB TSIO-360-F TSIO-360-FB TSIO-360-G TSIO-360-GB TSIO-360-H TSIO-360-HB TSIO-360-JB TSIO-360-KB TSIO-360-LB TSIO-360-MB TSIO-360-RB TSIO-360-SB TSIO-470-B

653129 653139 653129 653139 653129 653139 653129 653139 653129 653129 653129 653129 653129 653129 653129 652011

654793 654794 654793 654794 654793 654794A1 654793 654794 654793 654793 654793 654793 654793 654793 654793 646437A2

642338 639640 642338 639640 642338 639640 642338 639640 642338 642338 642338 642338 642338 642338 642338 630826

TSIO-470-C

652011

646437A2

630826

TSIO-470-D

652348

646437A2

630826

TSIO-520-AE TSIO-520-AF TSIO-520-B TSIO-520-BB TSIO-520-BE TSIO-520-C

649144-1 649134 649895 649898 649898 649134

655000 655004 655004 655005 655005 655004

630826 630826 630826 642398 642398 630826

TSIO-520-CE TSIO-520-D TSIO-520-E TSIO-520-EB TSIO-520-G

649148 649895 649895 649898 649134

655001 655004 655004 655005 655004

642398 630826 630826 642398 630826

TSIO-520-H

649134

655004

630826

TSIO-520-J TSIO-520-JB TSIO-520-K TSIO-520-KB TSIO-520-L TSIO-520-LB TSIO-520-M

649895 649898 649895 649898 649895 649898 649134

655004 655005 655004 655005 655004 655005 655004

630826 642398 630826 642398 630826 642398 630826

TSIO-520-N TSIO-520-NB TSIO-520-P

649895 649898 649134

655004 655005 655004

630826 642398 630826

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

BEARING SET

646597A1 646595A1 646597A1 646595A1 646597A1 646595A1 646597A1 646595A1 646597A1 646597A1 646597A1 646597A1 646597A1 646597A1 646597A1  627795A3 € 646588A1  627795A3 € 646588A1  627795A3 € 646588A1 646591A4  646591A3 646593A2 646592A2 646592A2 € 646588A1  646591A3 646592A2 646593A2 646593A2 646592A2 € 646588A1  646591A3 € 646588A1  646591A3 646593A2 646592A2 646593A2 646592A2 646593A2 646592A2 € 646588A1  646591A3 646593A2 646592A2 € 646588A1  646591A3

OIL CONTROL COLLAR

626739 626739 626739 626739 626739 629680 629680 629680 626739 626739 629680 629680 629680 626739 626739 629680 629680 629680 629680 629680 629680 626739 629680 629680 626739

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

6 of 35 SB 00-3

A

TABLE 1. ENGINE POWER TRAIN (continued) ENGINE MODEL

C/S ASSEMBLY

{ CONROD

CONROD BEARING

TSIO-520-R

649134

655004

630826

TSIO-520-T

649134

655004

630826

TSIO-520-UB TSIO-520TSIO-520-VB TSIO-520-WB TSIO-550-A TSIO-550-B TSIO, TSIOF550C

649898 655213 649898 649898 649900 649900 649900

655005 655006 655005 655005 655001 655001 655001

TSIO, TSIOF550-E TSIOL-550-A TSIOL-550-B TSIOL-550-C

649900 652359 652359 652359

BEARING SET

OIL CONTROL COLLAR

642398 642398 642398 642398 642398 642398 642398

€ 646588A1  646591A3 € 646588A1  646591A3 646592A2 646592A2 646592A2 646592A2 646592A2 646592A2 646592A2

626739

629680 629680 629680 629680 629680 629680 629680

655001

642398

646592A2

629680

655001 655001 655001

642398 642398 642398

646592A2 646592A2 646592A2

629680 629680 629680

626739

FOOT NOTES:  See Table 5 for new and old connecting rod part numbers and hardware to connecting rod specified usage. | With 633141 thrust washer. } Tapered crankshaft with removable prop flange. ~ Flange (prop) type crankshaft.  Has flange type bearing for use with Phase 1 style crankcase and crankshaft. See TCM Service Bulletin M78-9 or latest revision. € Thrust washer type bearings for use with Phase 2 style crankcase and crankshaft. See TCM Service Bulletin M78-9 or latest revision.  For use with Phase 3 style crankcase and crankshaft. See TCM Service Bulletin M78-9 or latest revision. ‚ For 0-470-G engines with modernized crankshafts using oil transfer collar. ƒ For 0-470-G engines with modified crankshafts. Remove and discard nylon wipers for 0470G.

„ Non-Production Engine

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

7 of 35 SB 00-3

A

TABLE 2. CRANKSHAFT ASSEMBLY PART NUMBER HISTORY SPEC. O-200-A O-200-B O-300-A O-300-C O-300-D O-470-A O-470-B O-470-C O-470-E O-470-F O-470-G O-470-J O-470-K O-470-L O-470-M O-470-N O-470R O-470-S O-470-U GO-300-A, C, D, E GIO-550-A } GTSIO-520-C GTSIO-520-D GTSIO-520-H GTSIO-520-K GTSIO-520-L GTSIO-520-M GTSIO-520-N IO-240-A IO, IOF-240-B IO-346-A IO-360-A IO-360-AB IO-360-C IO-360-CB IO-360-D IO-360-DB IO-360-ES IO-360-G IO-360-GB

MO 02

CRANKSHAFT ASSEMBLY 653012 653012 530860  653382  653382 649141 653697 649141 649141 649141 652005 649141 652039 652039 652039 653697 649141 649141 649138 627822 652800A1 653020 653020 653020 653020 653020 653020 653020 653164 653164 630778 653138 653129 653138 653129 653138 653129 653129 653139 653129

ISSUED DAY YEAR 02

2000

MO 10

SUPERSEDES

SUPERSEDES

SUPERSEDES

531434 531434 652110 652110 633225 633227 633225 633225 633225 633256 633225 633219 633219 633219 633227 633225 633225 643911

628124 628124 537290 539576 537290 537290 537290

652832 652832 652832 652832 652832 652832 652832

652821 652821 652821 652821 652821 652821 652821

652001 652001 652001 652001 652001 652001 652001

635104 635104 635104 635104 635104 635104 635104

652047 652014 652047 652014 652047 652014

649785 643627 649785 643627 649785 643627

639200 642350 639200 642350 639200 642350

634479

652048 652014

639786 643627

642350

REVISED DAY YEAR 29

SUPERSEDES

2004

537290 539665 539665 539665 539576 537290 641905

634479 634479

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

8 of 35 SB 00-3

A

TABLE 2. CRANKSHAFT ASSEMBLY PART NUMBER HISTORY (continued) SPEC. IO-360-H IO-360-HB IO-360-J IO-360-JB IO-360-K IO-360-KB IO-470-C IO-470-D IO-470-E IO-470-F IO-470-G IO-470-H IO-470-J IO-470-K IO-470-L IO-470-M IO-470-N IO-470-P IO-470-R IO-470-S IO-470-U IO-470-V IO-520-A IO-520-B IO-520-BA IO-520-BB IO-520-C IO-520-CB IO-520-D IO-520-E IO-520-F IO-520-J IO-520-K IO-520-L IO-520-M IO-520-MB IO-520-P IO-550-A IO, IOF-550-B IO, IOF-550-C IO, IOF-550-D IO, IOF-550-E IO, IOF-550-F IO, IOF-550-G IO, IOF-550-L

MO 02

CRANKSHAFT ASSEMBLY 653139 653129 653139 653129 653139 653129 652011 649133 649133 649133 649133 652011 652009 652009 652010 649133 652011 629882 630977 649133 649135 649135 649134 649895 649896 649898 649895 649898 649134 649134 649134 649134 649134 649134 649895 649898 649144-1 649900 649900 649900 646623 646623 646623 649900 646623

ISSUED DAY YEAR 02

2000

MO 10

SUPERSEDES 652048 652014 652048 652014 652048 652014 652006 630927 630927 630927 630927 652008 643089 643089 643090 630927 652006 629366 630927 632195 632195 631716 633620 639243 646438 633620 646438 631716 631716 631716 631716 631716 631716 633620 646438

639786 643627 639786 643627 639786 643627 633258 627530 627530 627530 627530 628995 633246 633246 630886 627530 643091

SUPERSEDES

SUPERSEDES

642350 642350 642350 626784

630977 628358 628358 628694

627348

630932

629309

627530

642396 642396

642396

646604 646604 646604

REVISED DAY YEAR 29

SUPERSEDES

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

9 of 35 SB 00-3

A

TABLE 2. CRANKSHAFT ASSEMBLY PART NUMBER HISTORY (continued) SPEC. IO-550-M } IO, IOF-550-N IO, IOF-550-P IO, IOF-550-R LIO-520-P LTSIO-360-E LTSIO-360-EB LTSIO-360-KB LTSIO-360-RB LTSIO-520-AE TSIO-360-A TSIO-360-AB TSIO-360-B TSIO-360-C TSIO-360-CB TSIO-360-D TSIO-360-DB TSIO-360-E TSIO-360-EB TSIO-360-F TSIO-360-FB TSIO-360-G TSIO-360-GB TSIO-360-H TSIO-360-HB TSIO-360-JB TSIO-360-KB TSIO-360-LB TSIO-360-MB TSIO-360-RB TSIO-360-SB TSIO-470-B TSIO-470-C TSIO-470-D TSIO-520-AE TSIO-520-AF TSIO-520-B TSIO-520-BB TSIO-520-BE TSIO-520-C TSIO-520-CE TSIO-520-D TSIO-520-E TSIO-520-EB TSIO-520-G TSIO-520-H TSIO-520-J

MO 02

CRANKSHAFT ASSEMBLY 654359 649900 649900 649900 649144-2 653137 653136 653136 653136 649144-2 653138 653129 653138 653139 653129 653139 653129 653139 653129 653139 653129 653139 653129 653139 653129 653129 653129 653129 653129 653129 653129 652011 652011 652348 649144-1 649134 649895 649898 649898 649134 649148 649895 649895 649898 649134 649134 649895

ISSUED DAY YEAR 02

2000

MO 10

SUPERSEDES

SUPERSEDES

652045 652015 652015

641382 643633 643633

643126-1 652047 652014 652047 652048 652014 652048 652014 652048 652015 652048 652014 652048 652014 652048 652014 652014 652015 652014 652014

649785 643627 649785 639786 643627 639786 643627 639786 643633 639786 643627 639786 643627 639786 643627 643627 643633 643627 643627

652008 652008 652007 643126 631716 633620 646438 646438 631716 646683 633620 633620 646438 631716 631716 633620

REVISED DAY YEAR 29

2004

SUPERSEDES

SUPERSEDES

639200 642350 639200

634479 634479

642350 642350 642376 642350 642350 642350 642350 642376 642350

628995 628995 632494

642396 642396

642396

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

10 of 35 SB 00-3

A

TABLE 2. CRANKSHAFT ASSEMBLY PART NUMBER HISTORY (continued) SPEC. TSIO-520-T TSIO-520-UB TSIO-520-VB TSI0O520-WB TSIO-550-A TSIO-550-B TSIO, TSIOF550-C TSIO, TSIOF550-E TSIOL-550-A TSIOL-550-B TSIOL-550-C

CRANKSHAFT ASSEMBLY 649134 649898 649898 649898 649900 649900 649900

SUPERSEDES

SUPERSEDES

631716 646438 646438 646438

642396 642396 642396

SUPERSEDES

SUPERSEDES

649900 652359 652359 652359

 653382 Crankshaft, 653381 Gear and 4 each 630692 Screws must be used together.  653382 Crankshaft, 630690 Gear and 4 each 630692 Screws must be used together. } Used in non-production engines only.

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

11 of 35 SB 00-3

A

TABLE 3. CRANKSHAFT ASSEMBLIES C/S ASSY. 530860

HNGR. BLD. BUSH. } 531015 & 530863

531113

531015 & 530863

627822

626566

628124

531015 & 530863

646623

350998

649133

350998

649134

350998

649135

649138

649141

649144-1

649144-2

649148

MO 02

350998

350998

350998

350998

350998

350998

ISSUED DAY YEAR 02

2000

BUSH. I.D. .4613 .4643 .435 .438 .4613 .4643 .435 .438 .732 .739 .4613 .4643 .435 .438 .622 .626

.622 .626 .622 .626

.622 .626

.622 .626

.622 .626 .622 .626 .622 .626 .622 .626

MO 10

CWT. QTY. 1

C/S CWT. 531017

CWT. BUSH. 531016

1

530864

530866

1

531017

531016

1

530864

530866

2 2 2 1

627821

626564

531017

531016

1

530864

530866

2

639195

639193

1

BUSH. I.D. .4613 .4643 .435 .438 .4613 .4643 .435 .438 .732 .739 .4613 .4643 .435 .438 .622 .626

CHEEK LOC. 2

CWT. PIN 630261-15

 2 2

630261-15

 2 5 8 2

630261-11

| 630261-15



643626-103

1

639196

5

643626-104

2 2 2

639195 639195 639195

2 5 2

643626-101

1

639196

5

643626-103

1

639196

5

643626-104

2

639195

2

643626-101

1

639196

5

643626-104

1

639196

5

643626-106

2

639195

2

643626-101

1

639195

5

643626-104

1

639195

5

643626-106

1

639195

2

643626-101

1

639195

2

643626-104

1

639195

2

643626-104

1

639195

2

643626-105

1

639195

2

643626-104

1

639195

2

643626-105

2

639195

2

643626-105

1

639196

5

643626-103

1

639196

5

643626-104

REVISED DAY YEAR 29

2004

639193

639193

639193

639193

639193

.622 .626

.622 .626

.622 .626 .622 .626 .622 .626 .622 .626

5

530868

402805 -3

.3758 .3768

3 3 3 5

633976

629004

530868

402805 -3

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

6

5

639193

.491 .492

2

639196

639193

CWT. RET. RET. ORDER PLATE RING 5 530868 402805 -3 6

6

643626-105

.622 .626 .622 .626

.3758 .3768

2

2

639193

PIN DIA. .3758 .3768

643626-101

.565 .566 .474 .475 .527 .528 .556 .557 .556 .557 .474 .475 .527 .528 .556 .557 .527 .528 .507 .508 .556 .557 .527 .528 .507 .508 .556 .557 .527 .528 .527 .528 .565 .566 .527 .528 .565 .566 .565 .566 .474 .475 .527 .528

6 4 5 6 6 6 4 5 6 5 4 1/2 6 5 4 1/2 6 5 5 6 5 6 6 4 5

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

12 of 35 SB 00-3

A

TABLE 3. CRANKSHAFT ASSEMBLIES (continued) C/S ASSY. 649895

649896

649898

649900

652005

652009

652010

HNGR. BLD. BUSH } 350998

350998

.622 .626

350998

.622 .626

350998

.622 .626

350998

.622 .626

350998

350998

652039

350998

652348

350998

652359

.622 .626

350998

652011

BUSH I.D. .622 .626

.622 .626 .622 .626 .622 .626 .622 .626

350998

.622 .626

653020

628975

.754 .757

653129

639580

.604 .607

MO 02

ISSUED DAY YEAR 02

2000

MO 10

CWT. QTY. 2

C/S CWT. 639195

1

CHEEK LOC. 2

643626-101

639196

5

643626-103

1

639196

5

643626-104

2

639195

2

643626-101

1

639196

5

643626-101

1

639196

5

643626-103

2

639195

2

643626-105

1

639196

5

643626-103

1

639196

5

643626-104

2

639195

2

643626-105

1

639196

5

643626-103

1

639196

5

643626-104

1

639197

2

643626-105

1

639197

2

643626-108

1

639195

2

643626-101

1

639195

2

643626-104

2

639195

2

643626-101

2

639195

5

643626-104

2 2 2 2 2

639195 639195 639195 639195 639195

2 5 2 5 2

643626-101

1

639196

5

643626-103

1

639196

5

643626-104

2

639195

2

643626-105

1

639196

5

643626-103

1

639196

5

643626-106

2 2 2 1

652833

628978

.754 .757

643626-104

639199

639198

.604 .607

2 5 8 2

1

639199

2

643626-111

REVISED DAY YEAR 29

2004

CWT. BUSH. 639193

639193

639193

639193

639193

639193

639193

639193 639193 639193

639193

BUSH I.D. .622 .626

.622 .626

.622 .626

.622 .626

.622 .626 .622 .626 .622 .626 .622 .626 .622 .626 .622 .626

.622 .626

CWT. PIN

643626-101 643626-101

643626-110

PIN DIA. .556 .557 .474 .475 .527 .528 .556 .557 .556 .557 .474 .475 .565 .566 .474 .475 .527 .528 .565 .566 .474 .475 .527 .528 .565 .566 .594 .595 .556 .557 .527 .528 .556 .557 .527 .528 .556 .557 .556 .557 .556 .557 .474 .475 .527 .528 .565 .566 .474 .475 .507 .508 .527 .528 .498 .499 .552 .553

CWT. ORDER 6

PLATE 643629

RET. RING 629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

643629

629104

631808

629004

653143

629004

4 5 6 6 4 6 4 5 6 4 5 6 4 6 5 6 5 6 6 6 6 6 4 5 6 4 4 1/2 3 3 3 4 1/2 6

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

13 of 35 SB 00-3

A

TABLE 3. CRANKSHAFT ASSEMBLIES (continued) C/S ASSY. 653136

HNGR. BLD. BUSH } 639580

639580

653137

653138

639580

653139

639580

BUSH I.D. .604 .607 .604 .607 .604 .607 .604 .607

653382

639580

.604 .607

653697

350998

.622 .626

652800A1

628975

.754 .757

350998

.622 .626

 654359



CWT. QTY. 1

C/S CWT. 639199

CWT. BUSH. 639198

1

639199

1

639199

1

639199

1 1 1

639199 639199 639199

1

639199

1

639199

639198

.604 .607

1 2

639199 639195

639193

.622 .626

2

639195

2 2 2 1 1

652833 652833 652833 639195

639198

639198 639198

BUSH I.D. .604 .607

CHEEK LOC. 2

643626-110

2

643626-111

2

643626-110

2

643626-111

2 2 2

643626-109

2

643626-111

2

643626-112

2 2

643626-112 643626-105

5

643626-105

2 5 8 2 2

643626-104

.604 .607 .604 .607 .604 .607

628978

.754 .757

639193

.622 .626

CWT. PIN

643626-110

643626-105

PIN DIA. .498 .499 .552 .553 .498 .499 .552 .553 .545 .546 .498 .499 .552 .553 .520 .521

CWT. ORDER 4 1/2

PLATE 653143

RET. RING 629004

653143

629004

653143

629004

653143

629004

5

653143

629004

5 6

643629

629104

652594

629004

643629

629104

6 4 1/2 6 6 6 4 1/2 6

.565 .566 .565 .566 .527 .528

6 3 3 3 6 6

.565 .566

 Used in non-production engines only.  If replacing 630261 pin with 643626 pin the 643629 plate must be used.

} Replacement crankshaft blade bushing may be purchased in standard and oversize dimensions as listed below:

MO 02

Crankshaft Blade Bushing P/N

STANDARD

P .0015

P .003

P .005

P .010

P .015

350998

AVAILABLE

AVAILABLE

AVAILABLE

AVAILABLE

AVAILABLE

AVAILABLE

530863

AVAILABLE

N/A

AVAILABLE

AVAILABLE

N/A

N/A

531015

AVAILABLE

N/A

AVAILABLE

AVAILABLE

N/A

N/A

537038

AVAILABLE

N/A

N/A

N/A

N/A

N/A

626566

AVAILABLE

N/A

N/A

AVAILABLE

N/A

N/A

628975

AVAILABLE

N/A

AVAILABLE

AVAILABLE

AVAILABLE

N/A

639580

AVAILABLE

AVAILABLE

AVAILABLE

AVAILABLE

AVAILABLE

AVAILABLE

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

14 of 35 SB 00-3

A

TABLE 4. WIDE ROD CRANKSHAFTS (NOT CURRENT PRODUCTION) C/S ASSEMBLY

HNGR. BLD. BUSH

BUSH I.D.

CWT. QTY.

352174

350996

.622 .626

2

537561

350998

(E-1851,3,8,9,11 &

.622 .626

537038

(E-1851,3,8,9,11)

E-225-4,8) 537290

350998

(O-470A,C,E,F,J

537038

& R) 539576

350998

(O-470-B & N)

537038

627576

350998

(O-470-G) 537038 539665

350998

(O-470K,L,M)

350998

627587

350998

2

1

352117

350997

.622 .626

.6534 .6554 .622 .626

1

537049

537044

1

352117

350997

.6534 .6554 .622 .626

1

537049

537044

1

352117

350997

.6534 .6554 .622 .626

1

537049

537044

1

352117

350997

.6534 .6554 .622 .626

1

625818

625817

2

352117

350997

352117

350997

.622 .626 .622 .626

2

352117

350997

2

352117

350997

.622 .626 .622 .626

2

352117

350997

2

352117

350997

350998

.622 .626

2

352117

350998

.622 .626

2

350998

.622 .626 .622 .626

350998

350998

& S) (IO-470-H)

350998 629366 (IO-470-R)

350998

629882

350998

(IO-470-P,T) 350998

02

.622 .626

2

(IO-470-D,

MO

350977

350997

350998

627348

352117

CWT..

352117

(IO-470-C)

E,F,G,M,

CHEEK LOC.

2

350998

627530

BUSH I.D.

.622 .626 .622 .626

(O-470-P)

626784

CWT. | BUSH.

C/S {

ISSUED DAY YEAR 02

2000

PIN DIA.

CWT. ORDER

PLATE }

630261-4

.5554 .5574

6

352115

2

630261-4

.5554 .5574

6

.6534 .6554 .622 .626

2

630261-4

5

2

630261-4

.5554 .5574 .5554 .5574

.6534 .6554 .622 .626

2

630261-4

2

630261-2

.5554 .5574 .5652 .5662

5

.6534 .6554 .622 .626

2

630261-1

2

630261-5

.6483 .6523 .622 .626

2

630261-5

2

630261-4

CWT. PIN 

.5947 .5967 .5931 .5951

6

.5931 .5951 .5554 .5574

6

.5554 .5574 .5554 .5574

6

.5554 .5574 .5554 .5574

6

.5554 .5574 .5554 .5574

6

630261-4

.622 .626 .622 .626

5

630261-4

2

630261-4

.622 .626 .622 .626

5

630261-4

2

630261-4

350997

.622 .626

5

630261-4

.5554 .5574

6

352117

350997

.622 .626

2

630261-4

.5554 .5574

6

2

352117

350997

5

630261-4

352117

350997

2

630261-4

.5554 .5574 .5554 .5574

6

2

.622 .626 .622 .626

.622 .626 .622 .626

2

352117

350997

5

630261-4

352117

350997

2

630261-2

.5554 .5574 .5554 .5574

6

1

.622 .626 .622 .626

.622 .626

1

352117

350997

.622 .626

2

630261-2

.5554 .5574

6

2004

352115

352116

352115

352116

352115

352116

6

2

29

352116

9

630261-4

10

352115

6

5

REVISED DAY YEAR

352115

352116

352115

352116

352115

352116

352115

352116

352115

352116

352115

352116

352115

352116

6

6

6

6

6

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

352116

6

.622 .626 .622 .626

MO

RET. ~ RING

15 of 35 SB 00-3

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TABLE 4. WIDE ROD CRANKSHAFTS (continued) (NOT CURRENT PRODUCTION) C/S ASSEMBLY

HNGR. BLD. BUSH

BUSH I.D.

CWT. QTY.

CWT. | BUSH.

BUSH I.D.

CHEEK LOC.

350998

.622 .626

1

352117

350997

.622 .626

2

630261-4

1

537049

537044

630261-4

2

352117

350997

.6534 .6554 .622 .626

2

.6534 .6554 .622 .626

2

630261-4

.622 .626 .622 .626

2

352117

350997

5

630261-3

2

352117

350997

.622 .626 .622 .626

2

630261-4

2

352117

350997

630261-4

2

352117

350997

.622 .626 .622 .626

5

350998

.622 .626 .622 .626

2

630261-4

350998

.622 .626

1

631968

350997

.622 .626

5

350998

.622 .626

1

631968

350997

.622 .626

5

628358 (IO-470-J,K)

537038 350998

628694 (IO-470-L)

350998

629309

350998

(IO-470-N) 350998 632195 (IO-470-U & V)

C/S. { CWT.

CWT. PIN

PIN DIA.

CWT. ORDER

.5554 .5574

6

.5554 .5574 .5554 .5574

5

.527 .528 .5554 .5574

5

PLATE } 352115

352116

352115

352116

352115

352116

352115

352116

6

6

.5554 .5574 .622 .626

6

630261-3

.622 .626

5

630261-32

.622 .626

41/2

6

Counterweight P/N 352117 superseded by P/N 639195 Counterweight P/N 537049 superseded by P/N 639205; P/N 639205 superseded by P/N 639205A1 Counterweight P/N 625818 superseded by P/N 639210; P/N 639210 superseded by P/N 639210A1 Bushing P/N 350997 superseded by 639193 Bushing P/N 537044 superseded by 639204 Plate P/N 352115 superseded by P/N 629105; P/N 629105 superseded by P/N 635623; P/N 635623 superseded by P/N 643629 Snap Ring P/N 352116 superseded by P/N 629104 Counterweight Suppression: When using P/N 630621-pins you must use P/N 635623 retainer plates When using P/N 643626-pins you must use P/N 643629 retainer plates

{

| } ~ 

Original Part Number 630261-4 630261-27 630261-3 630261-2 630261-32 N/A 630261-5 N/A N/A N/A N/A 630261-11 630261-15 630261-17

MO 02

ISSUED DAY YEAR 02

2000

MO 10

Pin Diameter .5554- .5574 .474 - .475 .5270 - .5280 .5652 - .5662 .507 - .508 N/A .5931 - .5951 N/A N/A N/A N/A .4916 - .4921 .3758 - .3768 .6700 - 6710

Superseded Part Number 630261-35 630261-38 630261-37 630261-40 630261-39 630261-34 630261-36 630261-41 630261-43 630261-44 N/A N/A N/A N/A

REVISED DAY YEAR 29

2004

Pin Diameter .5559 - .5569 .474 - .475 .5270 - .5280 .5652 - .5662 .507 - .508 .4902 - .4906 .5931 - .5951 .545 - .546 .498 - .499 .552 - .553 N/A N/A N/A N/A

Current Part Number 643626-101 643626-103 643626-104 643626-105 643626-106 643626-107 643626-108 643626-109 643626-110 643626-111 643626-112 N/A N/A N/A

Pin Diameter .556 - .557 .474 - .475 .527 - .528 .565 - .566 .507 - .508 .490 - .491 .594 - .595 .545 - .546 .498 - .499 .552 - .553 .520 - .521 N/A N/A N/A

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Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

RET. ~ RING

16 of 35 SB 00-3

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COUNTERWEIGHT IDENTIFICATION SEE FIGURES 1A THROUGH 1 I.

FIGURE 1A. 530864 COUNTERWEIGHT ASSEMBLY MADE WITH 530865 COUNTERWEIGHT AND 530866 BUSHINGS

FIGURE 1B. 531017 COUNTERWEIGHT ASSEMBLY MADE WITH 530865 COUNTERWEIGHT AND 531016 BUSHINGS

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

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A

FIGURE 1C. 639196 COUNTERWEIGHT ASSEMBLY MADE WITH 631903 COUNTERWEIGHT AND 639193 BUSHINGS

FIGURE 1D. 639197 COUNTERWEIGHT ASSEMBLY MADE WITH 633339 COUNTERWEIGHT AND 639193 BUSHINGS

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

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FIGURE 1E. 639195 COUNTERWEIGHT ASSEMBLY MADE WITH 351000 COUNTERWEIGHT AND 639193 BUSHINGS

FIGURE 1G. 652833 COUNTERWEIGHT ASSEMBLY MADE WITH 652834 COUNTERWEIGHT AND 628978 BUSHINGS FIGURE 1F. 639199 COUNTERWEIGHT ASSEMBLY MADE WITH 629693 COUNTERWEIGHT AND 639198 BUSHINGS

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

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FIGURE 1G. 652833 COUNTERWEIGHT ASSEMBLY MADE WITH 652834 COUNTERWEIGHT AND 628978 BUSHINGS

FIGURE 1H. 627821 COUNTERWEIGHT ASSEMBLY MADE WITH 626688 COUNTERWEIGHT AND 626564 BUSHINGS

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

20 of 35 SB 00-3

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.94

.12

X-1794-B Pin One Side Only

FIGURE 1 I. 639205 & 639210 COUNTERWEIGHT ASSEMBLY MADE WITH 351000 COUNTERWEIGHT 639205 COUNTERWEIGHT USES 639204 BUSHINGS 639210 COUNTERWEIGHT USES 630209 BUSHINGS

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

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CRANKSHAFT COUNTERWEIGHT HANGER BLADE AND COUNTERWEIGHT INSPECTION AND BUSHING REPLACEMENT

3. Federal Dimension Air Gauge with correct size Setting Ring and Air Plug or equivalent. See Figures 3 and 4 for specified bore sizes.

Special Instructions For GTSI0-520 Engines

Starrett No. 78 Series 3 point contact inside micrometers. Contact the L.S. Starrett Company 1-800-541-8887.

Service bulletin M90-12 mandated the replacement of all part number 631810 counterweights with part number 652833 or later design counterweights. Earlier design counterweights part number 631810 must be discarded. NOTE: Part number 652833 or later design counterweights that do not meet the inspection criteria must be replaced. Scrap all part number 631810 counterweights. Starter adapter viscous dampers must be replaced with new items at engine overhaul, whenever the starter adapter is overhauled or replaced, or whenever inspection per the latest revision of CSB94-4D indicates distress to either the starter shaft gear or to the crankshaft gear. If either gear shows distress, both gears must be replaced in addition to the starter adapter. NOTE: Refer to CSB94-4D or latest revision for specific instructions on starter adapter inspection and replacement. The following is for all Models: Inspection And Bushing Replacement Crankshaft hanger blade and counterweight bushing replacement must be performed using the specified procedure and the following special tools: 1. Borrough’s 8077A Crankshaft Hanger Blade Bushing Removal/Installation set or equivalent. 2. Borrough’s 8077C Counterweight Bushing Removal/Installation Fixture or equivalent.

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

Or

Warning Removing and replacing bushings with makeshift tools and methods may result in irreparable damage to the crankshaft and / or counterweight. Counterweight Removal and Inspection 1. Remove the counterweight snap rings from the two bores in the counterweight using snap ring pliers with a 90 degree bend. 2. Remove the counterweight pin retaining plates from their bores. The plates are a close tolerance fit and may require slight rocking to remove them. 3. Remove Counterweight pins with a magnet. Counterweight Inspection Only the case hardened (tuftrided) counterweight assemblies P/N 639195, 639196, 639197, 639199, 639205, or later design and 627821, 530864, 531017 (non-tuftrided) counterweight assemblies may be considered for bushing replacement. Discard all other earlier design counterweights. 1. Inspect the bump surface of the counterweight as shown in Figure 2. The bump surface contact marks must not exceed .005 inches in depth. 2. Counterweight bushings must be removed using the specified tools and discarded. Inspect the counterweights using the following procedure:

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INSPECT THIS BUMP SURFACE AREA FIGURE 2. COUNTERWEIGHT BUMP SURFACE INSPECTION

a) Presence of tuftriding on counterweight assemblies P/N 639195, 639196, 639197, 639199, 639205, may be determined by using a 4% solution (by volume) of copper sulfate and water (CUSO4). After removing the counterweight bushing, thoroughly clean the bushing bore. Place one drop of the 4% copper sulfate solution on the cleaned surface of the counterweight bushing bore. Allow at least 15 seconds for the chemical reaction to take place. Formation of red deposits indicates the absence of tuftriding. Discard all counterweights with this indication. b) The crankshaft and counterweights must be magnetic particle inspected by a certified technician.

CAUTION… Before magnetic particle inspection of any part, it must be completely cleaned and free of dirt, carbon, varnish, gum and paint. Plug small holes leading to obscure cavities with tight-fitting wood plugs or with a hard grease which is soluble in lubricating oil. This will prevent particles from lodging in places where they would be difficult to remove and places not subject to visual

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

inspection. After magnetic particle inspection remove all such plugs and clean the part thoroughly in solvent. Dry the part with compressed air. Check for complete demagnetization. Where magnetic particle inspection is required, use fluorescent method, wet continuous procedure. Refer to the latest revision of ASTM E 1444 for specific methods and procedures based on type of inspection being performed. ACCEPT / REJECT CRITERIA Rejectable discontinuities are any of the following: fatigue cracks, forming cracks, grinding and heat treat cracks, embrittlement cracks, seams, laps, burst. Parts which contain linear indications which cannot be reworked or indications which break into corners, edges, holes, thread roots, fillets, or keyways must be rejected. The particular magnetic particle manufacturer's information regarding use, safety data and disposal must be followed carefully.

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23 of 35 SB 00-3

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FIGURE 3. COUNTERWEIGHT BUSHING BORE INSPECTION COUNTERWEIGHT ASSEMBLY

COUNTERWEIGHT

“A” DIAMETER

530864

530865

.687 / .688

531017

530865

.687 / .688

627821

626688

1.000 / 1.001

639195 639205

.8745 / .8755

351000

639210 639196

631903

.8745 / .8755

639197

633339

.8745 / .8755

639199

629693

1.000 / 1.001

c) Crankshafts must be ultrasonically inspected in accordance with MSB9610. Refer to the applicable engine overhaul manual for specific instructions. Crankshafts exhibiting reject-able indications must be discarded. d) The counterweight bushing bores must be smooth. Counterweights with worn, pitted, fretted or out of round bushing bores must be discarded. Use an air gauge with correct size air plug and setting ring to verify the bushing bore diameter. Bushing bores must measure

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

as specified total indicator reading (T.I.R.) See Figure 3, Counterweight Bushing Bore Inspection, for bushing bore diameters. Counterweights with bushing bores exceeding the specified dimensions must be scrapped. e) Carefully inspect the counterweight counterbores for signs of wear in the wall that retains the counterweight pin retaining plates. This area is adjacent to the inside edge of the retaining ring groove. It may appear as an additional step and/or taper of the hole into the

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

24 of 35 SB 00-3

A

retaining ring groove. If any wear is evident the counterweight must be replaced. f) If no plate wear is evident, check the retaining ring groove in each hole for wear patterns which can affect the seating of the retaining ring. Any worn condition which may affect retaining ring seating will require replacement of the counterweight. g) Crankshaft counterweights are matched in pairs with a maximum weight variation of two (2) grams. If either counterweight is damaged a matched pair must be procured and replaced on that cheek. h) The counterweight bushings must be replaced using the specified tools. Refer to

Figures 5A and 5B for specifications regarding counterweight bushing removal and replacement. The replacement bushings must have an interference fit of .0015 to .003 inch into the bushing bores. 3. The crankshaft counterweight hanger blade

bushings must be replaced using the specified tools and following procedure. Refer to Figure 6 for specifications regarding crankshaft hanger blade bushing removal and replacement. a) After removal, measure the inside diameter of the crankshaft counterweight hanger blade bushing holes.

FIGURE 4. CRANKSHAFT HANGER BLADE BUSHING BORE INSPECTION

MO 02

CRANKSHAFT ASSEMBLY

“A” DIAMETER

CRANKSHAFT ASSEMBLY

“A” DIAMETER

530860 646623 649133 649134 649135 649138 649141 649148 649895 649896 649898 649900 652005 652009 652010

.687 / .688 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755

652011 652039 652348 652359 653020 653129 653136 653137 653138 653697 649144-1 649144-2 652800A1 654359 653382

.8745 / .8755 .8745 / .8755 .8745 / .8755 .8745 / .8755 1.1245 / 1.1255 .815 / .816 .815 / .816 .815 / .816 .815 / .816 .8745 / .8755 .8745 / .8755 .8745 / .8755 1.1245 / 1.1255 .8745 / .8755 .815 / .816

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

25 of 35 SB 00-3

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a) The bushing holes must be smooth. Crankshafts with worn, pitted, fretted or out of round bushing holes must be discarded. b) Using the same tools that were used for bushing removal install the new bushings. The replacement bushings must have an interference fit of .0015 to .003 inch into the bushing holes. c) Refer to Figure 6 for specifications regarding crankshaft hanger blade bushing removal and replacement. The new bushings must be installed into the same positions as the original bushings. Replacement crankshaft blade bushings are available in standard and some oversize dimensions. Refer to note } Table 3.

4. Dimensional verification of installed

bushings: a) Because of the close tolerances required, the replaced bushings must be inspected using an air gauge with correct size air plug and setting ring. Refer to Figures 5A, 5B and 6. b) After the bushings have been installed in both the counterweights and the crankshaft hanger blades, a magnetic particle inspection as specified, must be performed by a certified technician. This inspection is to insure that no cracks have developed during the bushing removal and installation process.

FIGURE 5A. COUNTERWEIGHT BUSHING REPLACEMENT AND ASSEMBLY FOR 360, 470, IO-520, L/TSI0-520, IO-550, TSI0-550, TSIOL-550 CRANKSHAFTS MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

26 of 35 SB 00-3

A

COUNTERWEIGHT ASSEMBLY 530864 531017 639195 639196 639197 639199 639205 639210 652833

DIAMETER “A” (Installed) .435 / .438 .4613 / .4643 .622 / .626 .622 / .626 .622 / .626 .604 / .607 .6514 / .6554 .6483 / .6523 .754 / .757

FIGURE 5B. COUNTERWEIGHT BUSHING ASSEMBLY FOR GTSIO-520 AND GIO-550 CRANKSHAFTS NOTE GTSIO-520 COUNTERWEIGHT BUSHING REPLACEMENT IS NOT ALLOWED

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

27 of 35 SB 00-3

A

{

FIGURE 6. CRANKSHAFT HANGER BLADE BUSHING INSTALLATION CRANKSHAFT ASSEMBLY 530860 646623 649133 649134 649135 649138 649141 649144-1 649144-2 649148 649895 649896 649898 649900 652005 652009

CRANKSHAFT 530789 643687 649132 649132 649132 649137 649137 649143 649146 649147 649894 649894 649897 649899 652004 652004

DIAMETER “A” (Installed) .4613 / .4643 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626

CRANKSHAFT ASSEMBLY 652010 652011 652039 652348 652359 653020 653129 653136 653137 653138 653139 653383 653697 E-652800 654359

CRANKSHAFT 652004 652004 649137 652004 649899 653019 652012 652013 652044 652046 652046 653382 649137 E-649474 643687

DIAMETER “A” (Installed) .622 / .626 .622 / .626 .622 / .626 .622 / .626 .622 / .626 .754 / .756 .604 / .607 .604 / .607 .604 / .607 .604 / .607 .604 / .607 .604 / .607 .622 / .626 .622 / .626 .622 / .626

{ Except as follows: 652012 Flush to .004 Below Surface 652013 Flush to .004 Below Surface 652044 Flush 652046 Flush 653019 Flush to .005 Below Surface

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

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CONNECTING ROD INSPECTION AND REPAIR

signatures of edge loading of the bolt under head surface contact area is cause for rejection and scrap.

CLEANING:

Visually inspect dowel surfaces at rod and cap bolt holes. Indications of distortion or scoring are cause for rejection and scrap.

Thoroughly clean connecting rods using an approved solvent or degreaser. Insure all surfaces are free of varnish, oil and residue that will affect reliability of visual, dimensional and magnetic particle inspection. INITIAL INSPECTION: Perform the following visual and dimensional inspections. Insure that connecting rod and cap mate marks are adjacent to each other and that the position numbers stamped on or adjacent to the bolt boss match. Scrap connecting rods and caps that do not meet this criteria. Visually inspect connecting rod for corrosion pitting, rust, discoloration (bluing), galling, impact damage, nicks, bending and twisting. Scrap connecting rods with any of these indications. Remove nuts and bolts from connecting rod and separate rod and cap. Visually inspect connecting rod and cap parting surface. Contact signatures resulting from assembly forces are normal and acceptable. However, connecting rods exhibiting fretting signatures that have resulted in the loss of metal as indicated by removal of the original machining marks, either locally or over the entire surface, are not acceptable for continued service. Scrap connecting rods with fretting at the parting surfaces, DO NOT REWORK. Visually inspect nut seat area. Excessive fretting signatures indicating loss of material or

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

Insuring that the mate marks are adjacent to each other and the position numbers match, assemble the connecting rod and cap by installing one bolt through cap and rod. With the cap seated firmly against the rod, you must be able to install the remaining bolt using hand pressure only. Scrap connecting rods not meeting this criteria. Lubricate connecting rod bolt and nut threads with clean 50 weight aviation oil. Torque nuts to the value specified in the latest revision of TCM Service Bulletin SB96-7. NOTE The new design Spiralock nuts are free running during installation. Locking is achieved through thread design when the nut is properly torqued. Inspect the inside diameter joint of the rod to cap with both bolts and nuts installed and torqued. Mismatch (or a step) of more than 0.001 inch is not acceptable. An acceptable method of checking mismatch is to use a dial indicator as follows: Place the rod on a surface plate so that the splitline is at the 6 and 12 o’clock position. Use vee blocks to hold the rod in place. Using a dial indicator mounted on a height gauge, zero out on one side of the splitline. Move the indicator across the splitline. There must be no more than 0.001 indicator movement.

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Warning Removing and installing the connecting rod pin bushing with makeshift tools can damage connecting rods resulting in subsequent failure. Remove piston pin bushing from connecting rod using Borrough’s part number 8098, or equivalent, Connecting rod Bushing Removal/ Installation Set and an arbor press. Inspect piston pin bushing bore and surrounding area for nicks, gouges and mechanical damage. Scrap connecting rods with any of these indications. Using precision measuring equipment, such as dial bore gauge or air gauge, verify that the connecting rod meets the dimensional specifications provided in Table 5. Reference Figure 7. Measure “D” diameter 15 to 30 degrees either side of connecting rod split line and 90 from the first measurement. Difference between the two measurements must not exceed .0015. Connecting rods and caps not meeting these specifications must be scrapped. Inspect the rod channel rails for damage such as nicks, gouges or mechanical damage. Scrap rods with any of these indications. NOTE: Connecting Rods with forging number 626119 must also meet the inspection criteria specified in TCM CSB96-13

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

MAGNETIC PARTICLE INSPECTION: Parts must be clean and free of rust, scale, oil or other residue that may affect reliability of magnetic particle inspection Connecting rods will be inspected using both the circular and longitudinal method of magnetization. Use florescent method, wet continuous procedure, Refer to the latest revision of ASTM E 1444 for specific methods and procedures based on type of inspection being performed. Acceptable indications must be associated with steel inclusions or shallow imperfections on the forging surface. Accept light indications running parallel to the rod axis or around the pin boss and cap ends less than 1/2 inch in length. Indications associated with forging laps or with heat treatment are deemed cracks and are not acceptable. The area of blend between the piston pin boss extending one inch into the channel section of the connecting rod, the bolt spotface areas and the channel rail edges are critical and must be free of any indications. Any indication transverse to the rod axis is not acceptable. Reject and scrap connecting rods exhibiting unacceptable indications.

PAGE NO REVISION TM

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30 of 35 SB 00-3

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CONNECTING ROD PISTON PIN BUSHING INSTALLATION:

Warning

5.

Visually inspect connecting rod for nicks or damage that may have occurred during bushing installation. Scrap connecting rods exhibiting these conditions. 6. Verify the piston pin bushing split is correctly positioned. Reference Figure 7.

Removing and installing the connecting rod pin bushing with makeshift tools can damage connecting rods resulting in subsequent failure.

PISTON PIN BUSHING BORING

Verify that the piston pin bushing being installed is the correct part number for the application.

Boring of the piston pin bushing requires the following equipment:

The piston pin bushing may be chilled slightly to aid installation.

1. Borough’s Tool Part Number 8111A, or equivalent. 2. Adapter Kit Part Number 8042C (E-series, 470 and 520) or Part Number 8072C (O-200, IO-240, 300 series and 360 series) or equivalent. 3. Vertical mill, or equivalent, capable of maintaining 1750 R.P.M. 4. Boring tool of the correct sizes.

Using Borroughs Tool Part Number 8098, Connecting Rod Bushing Removal and Installation set, or equivalent, and an arbor press install the piston pin bushing as follows. 1. Position connecting rod over the pilot so mate marks and piston pin bore chamfer facing up. 2. Place the bushing on the pilot so that bushing split is located 45 degrees from center line of the connecting rod, facing crankpin end. 3. Position the ram onto the pilot. 4. Using the arbor press, carefully press bushing flush with the piston pin bore.

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

the are

Bore bushing as follows. the the the

the

1. Place the connecting rod on the base plate and secure with retainers provided. 2. Select the correct adapter kit and boring tool for the connecting rod. 3. Using a vertical mill, or equivalent, bore the connecting rod bushing to size. Maintain 1750 RPM during boring process.

PAGE NO REVISION TM

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POST INSTALLATION INSPECTION: Using a Maar-Federal Tool and Supply Co. Inc., Dimension Air D-2500 or D-4000 Air Plug Gauge, the correct size Setting Ring and Air Plug for diameter being measured verify that the piston pin bushing is within the minimum and maximum limits for the connecting rod as specified in Table 5. If the piston pin bushing does not meet dimensional specifications, the bushing will have to be removed and a new bushing installed and bored to size. Using a profilometer check piston pin bushing surface finish. Surface finish must not exceed 16 Ra. Check connecting rod bushing for alignment and twist after bushing installation using Borrough’s tool number 8111A, or equivalent. An alternate method would be to use a surface plate, matched vee blocks, precision machined press to fit arbors at least eight inches in length for the pin and crank end of the rod, and two calibrated parallel blocks of flat machined steel at least eight inches long, one half inch wide, and two and one half inches high. To check connecting rod twist, insert the push to fit arbors into the pin and crank end of the rod. Place the connecting rod crank pin end onto the vee blocks. Place the pin end arbor on the two machined parallel steel blocks spaced equal distance from the center line of the rod, but not less than six inches apart

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

Use flat feeler stock to detect clearance between the machined steel blocks and the pin end arbor. Refer to Figure 7 for specified limits. To check connecting rod alignment, rotate the pin end of the connecting rod to a vertical position with the arbor resting against a positive stop. Using a dial indicator mounted on a vertical stand resting on the surface plate, measure the vertical distance of the pin end arbor from the surface plate at points equal distance from the centerline of the connecting rod. Refer to Figure 7 for the specified limits. Connecting rods exceeding the limits specified in Figure 7 must have the piston pin bushing replaced and reamed or the connecting rod must be scrapped. TOOLS AND EQUIPMENT: Tools referred to in this Service Bulletin may be purchased from: Borrough’s Tools available from: Kent - Moore 29784 Little Mack Roseville, MI 48066-2298 Phone:1-800-253-0138 Maar-Federal Tool and Supply Co. Inc. 1144 Eddy Street Providence, RI 02940 Phone: 1-800-343-2050

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

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WARNING FAILURE TO COMPLY WITH THESE SPECIFICATIONS AND INSTRUCTIONS WILL RESULT IN ENGINE MALFUNCTION AND STOPPAGE.

.0005 INCH MAXIMUM CONVERGENCE OF THESE AXES (WITH NEW BUSHING) EXAMPLE: LONGITUDINAL AXIS,CENTER-TO-CENTER DISTANCE OF L1 MINUS L2 MUST NOT EXCEED .004 OF AN INCH AFTER CONNECTING ROD BUSHING HAS BEEN FINISH MACHINED.

L1

NICKS OR BURRS .01 INCH DEEP OR LESS MAY BE BLENDED USING CROCUS CLOTH. BLENDED AREA MUST HAVE A CORNER RADIUS OF .06-.09. CONNECTING RODS WITH “V” NOTCH SHAPE NICKS 4.00 EXCEEDING .02 INCH IN DEPTH MUST BE DISCARDED.

4.00

“C” 16 Ra

B

LONGITUDINAL AXIS

B SECTION “B” BB NO NICKS, GOUGES OR OTHER DAMAGE PERMISSIBLE ON BORE AFTER BUSHING REMOVAL

BREAK SHARP EDGES .015 INCH BY 45o IF ORIGINAL CHAMFER WAS COMPLETELY REMOVED BY BORING OR REAMING OF REPLACEMENT BUSHING.

4.00

“E” 4.00

L2 1.00 .0005 INCH MAXIMUM TWIST (WITH NEW BUSHING).

STAMP CYLINDER POSITION NUMBER ON CONNECTING ROD AND CAP (ROD TO BE INSTALLED ON CRANKSHAFT WITH POSITION NUMBER “UP”)

“D”

BUSHING CL

BIG END CL

45º ± 5º SPLIT IN BUSHING IN THIS LOCATION

“A”

FIGURE 7. CONNECTING ROD AND BUSHING DIMENSIONS

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

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TABLE 5. CONNECTING ROD SPECIFICATIONS Engine Model

Con-Rod Part Number

Forging Part Number

|~ Nut P/N Bolt P/N

O / IO / TSIO470’S Small Bore IO & TSIO-520 ‘s IO-346

655910 Superceded 655000 655004 654999 646778

646126 Superseded 632041

E-Series O-4702,4,11,13A,15 IO-470C,G,J,K,P,R

654796 ‘ Superseded 646478 A36121 

646126 Superseded 632041

360 Large Bore IO-240-A&B

654793 ‘ Superseded 646320 642268

646116 Superseded 626119

654794 ‘ Superseded 646321 626128

646116 Superseded 626119

654795 ‘ Superseded 646322 530184 €

646116 Superseded 626119

360 Small Bore GO-300 O-200 / O-300 C-90 / C-145

530186€

654490 Nut

Connecting Rod Bores Centerline Distance

Pin end I.D. No Bushing

“B”

“C”

“D”

“E”

1.2340 1.2350

1.1267 1.1269

2.3755 2.3760

1.521 1.525

2.3755 2.3760

1.583 1.587

2.0615 2.0620

1.2215 1.2255

2.0615 2.0620

1.3015 1.3055

2.0615 2.0620

1.3015 1.3055

2.3755 2.3760

1.461 1.465

2.3755 2.3760

1.521 1.525

2.3755 2.3760

1.461 1.465

2.3755 2.3760

1.461 1.465

2.3755 2.3760

1.521 1.525

530658

6.6230 6.6270

1.2340 1.2350

6.3730 6.3770

1.0620 1.0630

1.0000 1.0005 538684

6.3730 6.3770

1.0620 1.0630

655959 Bolt 654487 Nut

1.1263 1.1265 530658

655959 Bolt 654487 Nut

C/S end width

“A”

655960 Bolt 654487 Nut

Crankpin Bore I.D.

6.6230 6.6270

655958 Bolt 654487 Nut

Bushing I.D. Bushing P/N

1.00001.0005 538684

6.3730 6.3770

1.0620 1.0630

.9230-.9235 530192

655959 Bolt

5561€ IO / TSIO520 Large Bore TSIO-520-BE

L / TSIO-520-AE

655911{ Superseded 655005 ‘ 646476 646475

646126 Superseded 632041

655910  Superseded

646126 Superseded 632041

655000 ‘ 646480 643166

6.6230 6.6270

1.2340 1.2350

655958 Bolt

655911  Superseded 655001 646482

646126 Superseded 632041

I0-550-B29, B33, B37, C25, C29, C30 TSIO-520-UB17

655911 { Superseded 655001 654440

646126 Superseded 632041

GTSIO-520’s

655910  Superceded 655004

626126 Superseded 632041

TSIO-520-CE IO / TSIO-550’s TSIOL-550’s

654490 Nut

654490 Nut

530658 6.6230 6.6270

1.2340 1.2350

655958 Bolt 654490 Nut

6.6230 6.6270

1.2340 1.2350

1.1267 1.1269 530658

6.6230 6.6270

1.2340 1.2350

655928 Bolt 654490 Nut

1.1267 1.1269 530658

655928 Bolt 654490 Nut

1.1267 1.1269

1.1267 1.1269 530658

6.6230 6.6270

1.2340 1.2350

655958 Bolt

1.1267 1.1269 530658

 Connecting Rod Assembly must utilize correspondingly identified bolt and nut from Table 5.  The most current part number connecting rod nuts and bolts must not be used on or with superceded part number nuts and bolts.

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

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‘ Current part number (serviceable) connecting rods must use the most current part number connecting rod new nuts and bolts. The most current connecting rod new nut and bolt part numbers can be used with old (serviceable) connecting rods of the same style. (Hex head rod bolts must replace hex head rod bolts, contour head rod bolts must replace contour head rod bolts.) ~ See the most recent revision of TCM Service Bulletin SB96-7 for connecting rod nut torque specifications.

 Used in balanced set P/N 655913. € P/N 530184 connecting rod (identified by forging number 530186), A35159 (Identified by forging number 5561) and A35160 (Also identified by forging number 5561) must be serviced as follows: a) P/N 530213 bolt, P/N 24804 or P/N 626140 nut and P/N 639292 cotter pin, torqued to value specified in latest revision of TCM SB96-7  P/N A36121 connecting rod assemblies utilizing the P/N 632041 forging must be serviced in accordance with Table 5 of this bulletin. P/N A36121 Connecting rod assemblies utilizing the P/N 40742 forging must be serviced as follows:

a) P/N 35972 connecting rod bolt, P/N 24804 nut and P/N MS24665-132 cotter pin, torqued to the value specified in the latest revision of TCM SB96-7.

Warning If the hardware listed in (a) of note 6 or note 7 is not available, the connecting rod must be changed to a serviceable later configuration rod with the appropriate P/N hardware.

MO 02

ISSUED DAY YEAR 02

2000

MO 10

REVISED DAY YEAR 29

2004

PAGE NO REVISION TM

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB 00-4A

SERVICE BULLETIN

Technical Portions FAA APPROVED

SUBJECT:

AUSTRALIAN AVGAS CONTAMINATION

PURPOSE:

To provide owners, operators and maintenance facilities with the minimum maintenance requirements for TCM engine fuel systems which have been operated with avgas contaminated with Ethylenediamine (EDA)

COMPLIANCE:

For engine fuel systems operated on avgas contaminated with EDA compliance with this service bulletin is required prior to further flight.

MODELS AFFECTED:

All

Teledyne Continental Motors (TCM) has received requests for maintenance recommendations for engine fuel systems that have been operated on Ethylenediamine (EDA) contaminated avgas. Fuel samples taken from effected aircraft have found the EDA concentration to be less than 10 PPM. EDA is a clear liquid with an odor similar to ammonia. EDA is classified as a hazardous material. Exposure of the skin to EDA in is likely to cause skin irritation. Higher levels of concentration may result in skin burns. Inhalation of EDA vapors at a concentration level of 200 PPM (parts per million) for 5 to 10 minutes will cause nasal irritation and possible wheezing. When Ethylenediamine comes into contact with brass or copper alloy materials this normally clear substance will become a dark material that may restrict small passages and orifices in the engine fuel system. Therefore, TCM recommends that any TCM fuel injected engine that has been operated on EDA contaminated avgas have the complete fuel injection system removed from the engine for overhaul or replacement. TCM engines equipped with fuel systems manufactured by Precision Airmotive Corporation must comply with Precision Airmotive Corporation service bulletins MSA-11 for engines equipped with carburetors and PRS-104 for engines equipped with Precision RS / RSA fuel injection servos. NOTE: Clearly identify all removed fuel injection systems as having been operated on EDA contaminated avgas.

ISSUED

Fuel Injection systems removed from engines operated on EDA contaminated avgas may be exchanged for Factory Rebuilt Fuel Injections Systems. Refer to TCM SIL 98-6B, or later revision, for fuel injection system applications. Exchange pricing is available from your local TCM Distributor. Fuel injection systems that have been removed from engines operated on EDA contaminated avgas for field overhaul must be completely disassembled and all components cleaned and flushed with distilled water. All fuel system components and parts must be inspected in accordance with the latest revision of TCM Form X30593A (Fuel Injection System Overhaul Manual). Components containing brass, copper or bronze alloys must be visually inspected for possible etching or pitting of there surface. Replace any fuel system component that exhibits etching or pitting of its surface. Clearly identify these components as “removed from an engine fuel system operated on EDA contaminated avgas”. Thoroughly dry all fuel injection components and parts. NOTE: EDA contaminated water must be disposed of as a hazardous material. Refer to the latest revision of TCM Form X30593A (Fuel Injection System Overhaul Manual) for specific instructions for overhaul of TCM fuel injection systems. Field overhauled fuel injection systems will not be covered by any TCM warranty policy. Warranty coverage for engines operated on avgas contaminated with EDA may be affected since there is no historical data on the effects EDA contaminated fuel may have on internal engine parts and components. If a possible

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

18

2000

03

07

2000

CONTINENTAL MOTORS

© 2000 TELEDYNE TECHNOLOGIES INCORPORATED

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

1 of 2 SB 00-4

A

warranty situation arises, TCM will assess the occurrence and possible warranty coverage on an individual basis. Prior to returning the aircraft and engine to service, ensure that the aircraft fuel system has been flushed of all EDA contamination in accordance with CASA AD/GENERAL/80 Amdt. 2 or later revision for “Simple Aircraft”, or CASA AD/GENERAL/81 Amdt.2 or later revision for “Complex Aircraft”. Additionally, comply with the instructions for continued airworthiness as provided by the aircraft manufacturer prior to returning the aircraft to service. Perform all necessary ground run ups and adjustments as required to the engine fuel injection system in accordance with TCM (Service Information Directive) SID97-3, or later revision. Visually inspect the engine and engine nacelle for security of all components, lines and hoses. Inspect for evidence of fuel and oil leaks. Correct any discrepancies noted. Make an entry in the engine logbook(s) clearly stating that the aircraft was serviced with EDA contaminated avgas and that the engine was operated on EDA contaminated avgas. Indicate the method of compliance with the applicable CASA AD (s) for decontamination of the aircraft fuel system and any specific instruction published by the aircraft manufacturer. On engines equipped with carburetors or fuel servo units manufactured by Precision Airmotive Corporation reference compliance with the applicable Precision Airmotive Corporation Service Bulletin. For TCM fuel injected engines reference compliance with this service bulletin. Include in the logbook entry the method of compliance, i.e. replacement or overhaul of the unit or system.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

18

2000

03

07

2000

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

2 of 2 SB 00-4

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB01-3A

Compliance Will Enhance Safety REASON For REVISION:

TECHNICAL PORTIONS FAA APPROVED

Incorporate identification characteristics for Stator Assembly P/N 649303 Revision G and H. Announce release of new Stator Assembly P/N 656079

SUBJECT:

TELEDYNE CONTINENTAL MOTORS P/N 649304A1 AND P/N 649305A1 GEAR-DRIVEN ALTERNATORS

PURPOSE:

To advise owners, operators and maintenance facilities of the possible loss of alternator electrical output and the release of a new alternator stator/rectifier assembly for the subject alternators.

COMPLIANCE:

At the next engine overhaul, alternator replacement or alternator overhaul, whichever occurs first.

MODELS AFFECTED:

IO-520-B, BA, BB, C, CB, M, MB; IO-550-A, B, C, G, N, P, R; TSIO-520-B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, U, UB, VB, WB; TSIO-550A, B, C, E; TSIOL-550-A, B, C; GIO-550-A: GTSIO-520-C, D, F, G, H, K, L, M, N, R engines utilizing alternators as originally equipped or purchased as a replacement part under part numbers 649304, 649304A1, 649305 and 649305A1.

Product evaluation of alternators returned to TCM for no electrical output has identified failures of the stator/rectifier assembly in 100 Ampere gear driven alternators. A revised alternator stator/rectifier assembly, part number 649303 Rev. G or H was installed in new and rebuilt alternators part numbers 649304, 649304A1, 649305 and 649305A1 beginning September 22, 2000. Part number 649303 Rev. G or H may be used as a service spare part for alternator’s part numbers 649304, 649304A1, 649305 and 649305A1. Additionally, Teledyne Continental Motors is making the new alternator stator/rectifier assembly, part number 656079 available as a service spare part for all geardriven 100 Ampere alternators. NOTE: Part number 649304 and 649304A1 is a 100 Ampere alternator supplied without the drive coupling and P/N 649305 and 649305A1 is a 100 Ampere alternator supplied with the drive coupling installed.

to P/N 649303 Rev. G with new part number 656079 stator/rectifier assembly at the next alternator service interval. For alternator service requirements and time intervals refer to latest revision of TCM Alternator Service Instructions Form X30531-3. TCM alternators are to be disassembled, inspected, repaired and tested to assure performance in accordance with the manufacturer’s specification every 500 hours of operation and at engine TBO. WARNING FAILURE OF A STATOR / RECTIFIER ASSEMBLY WILL RESULT IN LOSS OF ALTERNATOR ELECTRICAL OUTPUT. LOSS OF ELECTRICAL POWER CAN AFFECT SAFETY OF FLIGHT. AT THE FIRST INDICATION OF A LOSS OF ALTERNATOR OUTPUT, REDUCE ELECTRICAL LOAD TO MINIMUM REQUIREMENTS FOR SAFE FLIGHT AND LAND AS SOON AS PRACTICABLE.

Replace all stator/rectifier assemblies prior

MO 05

ISSUED DAY YEAR 15

2001

MO 12

REVISED DAY YEAR 10

2002

 2001 Teledyne Continental Motors, Inc.

PAGE NO REVISION

1 of 3 P.O. Box 90 Mobile Alabama • 251-438-3411

SB01-3

A

www.tcmlink.com

Alternators manufactured prior to September 22, 2000 (serial number I220025.0) and earlier do not incorporate the new stator/rectifier assembly addressed by this service bulletin. The date of manufacture may be determined by the unit serial number as follows:

Alternator P/ N 649304, Serial Number J 089911.0 is a new alternator manufactured on October 8, 1999 and was the eleventh (11) production unit of the day. See Table 1 and Figure 1. FIGURE 2 NEW ALTERNATOR DATA PLATE (manufactured on or after to January1, 2001) TABLE 2 Serial Number Codes Manufactured On or After January 1, 2001 (example) 0 01 A A047 Component 0=Alternator 0=Alternator 0=Alternator

FIGURE 1 NEW ALTERNATOR DATA PLATE (Manufactured prior to January1, 2001)

Month A= Jan B= Feb J = Oct

TABLE 1 Serial Number Codes Manufactured Prior to 2001 Day Year Unit # Component 01 96 01 .0=Alternator 02 97 02 .0=Alternator 08 99 11 .0=Alternator

Beginning January 1, 2001 a new component serial number format was initiated by TCM. See Table 2 for component serial number codes. Example: Alternator P/N 649304, serial number 001AA047 is an alternator, built in 2001, in the month of January, and is the 47th unit built that month. See Figure 2.

MO 05

ISSUED DAY YEAR 15

2001

MO 12

Year 01 01 01

2002

Unit # A047 A999 B001

New manufacture alternators have a red data plate; rebuilt alternators have a blue data plate that reads “Factory Rebuilt Alternator”. Additionally, rebuilt alternators have the letter “R” stamped after the last digit of the alternator serial number and part number, i.e. A019601.0 R and 649304 R. WARRANTY: Alternator replacement as a result of the issue addressed in this service bulletin may be covered by Teledyne Continental Motors warranty. Refer to the warranty policy provided with the engine or service spare part at the time of purchase. Alternators that required replacement or repair due to the issue addressed in this service bulletin may be eligible for warranty consideration if the condition can be verified.

REVISED DAY YEAR 10

Month A= Jan B= Feb B= Feb

PAGE NO REVISION 2 of 3 P.O. Box 90 Mobile Alabama • 251-438-3411

SB01-3

A

For you convenience Teledyne Continental Motors provides product warranty information on our web site at (www.tcmlink.com). NEW AND REBUILT EXCHANGE PRICING:

ALTERNATOR

For alternators manufactured prior to September 22, 2000 at alternator or engine overhaul, replace existing alternator with an alternator incorporating stator assembly P/N 649303 revision G or H, or with new stator/rectifier assembly P/N 656079. NOTE: Stator assembly P/N 649303, revision G and H may be identified by either the presence of an ultraviolet tracer incorporated into the stator winding coating or by an over coating of reddishbrown polyurethane insulating material. Stator/rectifier assemblies P/N 649303 revision G and H with ultraviolet tracer may be identified using an ultraviolet light source. When the luminant radiation from an ultraviolet light source is applied to the stator windings, the windings of stator/rectifier assemblies at revision G or H will radiate a brilliant purple hue. Stator assemblies P/N 649303, Revision H may utilize a reddish brown polyurethane insulating material to coat the winding wires. All P/N 656079 stator assemblies may be identified by the presents of a reddish brown polyurethane insulating material to coat the winding wires. Stator assemblies manufactured prior to revision G will not glow at all under ultraviolet illumination and are coated with translucent material which, when new, shows the copper color of the winding wires.

SERVICE SPARE STATOR / RECTIFIER ASSEMBLY EXCHANGE PRICING: For alternators manufactured prior to September 22, 2000, at alternator or engine overhaul, TCM recommends replacement of existing stator assembly with stator assembly P/N 649303, revision G or H, or with new stator/rectifier assembly P/N 656079 The new stator assembly P/N 656079 may be purchased at a special exchange price of $352.00 code IW . This special pricing is available for 24 months from the original issue date of this service bulletin.

TCM has established special exchange pricing for a period of 24 months after the issue date of this service bulletin as listed below. Alternator Type 649304A1* 649305A1* New Exchange $1,291.00DW $1,936.00DW Rebuilt Exchange $748.00DW $1,393.00DW *NOTE: Part number 649304A1 is a 100 Ampere alternator supplied without the drive coupling, P/N 646655, and P/N 649305A1 is a 100 Ampere alternator with drive coupling installed.

MO 05

ISSUED DAY YEAR 15

2001

MO 12

REVISED DAY YEAR 10

2002

PAGE NO REVISION 3 of 3 P.O. Box 90 Mobile Alabama • 251-438-3411

SB01-3

A

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SB01-5

SERVICE BULLETIN Compliance Will Enhance Safety

SUBJECT:

TECHNICAL PORTIONS FAA APPROVED

STARTER ADAPTER BEVEL GEAR INSPECTION

PURPOSE:

To Advise FBO’s, Owners, Operators and Engine and Accessory Overhaul Shop of Required Inspection of P/N 632617 Bevel Gear Installed in P/N 646220A38 Starter Adapter Assemblies.

COMPLIANCE:

Initial inspection required within the next 25 hours of engine operation. Repetitive inspections required at 50 hour intervals until gear P/N 632617 is replaced with gear P/N 655919, or starter adapter P/N 646220A54 or subsequent is installed.

MODELS AFFECTED:

Factory New and Rebuilt IO-360-C, CB, G, GB, LB engines listed by engine serial number in Table 1 on page 2. Any of the above engines models that have had a new, rebuilt or overhauled starter adapter P/N 646220A38 installed as a replacement and all service spare bevel gears P/N 632617.

GENERAL INFORMATION: Starter adapter assemblies P/N 646220A38 purchased from TCM from August 1998 to present are affected by this service bulletin. Starter adapter assemblies P/N 646220A38 that have been overhauled in the field and gear P/N 632617 installed are also affected by this service bulletin. INSPECTION: For affected engines listed in Table 1 and engines with field repaired or overhauled starter adapter P/N 646220A38 that utilized bevel gear P/N 632617; within the next 25 hours of engine operation perform a visual inspection of bevel gear P/N 632617 for spalling as outline below. Repeat this inspection at 50 hour intervals until starter adapter P/N 646220A38 is replaced with current production starter adapter P/N 646220A54. 1. 2. 3. 4.

MO 10

In accordance with the aircraft manufacturer’s instruction gain access to the engine and specifically the engine accessory area. Referring to Figure 1, remove the “T” drive cover plate P/N 633751, by removing 4 each screws, 4 each lock washers and 4 each flat washers. Remove gasket P/N 653743. Visually inspect bevel gear P/N 632617 for indication of gear tooth distress, spalling, broken or chipped gear teeth. Inspect interior of “T” drive housing for gear debris. If visual inspection DOES NOT reveal any damage to bevel gear P/N 632617 and there is no gear debris noted in “T” drive housing interior reinstall cover P/N 633751 using a new gasket P/N 653743 and new lock washers P/N MS35338-44. Torque screws P/N 535631 to 75 to 85 inch pounds. On completion of the above inspection, complete the owner notification form and mail it or fax it to TCM. {

ISSUED DAY YEAR 18

2001

MO

REVISED DAY YEAR

PAGE NO REVISION TM

C O N T IN E N T A L M O T O R S

 2001 TELEDYNE TECHNOLOGIES, INC.

A Te led yne Tec hnolo g ies C o m p a ny P.O . BO X 90 M O BILE ALABAM A 36601 • 334-438-3411

1 of 4 SB01-5

5.

If visual inspection reveals damage to bevel gear P/N 632617 or if there is debris in the interior of the “T” drive housing the starter adapter assembly will have to be removed for repair or replacement. Contact TCM Technical Service Support at 1-888-826-5465

REPLACEMENT: To place an order for an exchange starter adapter assembly Contact TCM Customer Support Center, Fairhope, AL at 1-888-200-7565. Have available the information requested on the Compliance Form on page 4. Bevel gear P/N 632617 is being replaced with bevel gear P/N 655919. Bevel gear P/N 655919 will be available the end of September 2001. TCM will, on an exchange basis, replace all starter adapters affected by this Service Bulletin once gear P/N 655919 is available. In the event an affected P/N 646220A38 starter adapter assembly requires replacement prior to bevel gear P/N 655919 being available, TCM will as an interim action supply a P/N 646220A38 starter adapter assembly. Starter adapters P/N 646220A38 will be replaced with starter adapter P/N 646220A54 when they become available. Service spare bevel gear P/N 632617 will be replaced by bevel P/N 655919. During field repair of overhaul bevel gear P/N 655919 must be used with gear P/N 640802. Refer to Figure 2. WARRANTY: Teledyne Continental Motors will reimburse the owner/operator or FBO the invoiced cost of a replacement Factory Rebuilt starter adapter assembly upon receipt of the removed, affected starter adapter assembly at Teledyne Continental Motors. Service spare bevel gears P/N 632617 in Distributor inventory will be exchanged for P/N 655919 bevel gear. No requests for return credits will be accepted. Warranty labor coverage will be as follows: One (1) man hour labor per engine for visual inspection. Four (4) man hours labor for starter adapter removal and installation on front engine. Six (6) man hours labor for starter adapter removal and installation on rear engine. Return the removed starter adapter assembly to: TCM Customer Support Center Fairhope Municipal Airport 8600 County Road 32 Fairhope, AL 36532 TABLE 1

MO 10

ISSUED DAY YEAR 18

2001

ENGINE MODEL IO-360-C

SERIAL NUMBER AFFECTIVITY 060687 thru 060699, 060702 thru 060707, 060709 thru 060713, 060716

IO-360-CB

236527 thru 236532

IO-360-G

244609 thru 244619, 244621 thru 244634, 244636 thru 244639

IO-360-GB

352971 thru 352974, 813014 thru 813027, 813029 thru 813031, 813034 thru 813039

IO-360-LB

No Factory New or Rebuilt Engines Affected

MO

REVISED DAY YEAR

PAGE NO REVISION TM

C O N T IN E N T A L M O T O R S A Te led yne Tec hnolo g ies C o m p a ny P.O . BO X 90 M O BILE ALABAM A 36601 • 334-438-3411

2 of 4 SB01-5

GEAR P/N 632617 Gasket P/N 653743

Cover P/N 633751

FIGURE 1 Exploded View P/N 646220A38 Starter Adapter Screw P/N 535631 Lock washer P/N MS35338-44 Flat washer P/N AN960-416

Replace Bevel Gear P/N 632617 with Bevel Gear P/N 655919

Note: assembled gear backlash . .008 - .012

P/N 640802

FIGURE 2

Exploded View P/N 646220A54 Starter Adapter

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C O N T IN E N T A L M O T O R S A Te led yne Tec hnolo g ies C o m p a ny P.O . BO X 90 M O BILE ALABAM A 36601 • 334-438-3411

3 of 4 SB01-5

COMPLIANCE FORM SB 01-5

Owner Name:

Aviator Services Membership #:

Date:

City:

State/Country:

Zip Code:

FBO Name:

FBO Services Membership #:

Date:

City:

State/Country:

Zip Code:

Aircraft Registration #:

Make/Model:

S/N:

Engine Model:

Serial Number:

Position: F – R – S

Date Installed:

Time Since Major O/H:

Engine Model:

Serial Number:

Date Installed:

Time Since Major O/H:

Address:

Address:

Time Since Top O/H: Position: F – R – S Time Since Top O/H:

Comments:

Mailing address: Teledyne Continental Motors P.O. Box 90 Mobile, Alabama 36601

{

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or

Fax number: 251(334)-433-2325 Attn: Bob Robbins or Richard Suk

PAGE NO REVISION TM

C O N T IN E N T A L M O T O R S A Te led yne Tec hnolo g ies C o m p a ny P.O . BO X 90 M O BILE ALABAM A 36601 • 334-438-3411

4 of 4 SB01-5

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB 02-10A

Compliance Will Enhance Safety

Supersedes SB02-10 Technical Portions FAA Approved

SUBJECT: FUEL INJECTION SYSTEM SERVO UNIT VIBRATION DAMPER PURPOSE:

COMPLIANCE:

MODELS AFFECTED:

To provide inspection, assembly and installation instructions for the fuel injection servo unit vibration damper. At the next 100 hour or annual inspection or when ever the fuel injection system servo unit is removed and replaced.

LTSIO-360-RB and TSIO-360-RB engines

Teledyne Continental Motors has received reports of incorrect positioning of the fuel injection servo unit vibration damper. If the fuel injection servo unit vibration damper is not correctly positioned damage may result to the cylinder induction tubes or the lower surface of the fuel injection servo unit body. When properly positioned the fuel injection servo unit vibration damper assembly will be angled forward and the rubber grommets will be in firm contact with the servo unit body. See Figure 1and 3.

FIGURE 1 Fuel Injection Servo and Vibration Damper ISSUED

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P.O. Box 90 Mobile Alabama • 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

A

INSPECTION: Remove the engine cowling in accordance with the aircraft manufacturer’s instructions to gain access to the fuel injection servo unit. 1. Visually inspect that the fuel injection servo unit vibration damper to ensure grommets are in contact with the lower surface of the servo housing. See Figure 1and 3. 2. If the vibration damper grommets are not in contact with the lower surface of the servo housing and are not damaged or deformed, proceed to the “Installation” section of this bulletin. 3. If the vibration damper assembly is positioned perpendicular to the crankcase backbone, the grommets are deformed or have become damaged proceed to the Removal section of the service bulletin. REMOVAL OF VIBRATION DAMPER ASSEMBLY: 1. 2. 3. 4. 5. 6.

Loosen and remove the nut and washer from the number 10 backbone bolt that secures the vibration damper to the engine. Rotate the vibration damper forward and out of contact with the fuel injection servo unit. Remove the bolt and washer from the vibration damper and the number 10 backbone bolt hole. Remove the vibration damper from the engine. Inspect the lower surface of the fuel injection servo unit body for chaffing or mechanical damage from the vibration damper brackets. If the fuel injection servo unit body has been damaged, contact your Regional Service Representative or Teledyne Continental Motors Customer Service at 1-888-826-5465.

3 each AN960-416 washers

4 each MS 35489-149X Grommets 2 each 654364 Brace

2 each P/N 649290 Spacers

FIGURE 2 Vibration Damper Assembly- Exploded View

VIBRATION DAMPER ASSEMBLY: To configure the vibration damper perform the following. Refer to Figure 2. 1. 2.

Position the four grommets, P/N MS 35489-149X, side by side. Insert one spacer P/N 649290 through two of the grommets. Repeat this for the remaining two grommets and spacer. ISSUED

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A

3. 4. 5. 6. 7. 8. 9.

Insert bolt, P/N AN4-14A, through one of the brackets, P/N 654364. Place one AN 960-416 flat washer over the bolt, resting against the inside of the bracket. Slide one of the assembled spacers and two grommets over the bolt. Place one AN 960-416 flat washer over the bolt, against the bushing and grommet. Place the other two grommets and bushings over the bolt. Place another AN 960-416 flat washer over the bolt and against bushing and grommet. Install the remaining brace, MS35338-44 lock washer, and AN315-5 plain nut.

VIBRATION DAMPER INSTALLATION: 1. 2. 3.

4. 5. 6. 7.

Using the following instructions, install the vibration damper at the number 10 backbone bolt from the front of the engine, counting from the position indicated. (Reference Figure 3.) If not already done, loosen and remove the nut, washer and bolt at the number 10 backbone bolt hole. Install the vibration damper by aligning the holes in the brackets with the number 10 backbone bolt hole and inserting the backbone bolt, removed in step 2 above, through the bracket, backbone and other bracket. Install the lock washer and nut. Snug the backbone bolt and torque the vibration damper bolt to 75-85 inch pounds. Rotate the vibration damper up until it comes into solid contact with the bottom of the fuel injection servo unit. While holding the vibration damper in solid contact with the fuel injection servo unit, torque the backbone bolt and nut to 100 to 125 inch lbs. Re-install any peripheral components that were removed to facilitate installation and adjustment of the fuel injection servo vibration damper.

No. 1 Backbone Bolt

Vibration Dampener

FIGURE 3 Vibration Damper Installation Location

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A

TELEDYNE CONTINENTAL

®

CATEGORY 3

AIRCRAFT ENGINE

SERVICE BULLETIN

SB 02-3

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

MAGNETO TACHOMETER SENSORS

PURPOSE:

To advise Owners, Operators and FBO’s operating and/or maintaining Teledyne Continental Motors engines as listed in “Models Affected” of possible erratic tachometer indications

COMPLIANCE:

Within the next 100 hours of engine operation; Annual or 100 hour inspection, which ever occurs first comply with the inspection and, if required, corrective actions in accordance with this Service Bulletin and the attached Spirent Service Bulletin #1.

MODELS AFFECTED:

IO-550-G Specification 5, 6, 7 & 8; IO-550-N Specification 7, 8, 10, 11, 12, 13 &15; all TSIO-550-B; all TSIO-550-C; all TSIO-550-E engines.

GENERAL INFORMATION: Teledyne Continental Motors has received notification from Spirent Systems of manufacturing errors that affect certain tachometer sensors supplied by them to Teledyne Continental Motors. Reference attached Spirent Systems Service Bulletin #1. Affected Sensors are identified with TCM P/N 653141, Spirent P/N 0406-004, manufactured from April 1, 2000 through August 31, 2001, serial number 96299 through 113397 and TCM P/N 653852, Spirent P/N 0406-003, serial number 105353 through 111403. The magneto tachometer sensor is installed on the left hand (2-4-6 side) magneto on all IO-550-G, TSIO550-C and TSIO-550-E engines; the right hand (1-3-5 side) magneto on all IO-550-N and TSIO-550-B engines. INSPECTION: To inspect the magneto tachometer sensor, remove the engine cowling in accordance with the aircraft manufacturer’s instructions. Locate the magneto tachometer sensor and the identification tag attached to the sensor lead. Record the sensor serial number. Determine if the serial number on the sensor is within the effected serial number range provided above. If the magneto tachometer sensor serial number is not within the effected serial number range, no further action is required. ISSUED

REVISED

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© 2002 Teledyne Continental Motors, Inc.

CONTINENTAL MOTORS

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

1 of 2

SB02-3

Reinstall the engine cowling. Make a logbook entry indicating compliance with this service bulletin and return the aircraft and engine to service. Be sure to include the sensor part number and serial number. If the magneto sensor serial number is within the effected serial number range, the sensor will require replacement. REPLACEMENT OF MAGNETO SENSOR: To expedite compliance with this service bulletin, replacement magneto sensors may be ordered from the from your TCM Distributor. To locate the nearest TCM Distributor go to www.tcmlink.com click on Distributor Services, then click on Distributor Locator. When placing your order please have the engine make, model, serial number and magneto tachometer sensor part number and serial number available. Refer to the applicable engine maintenance or overhaul manual for magneto removal and installation instructions. Remove the magneto that has the tachometer sensor installed. Remove the sensor from the magneto housing and clearly identify the sensor as being removed to comply with this service bulletin. Sensor will have to be returned to TCM for warranty payment. Install new sensor in bottom of magneto housing. Install magneto onto engine using a new gasket P/N 649954. Refer to TCM MSB94-8A, the engine maintenance or the engine overhaul manual for detailed instructions on timing the magneto to the engine. Perform a complete operational check of the engine, including magneto drop, magneto spread (difference between left and right magneto drop) and tachometer accuracy. Make a logbook entry indicating compliance with this service bulletin. Be sure to include the sensor part number and serial number. WARRANTY: Labor to replace the magneto tachometer sensor will be covered by Teledyne Continental Motors. No labor will be paid for the inspection. Teledyne Continental Motors will allow 1.5 man-hours labor for removal or the magneto from the engine, magneto tachometer sensor removal and installation, installation of the magneto on the engine and timing of the magneto to the engine.

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SERVICE BULLETIN Service Bulletin #1 Model 0406 Magneto Sensor Assembly Replacement I.

Planning Information A. Effectivity 0406-003 11/16 Magneto Sensor Assemblies from 4-1-00 (S/N 105353) through 8-31-01 (S/N 111403) 0406-004 9/16 Magneto Sensor Assemblies from 4-1-00 (S/N 96299) through 8-31-01 (S/N 113397) The modification covered by this service bulletin, though not mandatory, is strongly recommended at the 100 hour check or if experiencing intermittent tachometer operation. B. Reason Manufacturing errors in the subject sensor connector may cause intermittent tachometer readings. Wires were soldered into connector pins instead of being properly crimped. C. Description This modification consists of removing and replacing the subject sensor. D. Approval No approval is needed. The replacement part has an FAA-PMA. E. Manpower The subject modification takes approximately 1 hour to accomplish. F. Weight and Balance Weight and balance data is not affected. G. References Engine Maintenance Manual H. Other Publications Affected None

Nov 30/01 0406-003-014

Page 1 of 2 SB#1

SERVICE BULLETIN II.

Material Information A. Material Cost and Availability Each modification requires a replacement Magneto Sensor Assembly (SSW# 0406003/TCM# 653852) or (SSW# 0406-004/TCM# 653141). Parts and cost information are available from: Teledyne Continental Motors PO Box 90 Mobile, AL 36601

Spirent Systems Wichita, Inc. nd 8710 E. 32 Street North Wichita, KS 67226

Phone: 8 8 8 - 8 2 6 - 54 6 5 Fax: (334) 436-8507

P h one : (316) 636-2000 Fax: (316) 636-9098

B. Tools Standard hand tools III. Accomplishment Instructions STEP

PROCEDURE

1. Locate the Spirent Systems 0406-003 or 0406-004 Magneto Sensor Assembly mounted on the Teledyne Continental Motors engine (magneto). 2. Inspect the nameplate and verify the manufacture date and serial number (S/N) is within the range listed in the Effectivity of this service bulletin. 3. Remove the Magneto Sensor Assembly. 4. Install the new Magneto Sensor Assembly. 5. Apply electrical power to the airplane and perform a functional/operational check. 6. Make an entry in the airplane logbook stating this service bulletin has been accomplished. IV. Identification Affected articles that have been reworked to proper standards shall be identified with the original Part Number and Serial Number, with the date changed to the date of rework.

Nov 30/01 0406-003-014

Page 2 of 2 SB#1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

SB 02-7

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT: TELEDYNE CONTINENTAL MOTORS IGNITION SYSTEM SERVICE BULLETIN SB 663

PURPOSE:

To advise Owners, Operators and FBO’s of the release of TCM Ignition System Service Bulletin SB 663.

COMPLIANCE: MODELS AFFECTED:

As specified in TCM Ignition System SB 663. IO-360-C, CB, D, DB, G, GB; TSIO-360-A, AB, C, CB, D, DB, H, HB, JB

Teledyne Continental Motors requires compliance with the attached TCM Ignition Systems Service Bulletin number SB 663. Comply with TCM Ignition System Service Bulletin SB 663 as specified in the compliance section of this bulletin.

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Teledyne Continental Motors, Inc.

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SB-02-7

A Teledyne Technologies Company

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 3

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance, or Economy of Operation

SB663 FAA APPROVED

SUBJECT:

Two Wire Magneto Tachometer Breaker Contact Assembly P/N 10-400507

PURPOSE:

To advise of procedures to ensure isolation of tachometer circuit.

COMPLIANCE:

All affected magnetos must be inspected per this Service Bulletin whenever tachometer breaker contacts are installed or adjusted, and at intervals not to exceed 500 hours.

MODELS AFFECTED: Model Number: S4LN-21 S6LN-25 S4LN-204 S6LN-204 S4LSC-21T S6LSC-25T S4LSC-204T S6LSC-204T

Part Number: 10-51360-47 10-79020-11, 10-79020-17 10-163045-6 10-163050-12 10-500514-201, BL-500514-201 10-500556-203, BL-500556-203 10-600644-201, BL-600644-201 10-600646-201, BL-600644-201

BACKGROUND: Tachometer breaker assembly p/n 10-400507 (supersedes 10-361631) is designed to be electrically insulated from magneto ground when it is installed in the magneto. The following procedure is a method to determine the integrity of the isolation of the tachometer circuit. DETAILED INSTRUCTIONS: After replacement or adjustment of tachometer breaker, and at maintenance intervals not to exceed 500 hours: 1. If applicable, disconnect magneto tachometer wires from all airframe circuits in accordance with Airframe Manufacturer’s instructions. 2. Using Slaughter Model 1101 Dielectric Breakdown Tester* (or equivalent) set to 500 V, apply 500 V between each tachometer wire and ground. No indication of dielectric breakdown is permissible. 3. Replace all tachometer breaker assemblies that indicate any dielectric breakdown. 4. Reattach magneto tachometer wires to airframe wires in accordance with Airframe Manufacturer’s instructions. * Slaughter Model 1101 Dielectric Breakdown Tester available from: Slaughter Company, LLC P. O. Box 1805 Ardmore, OK 73402 Ph: 800-421-1921 Internet: www.coiltester.com ISSUED

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

1 of 1 SB 663

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

SB 02-9

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT: CYLINDER HEAD TO BARREL SEEPAGE P/N 654972 CYLINDER ASSEMBLY PURPOSE:

To provide inspection procedure for P/N 654972 cylinders to identify possible head to barrel seepage.

COMPLIANCE:

Within the next 25 hours of operation after the receipt of this service bulletin.

MODELS AFFECTED:

E-165, E-185, E-225, O-470-4,-7,-11,-13 and-15 series engines.

Teledyne Continental Motors has identified the possibility of head to barrel seepage and possible separation on P/N 654972 cylinders. Suspect cylinders were manufactured between January 11, 1999 and August 26,2000. The manufacturing date code is located on the center rocker shaft boss on the cylinder head. Refer to Figure 1. Date codes are scribed with month and year of manufacture, i.e. January 1999 would be 1- 99.

Manufacturer Date Code

FIGURE 1 MANUFACTURE DATE CODE

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SB-02-9

Within the next 25 hours of engine operation or the next scheduled inspection or engine servicing whichever ocurrs first, perform the detailed inspection listed below of each cylinder P/N 654972 with manufacture date code of 1-99 through 8-00. 1. 2.

Remove as necessary the engine cowling and access panels to allow access to the cylinder assemblies. Remove the rocker covers on each cylinder and inspect the cylinder for the manufacturing date code. Reference Figure 1. Cylinders with date codes of 1-99 through 8-2000 are affected by this service bulletin and must be inspected.

3.

Remove as necessary engine cowling and engine mounted equipment to gain access to the lower portion of the cylinder assembly.

4.

Visually inspect the area between the last large cylinder head cooling fin and the top of the cylinder barrel for presence of oil or oil residue. Reference Figure 2.

5.

If no oil or oil residue is present, make a logbook entry noting compliance with this service bulletin. No further inspections are mandated by this service bulletin. However, inspection of this area is required as a part of a 100 hour/annual inspection. Additionally, TCM service bulletin SB 96-12, Continued Airworthiness Instructions for TCM Cylinders, provides detailed inspection criteria for all TCM cylinders.

6.

If oil or oil residue is noted, contact TCM at 1-888-826-5465 option number 1. Please have the engine serial number, cylinder manufacture date code, total time on cylinders and cylinder installation date available when you phone.

Inspect this area for oil or oil residue

FIGURE 2 CYLINDER HEAD TO BARREL JUNCTURE

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB03-3 FAA APPROVED

Compliance Will Enhance Safety

SUPERSEDES M84-15

SUBJECT:

DIFFERENTIAL PRESSURE TEST AND BORESCOPE INSPECTION PROCEDURES FOR CYLINDERS.

PURPOSE:

This bulletin provides differential pressure test and borescope inspection procedures for cylinders to be used as a guide in the determination of their serviceability with respect to these tests.

COMPLIANCE: MODELS AFFECTED:

At each 100 hour interval, annual inspection or when cylinder problems are suspected.

All Teledyne Continental Motors (TCM) engine models.

GENERAL F.A.A. Advisory Circular (AC) 43.13-1. Chapter 8, Section 1, paragraph 8-1 states; “ Consult the manufacturer’s manuals, service bulletins and instruction books regarding the repair and overhaul, inspection, installation, and maintenance of aircraft engines, for that particular make, model and type of engine. This section lists acceptable inspection and repair procedures that may be used in the absence of an engine manufacturer’s maintenance information.” The following procedures are to be used as the standard for performing a cylinder differential pressure test on all TCM engines. Reference 14 CFR Part 43.13.

A.

CYLINDER CONDITION DISCUSSION

The cylinder differential pressure test has become a widely used method of assisting in determining the internal condition of cylinders and cylinder components. As with any test or inspection the cylinder differential pressure test has certain limitations that necessitate its use in conjunction with other non-invasive inspections. TCM requires a cylinder borescope inspection be accomplished in conjunction with the differential pressure test. In addition to the cylinder differential pressure test and borescope inspection, further inspection of any suspect cylinder is recommended in accordance with the guidelines set forth in this service bulletin. Refer to Tables 1 and 2. The technician should also be cognizant of the engines’ oil consumption, the appearance or color of the engine oil and any visual indications of high crankcase pressure (combustion blow-by) such as an oily, wet area on the aircraft belly or lower wing surface. Refer to the latest revision of TCM’s Service Bulletin (SB) 96-12 and Service Information Directive (SID) 97-2 for additional inspection items and pilot awareness topics.

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SB03-3

The purpose of the cylinder differential pressure test is to IDENTIFY LEAKS and the SOURCE OF LEAKS, with the engine under static conditions (not running), using a regulated pressure source. When performing a cylinder differential pressure test a regulated test pressure of eighty pounds per square inch (80 PSI) is directed into the cylinder with the piston at top dead center at the end of the compression stroke and the beginning of the power stroke. Eighty pounds per square inch (80 PSI) is used as a test pressure for safety reasons and is significantly less than the combustion pressure of 800 to 1000 PSI created during engine operation. Pistons, piston rings, valves and valve seats rely on combustion forces to assist in creating a complete seal during engine operation. NOTE: This static leak check does not relate directly to cylinder pressures developed during actual engine operations. The purpose of the cylinder borescope inspection is to provide a visual method of examining the internal cylinder components and must be used in conjunction with the differential pressure test. Excess cylinder wall or piston ring wear, broken piston rings and burned valves will normally be evidenced by additional conditions that must be taken into consideration when determining cylinder condition. These may include, but may not be limited to: Excessive cylinder barrel wear and/or piston ring wear: 1. Elevated crankcase pressure; reference the latest revision of TCM Service Bulletin M89-9. 2. Increased oil consumption. See note | on page 9. 3. Oil becoming discolored within first 10 hours after an oil change. 4. High iron content in oil analysis may be an indication. Broken piston rings: 1. Scored, grooved cylinder wall, evident via a borescope inspection. 2. Abnormal debris in oil filter or oil screen. 3. High iron content in oil analysis may be an indication. Burned Valves: 1. Usually results in differential leak test reading in the 0/80 to 40/80 range. 2. Easily identifiable during borescope inspection. Additionally, many variables affect what a technician sees from a differential pressure test reading. These variables include, but are not limited to: 1. Abnormal amounts of oil in cylinder. 2. Temperature of the engine and the uniformity of cylinder temperature at the time the differential pressure test is performed. 3. Accuracy of the test equipment being used. 4. Capacity and pressure output of the source of compressed air and the techniques used by the technician when performing the test.

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B.

CYLINDER DIFFERENTIAL PRESSURE TEST:

(a) Required Tools and Equipment: In addition to the standard complement of tools required to perform maintenance and repairs on aircraft engines the following tools and equipment are required to perform a cylinder differential pressure test. 1. Source of dry, compressed air capable of providing a minimum line pressure of 125 P.S.I. with a minimum flow capability of 15 Cubic Feet per Minute. 2. Cylinder differential pressure tester. Select one of the following units listed below or equivalent. •

Eastern Technology Corporation Model E2M{. See Figure 1. Recommended by TCM. This differential pressure tester incorporates the Master Orifice Tool. Eastern Technology Corporation 180 Roberts Street East Hartford, CT 06108 Phone: 860-528-9821

•

Eastern Technology Corporation Model E2A{. See Figure 2. This differential pressure tester requires you to purchase separately the Master Orifice tool P/N 646953. Eastern Technology Corporation 180 Roberts Street East Hartford, CT 06108 Phone: 860-528-9821

3. Master Orifice Tool P/N 646953A. This tool is available in limited supply. SPX Corp. - Kent Moore Tool Division 28635 Mound Road Warren, MI 48092 Phone: 800-345-2233 NOTE: Differential pressure test equipment must be certified and calibrated. Failure to properly maintain and calibrate test equipment may result in false cylinder differential compression readings. Eastern Technology Corporation offers calibration and repair service on these items.

{

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FIGURE 1 Eastern Technology Corp. Model E2M

FIGURE 2 Eastern Technology Corp. Model E2A

(b) Establishing the Acceptable Pressure Leakage Limit: The “Master Orifice” is a calibration standard that must be used prior to performing the cylinder differential pressure test. The “Master Orifice” establishes the Acceptable Cylinder Pressure Leakage Limit for the test equipment being used and the atmospheric conditions at the time of the test. The Acceptable Cylinder Pressure Leakage Limit reading must be recorded along with the individual cylinder readings in the engine logbook and the inspection work order.

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1) Eastern Technology Corporation Model E2M: This test is accomplished with no connections to the female quick connector. a) Set the Master Orifice Valve to the OFF position; handle horizontal and directly over the OFF label. b) Set the Slow Fill Valve (next to the pressure regulator) to the OFF position; handle vertical and pointing down. c) After making sure the Slow Fill Valve is OFF, connect your air source to the tester at the male quick connection fitting. d) Adjust pressure regulator so left hand gauge reads 80 PSI. e) Set the Master Orifice Valve to the TEST position; handle vertical and pointing down. f) Open the Slow Fill Valve completely; handle horizontal and over the PRESSURIZED label. g) If necessary, adjust the regulator to maintain 80PSI indication on the left-hand gauge. h) Record the pressure reading on the right hand gauge. This reading is the Minimum Acceptable Cylinder Pressure Leakage Limit. i)

Close the Slow Fill Valve completely; handle vertical and pointing down.

j)

Set the Master Orifice Valve to the OFF position; handle horizontal and directly over the OFF label.

You are now ready to perform the cylinder differential pressure test. 2) Standard Differential Pressure Tester and Master Orifice Tool P/N 646953:

FACTORY CALIBRATED ORIFICE

DUST CAP

DUST CAP

SPARK PLUG THREADS (18mm)

FIGURE 3 MASTER ORIFICE P/N 646953

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a) Make sure the Regulator Pressure Valve is backed all the way OUT. b) Make sure the Cylinder Pressure Valve is OFF or Closed. c) Remove the protective caps from both ends of the Master Orifice and install the Master Orifice onto the threaded end of the cylinder adapter and tighten hand tight. d) Connect the cylinder adapter with Master Orifice attached to the female quick connection on the supply hose from the differential test unit. e) Connect your air source to the tester at the male quick connection fitting. f) Adjust pressure regulator so regulator pressure gauge reads 80 PSI. g) Turn the cylinder pressure valve to the ON or OPEN position. h) If necessary, adjust the pressure regulator to maintain a reading of 80 PSI on the regulator pressure gauge. i)

Record the pressure reading on the cylinder pressure gauge. This reading is the Minimum Acceptable Pressure Leakage Limit.

j)

Turn the cylinder pressure valve to the CLOSED or OFF position.

k) Remove the cylinder adapter and Master Orifice from the female quick connection on the supply hose from the differential test unit. l)

Remove the Master Orifice from the cylinder adapter.

You are now ready to perform the cylinder differential pressure test. CYLINDER ADAPTER CYLINDER PRESSURE VALVE

CYLINDER PRESSURE VALVE

CYLINDER ADAPTER

CYLINDER PRESSURE GAUGE

CYLINDER PRESSURE GAUGE

RESTRICTOR ORIFICE

RESTRICTOR ORIFICE

REGULATOR PRESSURE GAUGE

REGULATOR PRESSURE GAUGE

MASTER ORIFICE (HAND TIGHT)

Read Cylinder Leakage on this Gauge

Read Minimum Acceptable Cylinder Leakage Limit on this Gauge

REGULATOR PRESSURE VALVE

CYLINDER

REGULATOR PRESSURE VALVE

COMPRESSED AIR SOURCE

COMPRESSED AIR SOURCE

Establishing Minimum Acceptable Performing Differential Pressure Test Cylinder Pressure Leakage Limit With FIGURE 3 Master Orifice Tool

FIGURE 4 Differential Pressure Test Equipment ISSUED

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(c) Performing The Cylinder Differential Pressure Test: Ideally, perform the cylinder differential pressure test as soon as possible after the aircraft has been flown. If the aircraft cannot be flown prior to performing the cylinder differential pressure test, it must be operated on the ground, with the cowling installed until a minimum cylinder head temperature (CHT) of 300 to 350 degrees Fahrenheit is observed on the aircraft gauge. For aircraft fitted with constant speed propellers operate the engine at a high enough power setting to allow the cycling of the aircraft propeller. For aircraft with fixed pitched propeller, operate the engine to full static RPM.

WARNING Magnetos must be grounded and fuel must be shut off prior to test to make certain that the engine cannot accidentally start. Take necessary precautions to prevent accidental rotation of the propeller while performing the differential pressure leak test. Differential Pressure tests are best performed with two people, one to adjust the pressure regulator and one to hold the aircraft propeller. NOTE:

The 360 series, 470 series and 520/550 Sandcast engines utilize a starter adapter design that results in an increased resistance in turning force when the propeller is turned in the opposite direction of normal rotation. The technician may, if he desires, reduce the amount of resistance by removing the starter motor from the starter adapter when performing this test.

1. Perform the test as soon as possible after the engine is shut down to ensure that the piston rings, cylinder walls, and other engine parts are well lubricated and at operating clearance. 2. Remove the most accessible spark plug from each cylinder. Identify the cylinder number and position of the removed spark plugs. Examination of the spark plugs will aid in diagnosing engine and cylinder conditions. Reference spark plug manufacturers’ technical data. 3. Turn the crankshaft by hand in the direction of rotation until the piston (in the cylinder being checked) is coming up on its compression stroke. 4. Install the cylinder adapter in the spark plug hole and connect the differential pressure tester to the adapter. (NOTE: Cylinder pressure valve is in the CLOSED position). Slowly open the cylinder pressure valve and pressurize the cylinder to 20 PSI. 5. Continue rotating the engine in the normal direction of rotation, against this pressure, until the piston reaches top dead center (TDC). TDC is indicated by a sudden decrease in the force required to turn the crankshaft. If the crankshaft is rotated too far, back up at least one-half revolution and start over again to eliminate the effect of backlash in the valve operating mechanism and to keep the piston rings seated on the piston ring lands. WARNING

Care must be exercised in opening the cylinder pressure valve, since sufficient air pressure will be built up in the cylinder to cause it to rotate the crankshaft if the piston is not at TDC. 6. With the piston at top dead center, open the cylinder pressure valve completely. Check the regulator pressure gauge and adjust, if necessary, to 80 PSI. 7. To assure that the piston rings are seated and the piston is square in the cylinder bore, move the propeller slightly back and forth with a rocking motion, while applying the regulated pressure of 80 PSI, to obtain the highest indication. Adjust the regulator as necessary to maintain a pressure gauge reading of 80 PSI.

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8. Record the pressure indication on the cylinder pressure gauge. The difference between this pressure and the pressure shown by the regulator pressure gauge is the amount of leakage through the cylinder. Record individual cylinder readings as; (pressure reading)/80 PSI. 9. Note any leakage source (air discharge) and determine serviceability. Refer to Table 1. 10. Proceed to the next cylinder and repeat Step 3 through 9 until all cylinders have been checked. 11. After all cylinder pressure indications have been recorded, proceed with a borescope inspection of each cylinder in accordance with Table 2, section C. TABLE 1 DIFFERENTIAL PRESSURE TEST RESULTS PRESSURE TEST VALUE SYMPTIONS AND OBSERVATIONS Cylinder differential pressure Normal Borescope Indications. test reading above leakage Oil Consumption stable, no limit. excessive oil discharge out engine breather. Cylinder differential pressure Normal Borescope Indications. test reading below leakage Oil Consumption stable, no limit. excessive oil discharge out engine breather. Cylinder differential pressure test reading below leakage limit after re-check N/A

AIR DISCHARGE SOURCE Air discharge at oil filler/crankcase breather.

Air discharge at oil filler/crankcase breather.

Cylinder differential pressure test reading above or below leakage limit.

ISSUED

Oil Consumption abnormal |, with oil discharge out engine breather. Borescope inspection reveals heavy carbon deposits in combustion chamber and on piston crown with excessive oil puddling in cylinder barrel

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RECOMMENDED ACTION Continue engine in service. Repeat differential pressure test at next 100-hour/annual inspection. Fly Aircraft at Cruise Power setting { and repeat cylinder differential pressure test Remove cylinder for repair

Remove cylinder for repair

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TABLE 1 (continued) AIR DISCHARGE SOURCE

Little to no air discharge at oil filler/crankcase breather.

Air discharge into induction system

Air discharge into exhaust system

Air escaping at spark plug spot face Air discharge at cylinder head to barrel juncture or between barrel fins

DIFFERENTIAL PRESSURE TEST RESULTS PRESSURE TEST VALUE SYMPTIONS AND OBSERVATIONS Oil Consumption abnormal | with oil discharge out engine breather. Cylinder differential pressure Borescope inspection reveals test reading abnormally high heavy carbon deposits in combustion chamber and on piston crown. Excessive oil puddling in cylinder barrel. Cylinder differential pressure Normal cylinder borescope test reading above leakage inspection results. limit.

RECOMMENDED ACTION

Remove cylinder for repair.

Continue engine in service.

Fly aircraft at cruise power { and repeat cylinder differential pressure test.

Cylinder differential pressure test reading below leakage limit.

Normal cylinder borescope inspection results.

Cylinder differential pressure test reading below leakage limit after re-check.

N/A

Remove cylinder for repair.

Cylinder differential pressure test reading above leakage limit.

Normal cylinder borescope inspection results.

Continue engine in service.

Cylinder differential pressure test reading below leakage limit.

Normal cylinder borescope inspection results.

Fly aircraft at cruise power { and repeat cylinder differential pressure test.

Cylinder differential pressure test reading below leakage limit after re-check.

N/A

Cylinder differential pressure test readings N/A Cylinder differential pressure test readings above leakage limit

Dye check of area reveals cracks. First cylinder head fin above cylinder barrel wet with oil or baked on oil residue. See also latest revision of SB96-12 for additional test to be performed.

Remove cylinder for repair Remove cylinder for replacement. Remove cylinder for replacement.

{ Fly the aircraft at a cruise power setting between 65 and 75 percent power, as specified in the aircraft Pilots Operating Handbook/Aircraft Flight Manual (POH/AFM), for a duration that will allow the engine oil and cylinder head temperatures to stabilize, or at least 45 minutes. Perform an additional differential compression test on the suspect cylinder(s). | A sudden increase in oil consumption from the established or normal trend for the engine or an oil consumption rate that exceeds 1/2 quart (liter) per hour during normal engine operation. ISSUED

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C. CYLINDER BORESCOPE INSPECTION (a) Required Equipment: In addition to the standard complement of tools required to perform maintenance and repairs on aircraft engines the following tools and equipment are required to perform a cylinder borescope inspection. 1. Borescope. •

AUTOSCOPETM – Lenox Instrument Company. See Figure 5. Recommended by TCM. Q. A. Technologies PO Box 61085 Savannah, GA 31420 Phone: 912-330-0500 Fax: 912-330-0104 E-mail: [email protected] Web-site: qatek.com Note: TCM customers receive a special discount when ordering from Q. A. Technologies.

FIGURE 5 (b) Performing the Inspection:

CAUTION Take preventative measures to avoid burns when performing a borescope inspection on a hot engine. 1. If not already removed for differential pressure test, remove the upper spark plug from each cylinder. 2. Position piston at bottom dead center on the power stroke. The exhaust valve will be open with the piston in this position. 3. Insert the borescope probe through the upper spark plug hole and inspect the internal surfaces of each cylinder, including the exhaust valve and exhaust valve seat in accordance with Table 2. 4. After completing inspection steps 1,2 and 3; position piston at bottom dead center at the end of the intake stroke. 5. Insert the borescope probe through the upper spark plug hole and inspect the intake valve and intake valve seat in accordance with Table 2. ISSUED

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TABLE 2 Borescope Inspection Objectives And Corrective Actions ITEM

Objective

If Abnormality Noted

Inspect: 1. Combustion chamber.

Valve seat inserts for erosion, burning.

2.

Sparkplug heli-coils for protrusion into combustion chamber. 3. Heavy carbon deposits/presence of excessive oil.

1.

Remove cylinder for repair

2.

Remove cylinder for repair

3. Remove cylinder for repair.

Inspect for signs of leakage or damage, indicated by: 1.

Localized discoloration on the valve face circumference. See Figure 7 page 12

1.

Repair or replace cylinder.

2.

Minute cracks.

2.

Repair or replace cylinder.

3.

Erosion (missing material).

3.

Repair or replace cylinder.

1. Localized discoloration on the valve face circumference. 2. Erosion (missing material) Inspect exposed surface of bore for:

1. 2.

Repair or replace cylinder. Repair or replace cylinder.

1.

Heavy scoring/piston rub. See Figure 10 on page 13.

2.

Piston pin rub (wide ban pattern in horizontal plane at 3 o’clock and/or 9 o’clock position). Upper portion of cylinder bore has no visible hone pattern. See Figure 11 &12 on page 13 and 14.

1. 2.

Repair or replace cylinder. {

3.

Normal indication for in service cylinders

4.

|

5.

Remove cylinder for repair

1.

Remove cylinder for repair

2.

Remove cylinder for repair

Exhaust valve face

Inspect for signs of leakage or damage, indicated by: Intake valve face.

Cylinder Bore.

3.

4. 5.

Corrosion. See Figure 9, on page 12. Excessive oil in cylinder/heavy deposits of carbon in combustion chamber Inspect for: Piston Head.

1. 2.

Piston crown for erosion, missing material Visible damage from foreign debris.

Experience and expertise in borescope examination requires the aviation technician to perform borescope inspection on a consistent basis. It is especially important that the technician perform borescope inspections prior to removal of a cylinder for any reason so that they may validate by visual indications viewed through the borescope, the actual conditions. The following photographs are provided as a guide to the aviation technician when performing borescope examinations. Teledyne Continental Motors welcomes inquiries and comments from the aviation technician. We urge you to call your Regional Service Representative or Teledyne Continental Motors Technical Support at (888) 826-5465. {

Remove cylinder for repair or replacement. Perform complete inspection of connecting rod bushing for correct installation and finishing. Refer to latest revision of TCM SB 00-3.

|

Refer to the latest revision of TCM Service Information Directive (SID) 97-2. See Figure 9.

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Normal Combustion Chamber. Exhaust valve has reddish combustion deposit in center with dark outer edge. Intake valve has light brown combustion deposits. Combustion chamber has light brown deposits.

Burned exhaust valve. Note edge of valve face that has lost all combustion residue and striations moving toward center of valve.

FIGURE 6

FIGURE 7

New Phosphate coated cylinder bore with revised cylinder bore hone pattern. Phosphate coating provides increase corrosion protection during the initial hours of engine operation.

Phosphated cylinder bore. Note phosphate coating remaining in valleys of cylinder bore hone pattern. Light corrosion at top of cylinder bore, above piston ring travel limit. Presence of light corrosion in this area is normal.

FIGURE 8

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FIGURE 9

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FIGURE 10 CYLINDER BARREL SCORING / PISTON RUB

FIGURE 11 UPPER RING TRAVEL AREA TYPICAL IN SERVICE CYLINDER BARREL

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FIGURE 12 TYPICAL IN SERVICE CYLINDER BARREL

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB 03-4

Compliance Will Enhance Safety SUBJECT:

Inspection of oil gauge rod and cap assemblies, P/N 652171-22 and P/N 652171-27.

PURPOSE:

To visually inspect the P/N 652171-22 and P/N 652171-27 oil gauge rod and cap assemblies for the presence of a 90-degree twist.

COMPLIANCE: MODELS AFFECTED:

At next oil level inspection, no later than next 100 HR / Annual Inspection. IO-550-P model engines utilizing the affected part number oil gauge rod and cap assemblies.

A report from the field indicates that one P/N 652171-22 oil gauge rod and cap assembly (dipstick) was forced through the crankcase breather reference hole in the oil filler housing. This caused the oil gauge rod to be damaged by the crankshaft. Subsequent damage to the crankshaft then occurred.

WARNING Incorrect installation of the oil gauge rod and cap assembly may cause breakage of the oil gauge rod and internal damage to the engine. Do not operate any engine with a damaged oil gauge rod until an internal engine examination is accomplished and any damage is repaired.

Inspection and Replacement Instructions: 1. Gain access to the oil gauge rod and cap assembly (dipstick) and remove it from the engine. 2. Visually inspect the oil gauge rod for a 90-degree twist beginning at 3.62” from the lower end of the oil gauge rod, reference Figure 1. 3. If a single twist is noted at this location or a double twist exists, no further action is required. Proceed to step 5. 4. If no twist is noted, a replacement P/N 652171-27 oil gauge rod and cap assembly must be installed. The oil gauge rod and cap assembly may remain in service until a replacement part is obtained by verifying that it is installed correctly with the oil gauge rod inserted properly into the oil filler housing. 5. Reinstall the oil gauge rod and cap assembly, taking care that the oil gauge rod is inserted properly into the oil filler housing assembly.

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SB 03-4

A Teledyne Technologies Company

© 2003 Teledyne Continental Motors, Inc.

Twist

Figure 1 Warranty TCM will provide a replacement oil gauge rod and cap assembly for those requiring replacement IAW this service bulletin for a period of six months from the date of issue of this service bulletin. Orders must be placed and a warranty claim filed with an authorized TCM distributor.

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SB 03-4

A Teledyne Technologies Company

© 2003 Teledyne Continental Motors, Inc.

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB03-5

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

New Limits For Crankshaft End Clearance

PURPOSE:

To update the specified crankshaft end clearance.

COMPLIANCE: MODELS AFFECTED:

During engine overhaul or anytime the engine is reassembled utilizing new bearings and thrust washers. C75, C85, O-200 Series

TCM has revised the specified crankshaft end clearance for all C75, C85, and O-200 series engines. The clearances contained in chart 1 of this service bulletin supercede the clearances contained in section XVIII Table of Limits of the C75, C85, C90 & O-200 Overhaul Manual Form Number X30010. SECTION XVIII TABLE OF LIMITS Ref. No. 24

Chart Description New Parts No. Crankshaft Minimum Maximum 2 Crankshaft to Thrust Washers….End Clear: 0.004 0.022

Service Maximum 0.025

Note: If the crankcase is the older type, equipped with dowels in the front main bearing boss to retain the thrust washers, thrust washer P/N 35552 or approved superceding part must be used. The above listed revised end clearance limits apply to both types of thrust washers.

These changes will be incorporated into the next revision of the C75, C85, C90 & O-200 series Overhaul Manual Form Number X30010.

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© 2003 Teledyne Continental Motors, Inc.

A Teledyne Technologies Company

PO Box 90 Mobile AL 36601 • 251-438-3411

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TELEDYNE CONTINENTAL

®

Category 3 SB03-7

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety SUBJECT:

TECHNICAL PORTIONS FAA APPROVED

IO-240-SERIES MAGNETO DRIVE GEAR

PURPOSE: To notify owners, operators, maintenance facilities and distributors of inspection, repair and/or replacement of magneto drive gear P/N 36066. COMPLIANCE: Initial compliance at next scheduled inspection, but not later than the next 50 hours of service. Recurring compliance each time the magneto is removed on condition and at each 500 hour manufacturers recommended magneto inspection. MODELS AFFECTED: All IO-240-A and IO-240-B series equipped with Slick Magnetos. NOTE: Engines on which previous compliance with bulletin SSI2001-1 can be verified may be considered in compliance with this service bulletin. Teledyne Continental Motors has received reports of premature wear on the magneto drive gears installed on the IO-240-Series engines equipped with Slick magnetos. PART A: GENERAL INFORMATION For affected engines, perform a visual inspection of the magneto drive gear P/N 36066 at the next scheduled maintenance event, but not later than the next 50 hours of engine operation. Gears showing indications of spalling or pitting distress must be removed from service and replaced with a new or serviceable P/N 36066 gear. Refer to Figures 1 & 2 for acceptable and unacceptable criteria. For gears that do not show indications of spalling or pitting proceed to and comply with Part C of this service bulletin. PART B: MAGNETO DRIVE GEAR INSPECTION Refer to the latest revision of the IO-240-A and B Engine Overhaul Manual Form X30622A chapter 8 for specific inspection instructions and criteria.

1. Remove the engine cowling in accordance with the aircraft manufacturer’s instructions. 2. Remove as necessary engine mounted components to gain access to the left and right magneto. 3. Remove the left and right magnetos from the engine accessory case. Refer to the IO-240-A & B Engine Overhaul Manual Form X30622A chapter 8. 4. Remove the magneto drive gear, P/N 36066, from the left and right magneto. Retain the P/N M3172 thrust washer and M3019 castle nut for reinstallation, if serviceable. Refer to the IO240-A & B Engine Overhaul Manual Form X30622A chapter 8. 5. With the magneto drive gears removed from the magneto, visually inspect each gear for indications of spalling and/or pitting of the gear teeth. Refer to figures 1 and 2. 6. If no indications of spalling or pitting are observed proceed to Part C. 7. If spalling and/or pitting is observed the gear must be removed from service. Obtain a new or serviceable P/N 36066 magneto drive gear.

WARNING Before performing any preventive maintenance, maintenance or inspections insure that the aircraft Master Switch is in the OFF position and the engine Ignition Switch is in the OFF position. ISSUED

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SB03-7

PART C: MAGNETO DRIVE GEAR INSTALLATION and SHIMMING 1. Install magneto drive gear P/N 36066 on magneto shaft, insuring that the drive lug slots engage the magneto driver assembly drive lugs. Refer to Figure 3. 2. Install one each (1 ea.) NAS 1149C0632R washer over the magneto drive shaft insuring the washer is seated against the hub P/N M5269. Refer to Figure 4. 3. Install thrust washer P/N M 3172 and castle nut P/N M 3019. Torque the castle nut to 120 inch lbs. minimum. Gradually increase the nut torque to align the castellated nut slots with the drilled hole in the magneto shaft. Nut torque must not exceed 320 inch lbs. Refer to figure 4. NOTE: Magneto drive gear must have slight angular movement in relation to the driver when correctly installed and the castellated nut torqued to the specified value. The assembly is designed so that the thrust washer clamps against the flat washer and drive hub, not the magneto drive gear.

4. Install new cotter pin P/N M 2556 (Unison P/N) or MS24665-300 and secure in accordance with section 5-4 of the Engine overhaul Manual Form X30622A. 5. Install magnetos in the reverse order of removal. Refer to Engine Overhaul Manual Form X30622 chapter 19 for specific instructions and magneto to engine timing procedures. 6. Install any engine mounted components removed to facilitate magneto removal and installation. 7. Install engine cowling in accordance with the aircraft manufacturer’s instructions. 8. Perform a complete engine ground run up. 9. Perform a magneto check in accordance with the aircraft manufacturer’s AFM/POH. 10. Visually inspect the engine for flammable fluid leaks. Correct any discrepancies noted prior to returning the aircraft and engine to service. 11. Make an engine logbook entry indicating compliance with TCM SB03-7.

Inspect gear teeth for indication of spalling and pitting. Scrap gear with indications similar to these. Inspect gear teeth for indications of spalling and pitting. Gears with indications similar to these may be continued in service

FIGURE 2 Unacceptable Gear Tooth Wear

FIGURE 1 Acceptable Gear Tooth Wear Pattern

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SB03-7

P/N M5269 Hub

M 5265 Driver Dog Ears

P/N 36066 Gear

FIGURE 3 Magneto Hub, Drive Assembly and Gear

M 2556 (Unison P/N) or MS24665-300 Pin, Cotter

M 3172 Washer

NAS 1149C0632R Washer P/N 36066 Gear

M 3019 Nut, Castellated

FIGURE 4 EXPLODED VIEW OF HARDWARE ASSEMBLY SEQUENCE ISSUED

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SB03-7

WARRANTY Teledyne Continental Motors will reimburse 4 hours labor to perform the initial inspection and shimming procedure specified in Service Bulletin SB03-7. If replacement of the P/N 36066 gear assembly is required, TCM will cover parts cost and freight for the gear assembly. The following procedures should be followed to obtain warranty reimbursement: 1) If the inspection and shimming procedures only are performed, submit the attached compliance form for reimbursement for labor and specified hardware costs. An itemized copy of the work order and invoice must be submitted with the compliance form. 2) If gear replacement is required, warranty for parts and labor must be submitted through the TCM authorized distributor from which the magneto drive gear is retained. In this case submittal of the compliance form will not be necessary.

COMPLIANCE FORM SB03-7 Reimbursement to be sent to _______Owner_______ FBO (CHECK ONE) Owner Name:

Aviator Services Membership #:

Date:

City:

State/Country:

Zip Code:

FBO Name:

Phone #

Address:

Fax#

Date:

Address: City:

State/Country:

Zip Code:

Aircraft Registration #:

Make/Model:

S/N:

Engine Model:

Serial Number:

Date Installed:

Total Time:

Time Since Major O/H:

Comments:

Signature Of Submitter:_____________________________________________ Mailing address:

{

ISSUED

Teledyne Continental Motors P.O. Box 90 Mobile, Alabama 36601 Attn: Bill Ross or Joe Barton

or

Fax number: 251-432-7352

REVISED

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SB03-7

®

TELEDYNE CONTINENTAL

Category 3

AIRCRAFT ENGINE

SB04-10

SERVICE BULLETIN Compliance Will Enhance Safety

Technical Portions FAA Approved Supersedes SIL02-1

SUBJECT:

PISTON POSITION MARKING

PURPOSE:

To advise owners, Operators and FBOs operating and/or maintaining Teledyne Continental Motors engines of the elimination of piston position marking on new and rebuilt engines.

COMPLIANCE: At next piston replacement MODELS AFFECTED: All

PISTON POSITION MARKING Teledyne Continental Motors has discontinued the practice of marking the piston position number on the crown of the piston for new and rebuilt engines. TCM has received reports from the field that a small number of pistons with position markings stamped in the vicinity of the piston pin bore have cracked in the area of the position stamp. Pistons installed in TCM engines must not be stamped or etched with piston position numbers, at any location on the piston, during field installation of replacement pistons. NOTE Some Teledyne Continental Motors Maintenance and Overhaul manuals may show procedures for piston position marking. These procedures are no longer approved by TCM. WARNING Piston position stamps over the piston pin bore may lead to piston failure with subsequent engine damage and engine failure.

ISSUED

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© 2004 Teledyne Continental Motors, Inc.

Teledyne Continental Motors, Inc.

1 of 1

PO Box 90 Mobile AL • 251-438-3411

SB04-10

A Teledyne Technologies Company

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB 04-11

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

VALVE GUIDE APPLICATION, INSTALLATION AND REAMING PROCEDURES

PURPOSE:

PROVIDE VALVE GUIDE APPLICATION BY CYLINDER PART NUMBER AND DIMENSIONAL FITS AND LIMITS FOR VALVES, PRE-FINISHED AND REAM IN PLACE VALVE GUIDES

COMPLIANCE: MODELS AFFECTED:

AT ENGINE MAJOR OVERHAUL, CYLINDER OVERHAUL OR CYLINDER REPAIR C-75, C-85, C-90, O-200, O-240 Rolls-Royce, O-300, G0-300, IO-240 IO-360, TSIO-360, LTSIO-360 E-SERIES, O-470, IO-470, TSIO-470, IO-520, TSIO-520, LTSIO-520, GTSIO-520, IO-550, TSIO-550 AND TSIOL-550 SERIES ENGINES.

GENERAL INFORMATION Teledyne Continental Motors has utilized pre-finished intake and exhaust valve guides in production cylinders and as service replacement parts for many years. This service bulletin announces the release of replacement ream in place valve guides. Dimensional specifications for ream in place and pre-finished valve guides are provided in tabular form in Table 1 and Table 3. Ream in place valve guides may be installed as a replacement for pre-finished valve guides. However, pre-finished valve guides must not be installed as replacements for ream in place valve guides. NOTE: Refer to the applicable engine overhaul manual for valve guide removal and installation instructions and specifications. All measurements must be made using properly calibrated and certified precision measuring devices. IN SERVICE VALVE AND VALVE GUIDE MEASUREMENTS 1. Refer to the applicable engine Maintenance or Overhaul Manual for specific inspection criteria for intake and exhaust valves. Valve stems must conform to specified new parts dimensions. 2. When measuring valve guide inside diameter during cylinder repair, take valve guide measurements at locations in the upper 1/3 and center 1/3 of the valve guide length, reference Figure 1 and Table 1. Measurements taken at the bottom of the intake and exhaust valve guide are not indicative of the overall serviceability of the valve guide. ISSUED

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SB04-11

© 2004 Teledyne Continental Motors, Inc.

3. Valve guide inside diameter must not exceed the “Service Limit” dimension for the specific engine and cylinder combination. Valve guides exceeding the “Service Limit” dimensions specified in Tables 1 and 3 as applicable will require replacement. PRE-FINISHED VALVE GUIDE MEASUREMENTS: 1. Pre-finished valve guides must be measured before installation to insure they conform with the new parts dimensions specified in Tables 1 and 3. 2. Measure valve guide inside diameter at three equally spaced locations along the length of the valve guide. Reference Figure 2 and Table 1. 3. Measure the outside diameter of the valve guide below the flange, reference Figure 2. Record these readings on the repair work order. 4. Measure valve stem diameter between the valve keeper annulus and the face of the valve. Record this reading on the repair work order. VALVE GUIDE INSTALLATION: CAUTION: When installing valve guides in cylinders verify that the valve guide is correct for the cylinder and engine application. Reference Table 1. 1. Refer to the applicable engine overhaul manual for specific installation instructions and specialized equipment and tooling required. 2. Before installing a replacement valve guide, the valve guide bore in the cylinder head must be reamed to the proper oversize dimension. The difference between the valve guide outside diameter and the valve guide bore inside diameter must be within the dimensional specification provided in Tables 1 and 3 for the applicable engine and cylinder combination. 3. A. (Pre-finished Guides) After installing new valve guides allow the cylinder to cool and stabilize at room temperature before taking any dimensional measurements. Measure valve guide inside diameter at three equally spaced locations along the length of the valve guide. Reference Figure 2. If inside diameter is not within the specific new minimum and maximum dimensional limits, the guide will require finish reaming to size or replacement. B. (Ream-in-place Guides) Post installation measurements are only required on ream-in-place guides after reaming procedures have been completed. Allow the cylinder to cool and stabilize at room temperature before taking any dimensional measurements. Measure valve guide inside diameter at three equally spaced locations along the length of the valve guide, reference Figure 2. If inside diameter is not within specifications, the guide will require refinishing or replacement.

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VALVE GUIDE REAMING PROCEDURES WARNING Do not attempt this procedure with hand held power tools. Valve guides that are reamed with hand held power tools must be replaced. (1) Install a suitable cylinder holding fixture (Borroughs 5221B or equivalent) into a drill press or vertical mill to hold the cylinder. Index the fixture to the proper angle and install the cylinder into the fixture. (2) Zero in the guide with a dial indicator (3) Select a proper size high-speed steel or carbide-tip spiral reamer. Ream the valve guide at 400 RPM for high-speed steel reamers and 700 RPM for carbide-tip reamers. Use a high quality cutting oil for all valve guide reaming operations. CAUTION Reamers are made to cut right hand only. Do Not turn backwards even a partial turn. ` (4) Check the valve guide final dimensions using precision measuring equipment. (5) Inspect the surface finish of valve guide inner bore after final reaming. The surface finish of the intake valve guide must not exceed 63 RA, the surface finish of the exhaust valve guide must not exceed 125 RA.

Guide P/N

Material

655166 655523 655525 655527

Aluminum-Bronze Aluminum-Bronze Aluminum-Bronze Aluminum-Bronze

Guide P/N

Material

636242 639282 655526 656011 655166

Ni-resist Ni-resist Ni-resist Aluminum-Bronze Aluminum-Bronze

ISSUED

TABLE 1 INTAKE VALVE GUIDES Length Reamer Reamer ± .01 Cutting Pilot Diameter Diameter 2.17 .4354 .4220 2.03 .3750 .3630 1.81 .3750 .3630 2.22 .3440 .3310

EXHAUST VALVE GUIDES Length Reamer Reamer ± .01 Cutting Pilot Diameter Diameter 2.36 .4374 .4220 2.22 .3750 .3630 2.12 .3750 .3630 2.36 .4375 .4220 2.17 .4354 .4220

Finished I.D.

Replaces Guide Pre-finished P/N

.4350 - .4362 .3745 - .3755 .3745 - .3755 .3432 - .3442

643766 646681 653802 643422

Finished I.D.

Replaces Guide Pre-finished P/N

.4370 - .4380 .3745 - .3755 .3745 - .3755 .4370 - .4380 .4350 - .4362

643767 653214 653726 649177 643766

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REVISION

MEASURE IN SERVICE VALVE GUIDE I.D. AT THESE LOCATIONS. SEE TABLE 1 FOR VALVE GUIDE LENGHTS TO CALCULATE MEASUREMENT LOCATIONS

FIGURE 1 IN SERVICE VALVE GUIDE DIMENSIONAL MEASURMENTS

VALVE GUIDE

MEASURE NEW VALVE GUIDES AT ALL THREE LOCATIONS (1) BEFORE AND AFTER INSTALLATION (PREFINISHED GUIDES) OR (2) AFTER REAMING (REAM-IN-PLACE GUIDES) SEE TABLE 1 FOR VALVE GUIDE LENGHTS.

MEASURE VALVE GUIDE O.D. AT THIS LOCATION

VALVE GUIDE BORE IN CYLINDER HEAD MEASURE BORE AFTER REAMING PRIOR TO INSTALLING GUIDE IN CYLINDER HEAD

FIGURE 2 INSTALLATION CRITICAL MEASUREMENT LOCATIONS

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REVISION

TABLE 2 VALVE GUIDE APPLICATIONS ENGINE C-75, C-85 C-75, C-85 C-90, O-200 O-300 O-200, O-300 GO-300 E-165, E-185 E-225 IO-346 360 Series Except as noted below IO-240-A,B IOF-240-B IO-360-ES TSIO-360-MB RB,SB LTSIO-360-RB O-470-A,E,J O-470-G,K,L, R,S [Except G(7), G(10) and GCI] O-470-U O-470-G(7) (10) O-470-GCI, O-470-M, IO-470-C IO-470-J,K IO-470-D,E, F, H,L,M,N,S, U,V IO-520 Series Except as noted IO-520-P LIO-520-P

CYLINDER ASSEMBLY 655483A14 Original Style 655482A6 New Style

INTAKE VALVE GUIDE 655527

INTAKE VALVE 655968

EXHAUST VALVE GUIDE 655166

EXHAUST VALVE 655969

655525

655970

655526

655971

655483A10 655483A16 655480A3

655527 655527 655166

655968 655968 655783

655166 655166 656011

655969 655969 655771

655481A3 655478A4

655166 655523

655783 655867

636242 639282

655771 655866

655479A11

655523

655867

639282

655866

655475A6 655467A5

655166 655166

655783 655783

636242 636242

655771 655771

655468A5 655467A6

655166 655166

655783 655783

636242 636242

655771 655771

655475A5 655468A7

655166 655166

655783 655783

636242 636242

655771 655771

655469A6

655166

655783

636242

655771

655476A3

655166

655783

636242

655771

Note: Consult the latest version of the applicable parts manual for part number information. TCM provides parts history and application data on line via FBO Services and Information Services. Visit TCM’s website at www.tcmlink.com for full details.

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REVISION

TABLE 2 (Con’t) ENGINE IO-550-G Platinum Series IO-550-G TSIO-520-BE IOF-550-G IO-550-A,B,C IOF-550-B,C IO-550-B,C Platinum Series IO-550-B, C Special Edition IO-550-D,E,F,L IOF-550-D,E,F,L IO-550-D,F,L Platinum Series IO-550-N,P,R Except Platinum Series IO-550-N Platinum Series IOF-550-N,P,R TSIO-520-UB(17) Special Edition TSIO-520-AF, CE,UB [Except UB(17) ] TSIO-520-B,BB, C,D,DB,E,EB,G, H,J,JB,K,KB,L, LB,M,N,NB,P,R,T,V B,WB TSIO-550-A,B,C,E TSIOL-550-A,B, C GTSIO-520-C,D, H GTSIO-520-F,K GTSIO-520-H(7),(8), L,M,N,R

CYLINDER ASSEMBLY

INTAKE VALVE GUIDE

INTAKE VALVE

EXHAUST VALVE GUIDE

EXHAUST VALVE

655891A1

655166

646283

636242

652956

655474A18 656094A1

655166 655166

655783 655783

636242 636242

655771 655771

655469A6

655166

655783

636242

655771

655472A3

655166

655868

636242

655771

655484A4

655166

655868

636242

655771

655471A3

655166

655783

636242

655771

655485A3

655166

655868

636242

655771

655465A3

655166

655783

636242

655771

655932A3 656093

655166 655166

655783 655783

636242 636242

655771 655771

655484A4

655166

655868

636242

655771

655469A6

655166

655783

636242

655771

655470A3 655477A5 655466A3 655473A3 655474A16

655166 655166 655166 655166 655166

655783 655783 655783 655783 655783

636242 636242 636242 636242 636242

655771 655771 655771 655771 655771

655474A8

655166

655783

636242

655771

Note: Consult the latest version of the applicable parts manual for part number information. TCM provides parts history and application data on line via FBO Services and Information Services. Visit TCM’s website at www.tcmlink.com for full details.

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REVISION

TABLE 3A VALVE GUIDE FITS and LIMITS O-240 Rolls-Royce, IO/IOF240A&B, IO-360-Series, L/TSIO360-Series PRE-FINISHED GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Pre-Finished Guides Intake Guide Bore (New) Pre-finished Guides Intake Guide Bore (installed in cylinder) Pre-Finished Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Pre-Finished Guides Exhaust Guide Bore (New) Pre-Finished Guides Exhaust Guide Bore (installed in cylinder) Pre-Finished Guides Exhaust Valve Stem Diameter

Minimum .0010 T

Maximum .0025 T

Service Limits

.0010 L

.0040 L

.006 L

.3760

.3770

.3745

.3770

.3725

.3733

.0010 T

.0025 T

.0025 L

.0057 L

.3760

.3770

.3745

.3770

.3712

.3720

.008 L

REAM-IN-PLACE GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Ream-In-Place Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Ream-In-Place Guides Exhaust Valve Stem Diameter

Minimum .0010 T

Maximum .0025 T

Service Limits

.0012 L

.0030 L

.006 L

.3725

.3733

.0010 T

.0025 T

.0025 L

.0043 L

.3712

.3720

.008L

NOTE See Table 1 for intake and exhaust valve guide finished dimensions and recommended reamer sizes.

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REVISION

TABLE 3B O/IO470-Series, O-470 4,11 and 13, IO/TSIO/LTSIO520-Series, IO/IOF/GIO/TSIO/TSIOF/TSIOL550-Series, GTSIO520-Series VALVE GUIDE FITS AND LIMITS PRE-FINISHED GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Pre-Finished Guides Intake Guide Bore (New) Pre-Finished Guides Intake Guide Bore (installed in cylinder) Pre-Finished Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Pre-Finished Guides Exhaust Guide Bore (New) Pre-Finished Guides Exhaust Guide Bore (installed in cylinder) Pre-Finished Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0010 L

.0042 L

.0065 L

.4367

.4377

.4350

.4377

.4335

.4340

.0010 T

.0025 T

.0035 L

.0062 L

.4385

.4395

.4375

.4395

.4334

.4341

.0085 L

REAM-IN-PLACE GUIDES Intake Valve Guide In Cyl. Head Intake Valve In Guide Ream-In-Place Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Ream-In-Place Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0010 L

.0032 L

.0065 L

.4335

.4340

.0010 T

.0025 T

.0029 L

.0046 L

.4334

.4341

.0085 L

NOTE See Table 1 for intake and exhaust valve guide finished dimensions and recommended reamer sizes.

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TABLE 3C C-75, C-85, C-90, O-200-Series, O/GO300-Series With P/N 655482 New Style Cylinders VALVE GUIDE FITS and LIMITS PRE-FINISHED GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Pre-Finished Guides Intake Guide Bore (New) Pre-Finished Guides Intake Guide Bore (installed in cylinder) Pre-Finished Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Pre-Finished Guides Exhaust Guide Bore (New) Pre-Finished Guides Exhaust Guide Bore (installed in cylinder) Pre-Finished Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0010 L

.0040 L

.006 L

.3760

.3770

.3745

.3770

.3730

.3735

.0010 T

.0025 T

.0025 L

.0057 L

.3760

.3770

.3745

.3770

.3713

.3720

.008 L

REAM-IN-PLACE GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Ream-In-Place Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Ream-In-Place Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0012 L

.0030 L

.006 L

.3730

.3735

.0010 T

.0025 T

.0025 L

.0043 L

.3713

.3720

.008 L

NOTE See Table 1 for intake and exhaust valve guide finished dimensions and recommended reamer sizes. ISSUED

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TABLE 3D C-75, C-85, C-90, O-200-Series, O/GO300-Series With P/N 655483 Old Style Cylinders VALVE GUIDE FITS AND LIMITS PRE-FINISHED GUIDES Intake Valve Guide In Cyl. Head Intake Valve In Guide Pre-Finished Guides Intake Guide Bore (New) Pre-Finished Guides Intake Guide Bore (installed in cylinder) Pre-Finished Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Pre-Finished Guides Exhaust Guide Bore (New) Pre-Finished Guides Exhaust Guide Bore (installed in cylinder) Pre-Finished Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0010 L

.0045 L

.006 L

.3447

.3457

.3432

.3457

.3413

.3421

.0010 T

.0025 T

.0035 L

.0057 L

.4367

.4377

.4360

.4377

.4320

.4325

.008 L

REAM-IN-PLACE GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Ream-In-Place Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Ream-In-Place Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0011 L

.0029 L

.006 L

.3413

.3421

.0010 T

.0025 T

.0025 L

.0042 L

.4320

.4325

.008 L

NOTE See Table 1 for intake and exhaust valve guide finished dimensions and recommended reamer sizes.

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TABLE 3E O470-4, 11 and 13, E-Series With P/N 654761 or P/N 654947 Cylinders VALVE GUIDE FITS and LIMITS PRE-FINISHED GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Pre-Finished Guides Intake Guide Bore (New) Pre-Finished Guides Intake Guide Bore (installed in cylinder) Pre-Finished Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Pre-Finished Guides Exhaust Guide Bore (New) Pre-Finished Guides Exhaust Guide Bore (installed in cylinder) Pre-Finished Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limits

.0010 L

.0042 L

.0065 L

.4367

.4377

.4350

.4377

.4335

.4340

.0010 T

.0025 T

.0026 L

.0053 L

.4376

.4386

.4366

.4386

.4333

.4340

.0076 L

REAM-IN-PLACE GUIDES Description Intake Valve Guide In Cyl. Head Intake Valve in Guide Ream-In-Place Guides Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Ream-In-Place Guides Exhaust Valve Stem Diameter

New Minimum .0010 T

New Maximum .0025 T

Service Limit

.0010 L

.0027 L

.0065 L

.4335

.4340

.0010 T

.0025 T

.0030 L

.0047 L

.4333

.4340

.0076 L

NOTE See Table 1 for intake and exhaust valve guide finished dimensions and recommended reamer sizes. ISSUED

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB04-4A

Compliance Will Enhance Safety

SUBJECT: PURPOSE: COMPLIANCE: ENGINES AFFECTED:

REPLACEMENT OF MANIFOLD VALVE SPRING P/N 630184

Technical Portions FAA Approved

To provide instructions for the replacement of manifold valve spring P/N 630184 with spring P/N 627378. At the next scheduled engine maintenance or preventive maintenance event. IO-240-B Series Engines.

Reason For Revision: Revised Warranty Statement and Manual References. See Revision Bars. General Information TCM has received reports of engine instability and occasional engine stoppage at low idle speeds during rollout. These conditions have been addressed by correctly setting idle speed and correctly adjusting the fuel system. However, the change to the manifold valve spring as addressed in this SB will enhance engine stability under low idle speed conditions. Note: This is NOT an alternative to correctly adjusting the fuel system and idle rpm of the engine as these adjustments are important to proper engine operation and performance.

CAUTION After installation of the manifold valve spring the fuel system must be set up in accordance with the latest revision of SID97-3 and the latest revision of the engine Maintenance Manual TCM Form X30621A A. INSPECTION 1.

Inspect the manifold valve and determine manifold valve part number.

2.

If manifold valve P/N 656151-1A5 or subsequent is installed, or the letter “S” is vibro-etched into the upper left corner of the manifold valve data plate, no further action is required. Make an engine logbook entry stating SB04-4A previously complied with, P/N 656151-1A5 manifold valve installed.

3.

Any manifold valve installed that does not meet the criteria in step 2 above, proceed to part “B”.

B. REPLACEMENT OF MANIFOLD VALVE SPRING Ensure that the ignition switch is in the OFF position. Ensure that the master switch is in the OFF position. Ensure that the throttle is CLOSED and mixture control is in IDLE CUT-OFF. Turn the aircraft fuel selector valve to the OFF position. Refer to Figure 1, page 3, for expanded view of the manifold valve assembly. CAUTION: 1.

The following procedure must be accomplished by a properly certified mechanic or repair station. The work area must be clean and free of debris.

If not already removed, remove the top cowling in accordance with the aircraft manufacturer’s instructions.

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1 of 3 SB04-4

A

2.

Locate the fuel injection system manifold valve located aft of the induction plenum.

3.

Clean all “torque Putty” from manifold valve fittings prior to loosening and removing any manifold valve fitting.

4.

Install protective plugs or caps on all lines and fittings as removed to prevent fuel system contamination.

5.

Loosen the “B” nut that secures the fuel supply line to the manifold valve body and remove the line.

6.

Loosen the “B” nut that secures the overboard vent line to the manifold valve cover and remove the vent tube.

7.

Loosen the “B” nut that secures the fuel pressure gauge line to the manifold valve body and remove the line.

8.

Loosen the fuel injection line “B” nuts at each of the four cylinder fuel injection nozzles.

9.

Loosen the fuel injection line fittings at the manifold valve and remove the fuel injection lines from the manifold valve.

10. Loosen and remove the nuts from the two backbone bolts that secure the manifold valve bracket to the engine. 11. Remove the two backbone bolts that secure the manifold valve to engine and remove the manifold valve. 12. Using a permanent marker, identify the assembled position of the manifold valve body, cover and bracket prior to disassembly. 13. Remove the lockwire from the four screws that secure the manifold valve cover and bracket to the manifold valve body. 14. To remove the manifold valve bracket and cover, loosen and remove two screws, lock washers and plain washers diagonally across from each other. Then loosen and remove the other two screws, lock washers and plain washers while holding the manifold valve bracket and cover in place with slight hand pressure. 15. Slowly release hand pressure from the manifold valve bracket and cover and lift the cover from the manifold valve body. Do not remove the manifold valve diaphragm and plunger assembly. 16. Remove manifold valve spring P/N 630184, one coil dyed green, which is positioned between the manifold valve diaphragm and plunger assembly and the manifold valve cover. 17. Install manifold valve spring P/N 627378, which does not have a color coded coil, with the large diameter of the spring against the manifold valve diaphragm retainer. 18. Re-install the manifold valve bracket and cover in the reverse order of removal. Make sure the cover vent fitting is correctly orientated with the vent tube. Install the manifold valve bracket and cover with four screws, lock washers and plain washers. WARNING:

Always use calibrated torque equipment. Failure to properly torque fasteners and fittings may result in fuel leaks, loss of engine power, possible engine fire, forced landing, possible bodily injury that may result in death.

19. Torque manifold valve cover screws to 24 inch pound ± 2 inch pounds. Safety wire the screws in pairs. 20. Re-install the manifold valve and bracket on the engine using the two bolts, washers and nuts. Torque the backbone bolt and nut to 100 to 125 inch pounds. 21. Remove protective plugs and caps, installed in step 4 above, as each system line or hose is reattached. 22. Re-install the fuel injection lines to the manifold valve. Do not torque at this time. 23. Re-install the fuel injection lines to the four fuel injection nozzles in each cylinder. Ensure fuel injection nozzle lines are correctly routed and supported. Torque each fuel injection nozzle line “B” nut at nozzles to 40 to 45 inch pounds. MO 04

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PAGE NO REVISION A 2 of 3 SB04-4

24. Torque each fuel injection nozzle line fittings at manifold valve to 55 to 60 inch pounds. 25. Connect the manifold valve cover vent tube “B” nut to the manifold valve cover fitting and torque to 100 to 140 inch pounds. 26. Connect the fuel supply line “B” nut to the manifold valve fitting and torque to 100 to 140 inch pounds. Connect the fuel gauge line “B” to its fitting and torque to 100 to 140 inch pounds. 27. Turn the aircraft fuel selector to the ON position. 28. Turn the aircraft master switch ON. 29. Position the throttle to full OPEN and mixture control to FULL RICH. Turn the fuel boost pump ON and inspect all lines and fittings for signs of leakage. Correct any discrepancies prior to proceeding. Perform a complete fuel injection system set up in accordance with the latest revision of TCM service bulletin SID97-3 and the latest revision of the IO-240 Aircraft Engine Maintenance Manual TCM Form X30621A. 30. Re-install engine cowling in accordance with the aircraft manufacturer’s instructions. 31. Make a logbook entry indicating compliance with SB04-4A and installation of fuel manifold valve spring P/N 627378. Vibro-etch the letter “S” on the upper left corner of the manifold valve data plate.

4 7

3 6

2

5

1

FIGURE 1 MANIFOLD VALVE EXPANDED VIEW ITEM 1 2 3 4 5 6 7

PART NUMBER AN 503-8-12 MS 35338-42 653887 AN960-8 634325 627378 N/A

NOMENCLATURE SCREW WASHER, LOCK BRACKET WASHER COVER SPRING-2 PSI BODY-MANIFOLD VALVE

QUANTITY 4 4 1 4 1 1 1

WARRANTY: TCM will cover the replacement manifold valve spring and up to 1.0 hour labor for replacement of the manifold valve spring. Warranty claims for parts and labor must filed through a TCM distributor. MO 04

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PAGE NO REVISION A 3 of 3 SB04-4

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB04-7

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

IO-240-SERIES CRANKSHAFT CLUSTER GEAR INSPECTION AND REPLACEMENT

PURPOSE:

To announce the availability of an improved crankshaft cluster gear P/N 656752 for IO-240 series engines and provide inspection criteria for currently installed crankshaft cluster gears.

COMPLIANCE:

Initial inspection at starter removal, no later than the next scheduled inspection. Recurring inspection for crankshaft cluster gear condition required at every starter removal.

MODELS AFFECTED:

IO-240-Series engines

GENERAL INFORMATION Engines assembled between 06/14/2002 and 12/31/2003 may have incorporated a cluster gear P/N 656072, which has a chamfer machined into the driven side of the starter gear tooth profile. IO-240-Series engines must have the crankshaft cluster gear visually inspected to determine the gear tooth profile of the installed gear in accordance with Inspection Instructions Part I of this bulletin. In addition, at each starter removal, the crankshaft cluster gear should be inspected for condition in accordance with the instructions in Part II of the inspection procedures contained in this bulletin.

NOTE: This bulletin must be accomplished in conjunction with the latest revisions of SB03-7 “IO-240-Series Magneto Drive Gear” and SB04-8 “Replacement Starter for IO-240-B Series Engines”, if applicable. After crankshaft gear replacement, magneto timing must be reset IAW the instructions contained in the latest revision of MSB94-8 and the engine Maintenance Manual. INSPECTION INSTRUCTIONS: PART I (1) Remove the starter assembly using the instructions contained in the latest revision of the IO-240 Maintenance Manual.

(2) Visually inspect the crankshaft cluster gear through the starter assembly mounting hole in the accessory case and identify the gear tooth profile using Photograph 1 and Photograph 2 of this bulletin as a reference. (3) Verify if the gear tooth profile has a chamfer machined into the driven side of each starter gear tooth, as shown in Photograph 1. This cluster gear assembly may be identified as P/N 656072 or 656072A. Any gear identified to have this gear tooth profile or part number, or if you cannot confirm the part number of the gear currently installed, the gear must be replaced with a new P/N 656762 crankshaft cluster gear using the procedures contained in the IO-240 Overhaul Manual. (4) If the gear is manufactured with a gear tooth profile as shown in Photograph 2 and is confirmed to be P/N 656762, proceed to “Inspection Instructions Part II” of this bulletin. ISSUED

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

1 of 4 SB04-7

CHAMFER

656072 CLUSTER GEAR PHOTOGRAPH 1

656762 CLUSTER GEAR

PHOTOGRAPH 2

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INSPECTION INSTRUCTIONS PART II 1. Ensure that the ignition switch is OFF and the magnetos are properly grounded so that engine ignition cannot occur. 2. With the starter assembly removed, use a flashlight to visually inspect the crankshaft cluster gear through the starter assembly mounting hole in the rear of the accessory case. 3. Inspect the larger of the two gears in accordance with the criteria listed below in items 4 and 5. After inspection of the visible area of the gear tooth surface is complete, have a helper slowly rotate the engine so that the next portion of the gear is available for inspection. Repeat the process until a full 360° of rotation is achieved and all gear tooth surfaces have been inspected.

PHOTOGRAPH 3

PHOTOGRAPH 4

4. Photographs 3 and 4 show two examples of normal wear signatures for the crankshaft cluster gear. There will be visible signs of polishing to the contact surfaces of the larger gear teeth that receive initial contact from the pinion gear during start. The wear should be generally even and consistent around the entire circumference of the gear. The IO-240-B engine when equipped with a light weight or composite propeller has a tendency to stop in one of two positions so there may be two areas, 180° apart on the gear face, which show more wear than that of adjacent areas as in Photo 4. This wear pattern is normal and should not be confused with damaged gear teeth as shown in Photographs 5 and 6.

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PO Box 90 Mobile AL • 251-438-3411

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PHOTOGRAPH 5

PHOTOGRAPH 6

5. Photograph 5 and 6 show abnormal wear on a crankshaft cluster gear. There will be extremely rough areas with damage to the tooth surfaces and the surrounding gear areas. In some circumstances portions of teeth may be broken away from the gear. The most extreme cases may have whole teeth missing. If the damage is considered abnormal without complete teeth missing, replace the cluster gear in accordance with the instructions contained in the applicable sections of the IO-240-B Overhaul Manual (X30622A). Please note in Section 18-6 of the Overhaul Manual that the crankshaft cluster gear must be heated to a temperature of 325° to 350° F (163° C - 177° C) for one hour just prior to installation. If the cluster gear is missing one or more complete teeth, please contact Teledyne Continental Motors Customer Service Department directly at 1-888-826-5465 or 1-251-438-3411. WARNING Do not heat the cluster gear longer than the time specified. Damage to the gear will result, and engine failure may occur. 6. If damage is found to the crankshaft cluster gear, inspection of the starter gear for damage will be required. Note: If starter P/N 655957 is not installed, reference the latest revision of SIL04-8 For further instructions.

PARTS REQUIRED FOR CRANKSHAFT CLUSTER GEAR REPLACEMENT: The following parts are required for crankshaft cluster gear replacement: QTY (1)

TCM P/N 656762

DESCRIPTION Cluster Gear

LOCATION Bolted to Crankshaft aft face

(4)

22532

Bolt, Cluster Gear

Bolts cluster gear to crankshaft

(1)

652272

Gasket

Accessory case to crankcase

(1)

652238

Gasket

Alternator mounting

(1)

653673

Gasket

Starter mounting

(2)

10-400613

Gasket

Magneto mounting

.032 MS20995 Condition A Lockwire, as required

WARRANTY TCM will cover the parts required to replace any crankshaft cluster gear assembly that fails the Inspection Procedures Part I or Part II under warranty. ISSUED

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB05-10

Compliance Will Enhance Safety

SUBJECT:

Technical Portions FAA Approved

TSIO-550-B, C AND E MAINTENANCE AND OVERHAUL MANUAL REVISION

PURPOSE: MODELS AFFECTED:

To correct an error concerning exhaust clamp torque as shown in manual X30616A. TSIO-550-B, C and E engines

Teledyne Continental Motors has isolated an error in the TSIO-550-B, C and E Maintenance and Overhaul Manual X30616A originally issued in January of 1997. This issue involves the listed torque for installation of the LH exhaust pipe to turbocharger clamp. Page 72-60-14, paragraph G, has been changed to read as follows: G. Place new clamp assemblies (14) halfway on turbine exhaust flanges. Slide by-pass assembly components (6,7) together and slide assembly onto rear ports of exhaust risers (3,4). Push tailpipe (12) flange against turbine exhaust flange and center clamp assembly squarely over both flanges. Torque clamp nut to 35-40 inch pounds torque. Using a rubber mallet, tap circumference of clamp and re-torque. Push tailpipe (13) against R.H. turbine exhaust flange and center clamp (14) squarely over both flanges. Torque clamp nut to 35-40 inch pounds torque, tap circumference with rubber mallet and re-torque. A copy of this bulletin must be inserted into the affected manual until the next manual revision is issued. NOTE… This bulletin contains updates to the Manufacturer's Instructions For Continued Airworthiness as required by FAR43.13.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB05-11

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

PIPER SERVICE BULLETIN 1157A

PURPOSE:

To announce the issuance of Piper Service Bulletin 1157A

COMPLIANCE:

See Piper Bulletin

MODELS AFFECTED:

TSIO360RB, LTSIO360RB

Teledyne Continental Motors recommends compliance with the Piper Mandatory Service Bulletin 1157A. For further information concerning this bulletin interested parties may contact: The New Piper Aircraft Inc. 2626 Piper Dr. Vero Beach, FL 32960 1-772-567-4361

Teledyne Continental Motors does not supply internal magneto parts for Slick magnetos. Required parts may be purchased from any Slick magneto distributor. For information concerning Slick magnetos or parts, interested parties may contact: Unison Industries® 7575 Bay Meadow Dr. Jacksonville, FL 32256 Piston Help Desk at 1-904-739-4081. E-mail: [email protected]

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®

TELEDYNE CONTINENTAL

Category 3

AIRCRAFT ENGINE

SB05-2

SERVICE BULLETIN Compliance Will Enhance Safety

Technical Portions FAA Approved Supersedes M89-15

SUBJECT:

OVERSPEED LIMITATIONS

PURPOSE:

To establish criteria for engine RPM overspeed calculations and to provide instructions for inspection after engine RPM overspeeds.

MODELS AFFECTED:

All

Engine operation at speeds in excess of rated RPM (revolutions per minute) limitations can cause serious damage to the engine and can result in subsequent catastrophic engine failure. The following criteria is established for use when engines have inadvertently experienced some degree of overspeed for limited periods of time: RATED RPM LIMITATION (See Note 1)

CAT. I TO

CAT.II TO

CAT.III OVER

GTSIO-520

3200-3400

3500

3700

3700

IO & L/TSIO-520 and IO & TSIO-550

2400-2850

3000

3300

3300

O, IO, & TSIO-470

2400-2625

2900

3200

3200

3200

3500

3700

3700

2500-2800

3000

3300

3300

IO-346

2700

3000

3300

3300

GO-300

3200

3500

3700

3700

0-300

2700

3000

3300

3300

2575-2800

3000

3300

3300

Tiara 6-285

4000

4100

4200

4200

Tiara 6-320

4400

4500

4600

4600

ENGINE

GIO-470 IO & L/TSIO-360

IO-240-A&B, 0-200, C-Series

NOTE1 For aircraft equipped with digital RPM measuring equipment, the rated RPM limitation may be established to include a variance of + 2% for normal operations. Any operation of the engine beyond the rated RPM limitation plus the 2% allowed variance must follow the inspection criteria for the appropriate Category RPM Limitation Inspection as contained in this bulletin. ISSUED

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© 2005 Teledyne Continental Motors, Inc.

Teledyne Continental Motors, Inc. A Teled yne Technologies Compa ny

PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

1 of 2 SB05-2

INSPECTION CRITERIA CATEGORY I – RPM LIMITATIONS A. B.

Less than 10 seconds – No action required. More than 10 seconds – Proceed as follows: 1. Drain the oil, then remove oil screens and filters as applicable. Inspect for contaminants in the oil, screens and filters. (Where applicable.) 2. Remove the rocker covers and inspect the valves, springs, rocker arms, tappets, spring retainers and pushrods for condition in accordance with the latest revision of the applicable service publications. 3. Check all accessory drives for excessive backlash. NOTE If no discrepancies are indicated with the above listed inspection procedures, repeat item B-1 after the next 5 hours of flight time.

CATEGORY II - RPM LIMITATIONS A. B.

Less than 10 seconds – Same action required as for Category I B. More than 10 seconds – In addition to the actions required for Category I B, proceed as follows: 1. Remove all cylinder assemblies, including pistons and rods. 2. Remove all counterweights, as applicable. (On Tiara engines, inspect VTC unit.) 3. Inspect and reinstall removed parts in accordance with the latest revision of the appropriate service publications, using new connecting rod nuts and bolts. NOTE If no discrepancies are indicated with the above listed inspection procedures, repeat item Category I B-1 after the next 5 hours of flight time.

CATEGORY III – EXCESSIVE OVERSPEED Engines which have experienced overspeeds of this magnitude are considered to have suffered an excessive overspeed condition. These engines must be dealt with on an individual basis by the TCM Technical Customer Service department located in Mobile, Alabama, 1-251-438-3411 Extension 8299 or 1-800-826-5465 Option 1. Factors such as time at speed, engine age, engine type, application and other related circumstances will be taken into consideration. As a minimum, the following procedures will be required: A. B. C.

Remove the engine and clearly identify as “Removed for excessive overspeed”. The engine must be completely overhauled in accordance with the manufacturers overhaul instructions. Accessories must be inspected and overhauled in accordance with their manufacturer’s maintenance instructions. Connecting rods, connecting rod bolts, and all valve train components must be replaced without consideration of normal wear tolerances of inspection procedures.

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB05-8

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

IMPROVED CAMSHAFT GEAR P/N 656818

PURPOSE:

To announce the production of an improved camshaft gear P/N 656818 which will supersede the current gear P/N 656031

COMPLIANCE: At next engine overhaul or at camshaft gear replacement. MODELS AFFECTED:

IO-470-U,V; IO-520-Series; TSIO-520-Series; IO-550-Series; IOF-550Series; TSIO-550-Series; TSIOL-550-Series

GENERAL As part of our ongoing product improvement initiative, Teledyne Continental Motors has released for production an improved camshaft gear, P/N 656818, for the above listed engines. The new camshaft gear will supersede the current production camshaft gear P/N 656031. TCM recommends that the new gear be incorporated at the next engine overhaul or whenever replacement of the camshaft gear is required. The P/N 656818 camshaft gear is nominally 0.060" wider than the P/N 656031 camshaft gear. On engine models utilizing the Sandcast style of crankcase, the P/N 656818 camshaft gear may be installed as a direct replacement for the P/N 656031 camshaft gear. On engine models utilizing the Permold style of crankcase, modification of the starter adapter bearing boss is required to provide clearance for the wider camshaft gear. NOTE . . . On Sandcast crankcase installations clearance must be verified between the new P/N 656818 camshaft gear and the oil gallery plug located directly below the starter adapter boss. (Reference figure 4.) PERMOLD CRANKCASE MODIFICATION The Permold style of crankcase must me modified to allow use of the new, thicker camshaft gear. A clearance cut is made in the starter drive bearing boss in accordance with the dimensions shown in Figure 3. TCM recommends that a properly certified repair station machine the required clearance. CAUTION… Installation of the new P/N 656818 gear in an unmodified permold style crankcase will result in damage to the gear and/or the crankcase ISSUED

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

1 of 4 SB05-8

No Clearance Cut

Figure 1. Un-Modified Permold Crankcase

Machined Clearance

Figure 2. Modified Permold Crankcase

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A

A

6.197 " to 6.187' Radius From Camshaft Bore Centerline

ACCESSOY FACE

Figure 3. Permold Crankcase Modification

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OIL GALLERY PLUG

Figure 4. Inspect For Clearance Between The Camshaft Gear And The End Of The Oil Gallery Plug (Where Indicated).

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB05-9

Compliance Will Enhance Safety

Technical Portions FAA Approved Supersedes M88-14

SUBJECT:

SLICK SERVICE BULLETIN SB1-88B

PURPOSE:

To announce the issuance of revision B to Slick Bulletin SB1-88

COMPLIANCE:

See Slick Bulletin

MODELS AFFECTED:

TCM engines utilizing Slick Magneto model numbers 6320 and 6324.

Teledyne Continental Motors recommends compliance with the Slick Service Bulletin SB1-88B. Teledyne Continental Motors does not supply internal magneto parts for Slick magnetos. Required parts may be purchased from any Slick magneto distributor. For a copy of Slick Service Bulletin SB1-88B, or further information about this bulletin, interested parties may contact: Unison Industries® 7575 Bay Meadow Dr. Jacksonville, FL 32256 Piston Help Desk at 1-904-739-4081. E-mail: [email protected]

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB06-1

Compliance Will Enhance Safety

SUBJECT:

TELEDYNE CONTINENTAL MOTORS (TCM) FUEL SYSTEM FUEL NOZZLE INSPECTION AND REPLACEMENT

PURPOSE:

Technical Portions FAA Approved

To provide criteria for inspection and/or replacement of TCM fuel system fuel injector nozzle assemblies manufactured between July 1, 2005 and March 1, 2006.

MODELS AFFECTED: IO-550-G, N, P and R Series; GTSIO-520-D, H, L, M and N Series; TSIO 520-BE Series; TSIO-520-AF, B, BB, C, CE, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, UB, VB and WB Series; TSIO-550-A, B, C and E Series; and TSIOL-550-A and C Series engines PART I On June 1st of 2005 Teledyne Continental Motors (TCM) initiated improvements to the fuel nozzle injector bodies. TCM has verified reports that some fuel injection systems or fuel nozzle sets delivered between July 1, 2005 and March 1, 2006,may have a mixture of early style and new style nozzle bodies, which may lead to undesirable operational characteristics of the fuel nozzle assemblies as a set. If excessive variances in cylinder to cylinder EGT readings are noted (on engines equipped with six point EGT systems) or rough operation is noted, especially at idle, at the next scheduled maintenance visit perform the procedures required by PART I Steps (1) and (2) of his bulletin. In the absence of the above listed indications, no action is required. 1) On engines with model specifications that are listed in TABLE 1 of this bulletin, which shipped from the factory between July 1, 2005 and March 1, 2006, perform the inspection procedures contained in PART II of this service bulletin. If any fuel nozzles are found to require replacement after performance of the inspection procedures contained in PART II of this bulletin, the entire fuel nozzle set must be replaced with the most current part number fuel nozzle set. 2) On all affected engines with model specifications as listed in TABLE 1, using the engine logbook and all other available maintenance records, determine if during the time period of July 1, 2005 through March 1, 2006, any complete fuel injection systems, fuel injector nozzle sets or individual fuel injection nozzle assemblies listed in TABLE 1, were installed: (a) If no complete fuel injection systems, fuel injector nozzle sets or individual fuel injection nozzle assemblies that are listed in TABLE 1 have been installed, no further action is required. Make a logbook entry verifying compliance with the inspection procedure required by PART I (2)(a) of this service bulletin. (b) If any complete fuel injection system, fuel injector nozzle set or individual fuel injection nozzle assemblies that are listed in TABLE 1 have been replaced during the specified time period, proceed to PART II of this service bulletin. If any fuel ISSUED

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nozzles are found to require replacement after performance of the inspection procedures contained in PART II of this bulletin, the entire fuel nozzle set must be replaced with the most current part number fuel nozzle set. 3) Any new, unused fuel injection systems, fuel injector kits or fuel injector nozzle assemblies listed in TABLE 1 that were received from TCM during the time period of July 1, 2005 through March 1, 2006 must be inspected using the criteria contained in PART II of this bulletin prior to installation.

WARRANTY Warranty will apply to the issues addressed in this bulletin under the following policy: 1) TCM will cover up to 4 hours at the posted shop rate for the inspection and reinstallation of fuel nozzle assemblies under steps (1) and 2(b) of PART I of this service bulletin. 2) Nozzle replacements, if required under steps (1) and (2)(b) of this bulletin, will be covered for the required parts, ground shipping costs and up to 2 additional hours labor at the posted shop rate for fuel system verification in accordance with the latest revision of Service Information Directive SID97-3. Replacement fuel nozzle sets must be obtained from a TCM Authorized Distributor. The warranty claim must be filed through the authorized TCM Distributor from which the parts were obtained. All core nozzles must be returned to TCM prior to warranty credit being issued. 3) TCM will not cover inspection of new, uninstalled stock nozzle assemblies under warranty.

PART II FUEL NOZZLE INSPECTION PROCEDURES (1) Referring to the airframe manufacturers maintenance instructions: WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. (a) Remove electrical power from the aircraft. (b) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. (c) Remove upper engine cowlings from the aircraft. 2) Loosen and remove the fuel line from each fuel injector nozzle assembly. On turbocharged engines remove the air reference sleeves from the fuel nozzle assembly. Install protective caps on all lines to prevent contamination. 3) Loosen and remove the fuel injector nozzle assemblies, taking care to note the position from which they were removed. 4) Using a pin gauge of the proper diameter, inspect each nozzle assembly as shown in figure 1. ISSUED

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CAUTION: The pin gauge must be inspected prior to use to ensure it is free of burrs and must not be inserted into the fuel injector body beyond the depth shown in Figure 1 or damage to the fuel nozzle will occur. Never attempt to clear a nozzle obstruction with wire or by any other mechanical means.

Measure the diameter of the housing using pin

PIN INSERTION DEPTH 1¼ INCHES MAXIMUM

FIGURE 1 FUEL INJECTOR NOZZLE INSPECTION PROCEDURE FUEL NOZZLE FOR NORMALLY ASPIRATED ENGINES SHOWN; TURBO-CHARGED ENGINE NOZZLES ARE SIMILAR.

5) For the IO-550-G, N, P and R Series; GTSIO-520-D, H, L, M and N Series;TSIO-520-BE Series; TSIO-550-A, B, C and E Series; and TSIOL-550-A and C Series engines: Select a 0.062" diameter pin and test each fuel injector nozzle body as shown in FIGURE 1. Verify that the fuel injector nozzle bodies orifices are all machined to the same size by determining if the pin can or cannot be inserted into each fuel injector nozzle body in the set. ISSUED

REVISED

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a) If the fuel injector nozzle bodies are all determined to be the same size, no further action is required. Proceed to PART II Step 8. b) If the inspection with the pin gauge indicates a mixture of orifice sizes installed, then the fuel injector nozzle set must be replaced with a new set obtained from an authorized TCM distributor. 6) For the TSIO-520-AF, B, BB, C, CE, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, UB, VB and WB Series engines: Select a 0.055" diameter pin and test each fuel injector nozzle body as shown in FIGURE 1. Verify that the fuel injector nozzle bodies orifices are all machined to the same size by determining if the pin can or cannot be inserted into each fuel injector nozzle body in the set. a) If the fuel injector nozzle bodies are all determined to be the same size, no further action is required. Proceed to PART II Step 8. b) If the measurement with the pin gauge indicates a mixture of orifice sizes installed, then the fuel injector nozzle set must be replaced with a new set obtained from an authorized TCM distributor. 7. If re-installing the previously removed fuel injector assemblies, they must be cleaned by soaking in lacquer thinner, methyl ethyl ketone or acetone for several hours. If a fuel nozzle assembly is obstructed and cannot be cleaned by solvent action it must be replaced. CAUTION: Do not attempt to clear nozzle obstructions with wire or by other mechanical means. Any nozzle that is cleaned by mechanical means must be replaced. 8) Reinstall the fuel nozzles in accordance with the following procedure: a) Apply TCM P/N 646943 antiseize lubricant to the cylinder end of each nozzle assembly in accordance with Figure 2. Install the nozzle into the appropriate cylinder and torque to 55-65 inch-pounds. b) For turbocharged engines only, install new 2 each new P/N 630979-9 o-rings onto the fuel injector body. c) For turbocharged engines only, slide the air reference sleeve onto the fuel injector assembly, taking care not to damage the 0-rings. Install 1 each new P/N 640612 washer and the retained serviceable 628556 metal washer onto the fuel injector nozzle above the air reference sleeve. d) Install the fuel line onto the nozzle assembly. Torque the fuel line "B" nut to 40-45 inchpounds. e) For turbocharged engines only, using a new compression seal P/N 633958-3, install the air reference sleeve to the air reference tube and torque the "B" nut by snugging finger tight to set the seal, then tighten an additional 3/4 to 1 turn. 9) Restore electrical power to the aircraft. Using the fuel boost pump, leak-check the fuel system. Correct any defects noted before proceeding to the next step.

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WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. 10) Perform the fuel system verification in accordance with the procedures contained in the latest revision of TCM bulletin SID97-3 11) Reinstall the cowlings in accordance with the airframe manufacturer’s maintenance instructions. 12) Make a log book entry verifying compliance with this service bulletin.

DO NOT APPLY ANY SEALANTS OR LUBRICANTS TO TOP THREADS ON FUEL NOZZLES

FUEL INJECTOR NOZZLE ASSEMBLY

APPLY ANTISEIZE SPARINGLY HERE DO NOT APPLY ANTISEIZE LUBRICANT TO THE FIRST TWO THREADS

FIGURE 2 ANTISEIZE COMPOUND APPLICATION NORMALLY ASPIRATED ENGINE FUEL NOZZLE ASSEMBLY SHOWN FOR CLARITY TURBOCHARGED ENGINE NOZZLE SIMILAR

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT (SEE NOTE 1) IO-550-G1B (N)(R) IO-550-G2B (N)(R) IO-550-G4B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649053A5 (N) 649053A5R (R)

FUEL INJECTOR NOZZLE PART NUMBERS (SEE NOTE 2) 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E

IO-550-G5B (N)(R) IO-550-G6B (N)(R) IO-550-G8B (N)(R) IO-550-G9B (N)(R)

649053A5-1 (N) 649053A5-1R (R)

IO-550-G7B (N)

649053A5-5 (N)

IO-550-N1B (N)(R) IO-550-N6B (N)(R) IO-550-N8B (N) IO-550-N13B (N)(R) IO-550-N14B (N) IO-550-N17B (N)(R) IO-550-N19B (N) IO-550-N23B (N)(R) IO-550-N34B (N) IO-550-N35B (N)(R) IO-550-N2B (N)(R) IO-550-N18B (N)(R) IO-550-N25B (N) IO-550-N28B (R) IO-550-N36B (N) IO-550-N38B (R)

649053A5-4 (N) 649053A5-4R (R)

649053A5-2 (N)

652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E

IO-550-N7B (N)(R)

649053A5-12 (N) 649053A5-12R (R) 652312A2 (KIT) EQ7477 (KIT)

IO-550-N10B (N) IO-550-N11B (N) IO-550-N12B (N) IO-550-N20B (N) IO-550-N21B (N) IO-550-N22B (N)

649053A5-6 (N)

652312-112E 652312-212E 652312-312F 652312-412EF 652312-512EF 652312-612D 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E

TABLE 1

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

6 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS

IO-550-N15B (N) IO-550-N37B (N) IO-550-N40B (N)

649053A5-7 (N)

IO-550-N16B (N)(R)

649053A5-11 (N)

IO-550-N24B (N)(R) IO-550-N26B (N)(R)

649053A5-8 (N)

IO-550-B27B (N)

649053A5-13 (N) 652312A2 (KIT) EQ7477 (KIT)

IO-550-N30B (N) IO-550-N32B (N) IO-550-N42B (N)

649053A5-9 (N)

IO-550-N31B (N)(R)

649053A5-10 (N)

IO-550-N41B (N) IO-550-N43B (N)

649053A5-3 (N) 649053A5-3R (R)

IO-550-P1B (N)(R) IO-550-P2B (N)(R) IO-550-P3B (N)(R) IO-550-P4B (N)(R) IO-550-P5B (R) IO-550-P6B (N)(R)

649053A5-8 (N)

FUEL INJECTOR NOZZLE PART NUMBERS 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312F 652312-412EF 652312-512EF 652312-612D 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E

TABLE 1 (CON'T) ISSUED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

7 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT IO-550-R1B (N)(R) IO-550-R2B (N)(R) IO-550-R3B (N)(R) IO-550-R4B (N)(R) IO-550-R5B (N)(R) IO-550-R6B (N)(R) IO-550-R7B (N)(R) IO-550-R8B (N)(R) GTSIO-520-D21D (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649053A5-4 (N) 649053A5-4R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 652312-112E 652312-212E 652312-312E 652312-412E 652312-512E 652312-612E

649055A2 (N) 649055A2R (R)

633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A 633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A 633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A 633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A 633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A 633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A

GTSIO-520-D22B (N)

649058A2 (N) 649058A2R (R)

GTSIO-520-D23B (N)(R)

649055A2-1 (N) 649055A2-1R (R)

GTSIO-520-D24B (N)(R)

649055A3-1 (N) 649055A3-1R (R)

GTSIO-520-H1B (N)(R) GTSIO-520-H9B (N)(R)

649058A1 (N) 649058A1R (R)

GTSIO-520-H2B (N)(R) GTSIO-520-H5B

649058A2 (N) 649058A2R (R)

TABLE 1 (CON'T)

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

8 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT GTSIO-520-H6B (R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649058A2-1 (N) 649058A2-1R (R)

GTSIO-520-L1B (N)(R) GTSIO-520-L3B (N)(R)

649055A5 (N) 649055A5R (R)

GTSIO-520-L2B (N)(R) GTSIO-520-L4B (N)(R)

649055A6 (N) 649055A6R (R)

GTSIO-520-L5B (N)(R) GTSIO-520-L7B (N)(R)

649055A5-1 (N) 649055A5-1R (R)

GTSIO-520-L6B (N)(R) GTSIO-520-L8B (N)(R)

649055A6-1 (N) 649055A6-1R (R)

GTSIO-520-M1A (N) GTSIO-520-M1B (N)(R) GTSIO-520-M2A (N) GTSIO-520-M2B (N)(R) GTSIO-520-M3B (R)

649055A7 (N) 649055A7R (R)

GTSIO-520-N1A (N) GTSIO-520-N1B (N)(R) GTSIO-520-N3B (N)(R) GTSIO-520-N5B (N)(R) GTSIO-520-N7B (N)(R) GTSIO-520-N9B (N)(R) GTSIO-520-11B (N)(R)

649055A8 (N) 649055A8R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 633723-119A 633723-219A 633723-319A 633723-419A 633723-519A 633723-619A 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A

TABLE 1 (CON'T)

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

9 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT GTSIO-520-N2A (N) GTSIO-520-N2B (N)(R) GTSIO-520-N4B (N)(R) GTSIO-520-N6A (N) GTSIO-520-N6B (N)(R) GTSIO-520-N8B (N)(R) GTSIO-520-N10B (N)(R) GTSIO-520-N12B (N)(R) TSIO-520-AF1A (N) TSIO-520-AF1B (N) (R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649055A9 (N) 649055A9R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 639368-119A 639368-219A 639368-319A 639368-419A 639368-519A 639368-619A

649054A16-1 (N) 649054A16-1R (R)

TSIO-520-AF2A (N) TSIO-520-AF2B (N)(R) TSIO-520-AF3B (N)(R)

649054A5 (N) 649054A5R (R)

TSIO-520-AF5B (N)(R)

649054A5-2 (N) 649052A5-2R (R)

TSIO-520-B1B (R) TSIO-520-B5B (R) TSIO-520-B9B (R) TSIO-520-B11B (R) TSIO-520-B13B (R) TSIO-520-B15B (R) TSIO-520-B16B (R) TSIO-520-B2B (R) TSIO-520-B10B (R) TSIO-520-B12B (R) TSIO-520-B14B (R) TSIO-520-B17B (R)

649054A7-1 (N) 649054A7-1R (R)

655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-115B 655534-215B 655534-315B 655534-415B 655534-515B 655534-615B

TSIO-520-BB5B (N)(R) TSIO-520-BB9B (N)(R) TSIO-520-BB11B (N)(R) TSIO-520-BB13B (N)(R) TSIO-520-BB15B (N)(R) TSIO-520-BB17B (N)(R) TSIO-520-BB19B (N)(R) TSIO-520-BB21B (N)(R) TSIO-520-BB23B (N)(R)

649054A8-1 (N) 649054A8-1R (R)

649054A7 (N) 649054A7 (R)

655534-115B 655534-215B 655534-315B 655534-415B 655534-515B 655534-615B 655534-115B 655534-215B 655534-315B 655534-415B 655534-515B 655534-615B

TABLE1 (CON'T)

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

10 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-BB10B (N)(R) TSIO-520-BB12B (N)(R) TSIO-520-BB14B (N)(R) TSIO-520-BB16B (N)(R) TSIO-520-BB18B (N)(R) TSIO-520-BB20B (N)(R) TSIO-520-BB22B (N)(R) TSIO-520-BB24B (N)(R) TSIO-520-BE1A (N) TSIO-520-BE1F (N)(R) TSIO-520-BE1G (N)(R) TSIO-520-BE2F (N) (R) TSIO-520-BE2G (N)(R) TSIO-520-BE3B (N)(R) TSIO-520-BE4B (N)(R) TSIO-520-C1B (R) TSIO-52O-C2B (N)(R) TSIO-520-C5B (N)(R) TSIO-520-C7B (N)(R) TSIO-520-C9B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A8 (N) 649054A8R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-115B 655534-215B 655534-315B 655534-415B 655534-515B 655534-615B

NOT AVAILABLE NOT AVAILABLE NOT AVAILABLE 649054A6 (N) 649054A6R (R)

639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B

649054A9-2 (N) 649054A9-2R (R)

TSIO-520-C3B (N)(R) TSIO-520-C6B (N)(R) TSIO-520-C8B (N)(R) TSIO-520-C10B (N)(R) TSIO-520-C11B (N)(R)

649054A9 (N) 649054A9R (R)

TSIO-520-CE1A (N) TSIO-520-CE1B (N)(R) TSIO-520-CE1F (N)(R)

649054A10 (N) 649054A10R (R)

TSIO-520-CE2B (N)(R)

649054A10-1 (N) 649054A10-1R (R)

TSIO-520-D1B (R) TSIO-520-D2B (R) TSIO-520-D3B (R) TSIO-520-D7B (R) TSIO-520-D8B (R)

649054A11 (N) 649054A11R (R)

655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-117C 655534-217C 655534-317C 655534-417C 655534-517C 655534-617C 655534-117C 655534-217C 655534-317C 655534-417C 655534-517C 655534-617C 655534-115B 655534-215B 655534-315B 655534-415B 655534-515B 655534-615B

TABLE1 (CON'T)

ISSUED

REVISED

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MO

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

11 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-DB1B (N)(R) TSIO-520-DB2B (N)(R) TSIO-520-DB3B (N)(R) TSIO-520-DB8B (R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A12 (N) 649054A12R (R)

TSIO-520-E1B (R) TSIO-520-E3B (R) TSIO-520-E5B (R) TSIO-520-E8B (R) TSIO-520-E14B (R) TSIO-520-E15B (R) TSIO-520-E17B (R) TSIO-520-E20B (R) TSIO-520-E23B (R) TSIO-520-E2B (R) TSIO-520-E4B (R) TSIO-520-E9B (R) TSIO-520-E10B (R) TSIO-520-E16B (R) TSIO-520-E18B (R) TSIO-520-E19B (R) TSIO-520-E21B (R) TSIO-520-E22B (R) TSIO-520-EB2B (R) TSIO-520-EB4B (N)(R) TSIO-520-EB9B (N)(R) TSIO-520-EB10B (N)(R) TSIO-520-EB16B (N)(R) TSIO-520-EB17B (R) TSIO-520-EB19B (R) TSIO-520-EB21B (N)(R)

649054A13-1 (N) 649054A13-1R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-115B 655534-215B 655534-315B 655534-415B 655534-515B 655534-615B 655534-114G 655534-214G 655534-314G 655534-414G 655534-514G 655534-614G

649054A13 (N) 649054A13R (R)

655534-114G 655534-214G 655534-314G 655534-414G 655534-514G 655534-614G

649054A13-2 (N) 649054A13-2R (R)

655534-114G 655534-214G 655534-314G 655534-414G 655534-514G 655534-614G

TSIO-520-EB3B (N)(R) TSIO-520-EB5B (N)(R) TSIO-520-EB8B (N)(R) TSIO-520-EB14B (N)(R) TSIO-520-EB15B (N)(R) TSIO-520-EB18B (N)(R) TSIO-520-EB20B (N) (R)

649054A13-3 (N) 649054A13-3R (R)

655534-114G 655534-214G 655534-314G 655534-414G 655534-514G 655534-614G

TSIO-520-G1B (N)(R) TSIO-520-G3B (N)(R) TSIO-520-G4B (N)(R)

649054A16 (N) 649054A16R (R)

655534-115C 655534-215C 655534-315C 655534-415C 655534-515C 655534-615C

TABLE 1 (CON'T)

ISSUED

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

12 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-H1B (R) TSIO-520-H4B (N)(R) TSIO-520-H5B (N)(R) TSIO-520-H6B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A9 (N) 649054A9R (N)

TSIO-520-H7B (N)(R)

649054A9-3 (N)

TSIO-520-J1B (R) TSIO-520-J13B (R)

649054A15 (N) 649054A15R (R)

TSIO-520-J2B (R) TSIO-520-J4B (R) TSIO-520-J14B (R0

649054A15-1 (N) 649054A15-1R (R)

TSIO-520-J9B (R)

649054A15-4 (N) 649054A15-4R (R)

TSIO-520-J10B (R) TSIO-520-J12B (R)

649054A15-5 (N) 649054A15-5R (R)

TSIO-520-JB1B (N)(R) TSIO-520-JB14B (N)(R)

649054A15-2 (N) 649054A15-2R (R)

TSIO-520-JB2B (N)(R) TSIO-520-JB4B (N)(R) TSIO-520-JB13B (N)(R)

649054A15-3 (N) 649054A15-3R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

TABLE 1 (CON'T)

ISSUED

REVISED

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-JB9B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A15-6 (N) 649054A15-6R (R)

TSIO-520-JB10B (N)(R) TSIO-520-JB12B (N)(R)

649054A15-7 (N) 649054A15-7R (R)

TSIO-520K1B (R) TSIO-520-K5B (R)

649054A19 (N) 649054A19R (R)

TSIO-520K2B (R)

649054A19-1 (N) 649054A19-1R (R)

TSIO-520-KB1B (N)(R)

649054A19-2 (N) 649054A19-2R (R)

TSIO-520-KB2B (N)(R)

649054A19-3 (N) 649054A19-3R (R)

TSIO-520-KB3B (N)(R)

649054A19-4 (N) 649054A19-4R (R)

TSIO-520-KB4B (N) (R)

649054A19-5 (N) 649054A19-5R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

TABLE 1 (CON'T)

ISSUED

REVISED

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14 of 22 SB06-1

ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-L1B (R) TSIO-520-L4B (R) TSIO-520-L7B (R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A23-1 (N) 649054A23-1R (R)

TSIO-520-LB1B (N)(R) TSIO-520-LB4B (N)(R) TSIO-520-LB6B (R)

649054A23 (N) 649054A23R (R)

TSIO-520-M1B (N)(R) TSIO-520-M3B (N)(R) TSIO-520-M4A (N) TSIO-520-M4B (N) TSIO-520-M6B (N)(R) TSIO-520-M7B (N)(R) TSIO-520-M8A (N) TSIO-520-M8B (N) TSIO-520-M9B (N)(R) TSIO-520-M10B (N)(R) TSIO-520-M11B (N)(R)

649054A16 (N) 649054A16R (R)

TSIO-520-N1B (R) TSIO-520-N19B (R)

649054A27 (N) 649054A27R (R)

TSIO-520-N2B (R) TSIO-520-N4B (R) TSIO-520-N20B (R) TSIO-520-N21B (R)

649054A27-1 (N) 649054A27-1R (R)

TSIO-520-N5B (R)

649054A29-1 (N) 649054A29-1R (R)

649054A16-3 (N) 649054A16-3R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

TABLE 1 (CON'T)

ISSUED

REVISED

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-N6B (R) TSIO-520-N8B (R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A29-2 (N) 649054A29-2R (R)

TSIO-520-N9B (R)

649054A29-4 (N) 649054A29-4R (R)

TSIO-520-N10B (R) TSIO-520-N12B (R)

649054A29-5 (N) 649054A29-5R (R)

TSIO-520-N13B (R)

649054A27-4 (N) 649054A27-4R (R)

TSIO-520-N14B (R) TSIO-520-N16B (R)

649054A27-5 (N) 649054A27-5R (R)

TSIO-520-NB1B (N)(R) TSIO-520-NB19B (N) TSIO-520-NB31B (N)(R) TSIO-520-NB35B (R) TSIO-520-NB39B (N)(R)

649054A27-2 (N) 649054A27-2R (R)

TSIO-520-NB2B (N)(R) TSIO-520-NB4B (N)(R) TSIO-520-NB20B (N)(R) TSIO-520-NB21B (N)(R) TSIO-520-NB32B (N)(R) TSIO-520-NB34B (R) TSIO-520-NB5B (N)(R) TSIO-520-NB22B (N)(R)

649054A27-3 (N) 649054A27-3R (R)

649054A29 (N) 649054A29R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

TABLE 1 (CON'T)

ISSUED

REVISED

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-NB6B (N)(R) TSIO-520-NB8B (N)(R) TSIO-5200NB17B (N)(R) TSIO-520-NB18B (N)(R) TSIO-520-NB23B (N)(R) TSIO-520-NB24B (N)(R) TSIO-520-NB9B (N)(R) TSIO-520-NB25B (N)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A29-3 (N) 649054A29-3R (R)

TSIO-520-NB10A (N) TSIO-520-NB10B (N)(R) TSIO-520-NB12A (N) TSIO-520-NB12B (N)(R) TSIO-520-NB26B (N)(R) TSIO-520-NB27B (N)(R) TSIO-520-NB37B (N)(R)

649054A29-7 (N) 649054A29-7R (R)

TSIO-520-NB13A (N) TSIO-520-NB13B (N)(R) TSIO-520-NB28B (N)(R) TSIO-520NB33B (N)(R)

649054A27-6 (N) 649054A27-6R (R)

TSIO-520-NB14B (N)(R) TSIO-520-NB16A (N) TSIO-520-NB16B (N)(R) TSIO-520-NB22B (N) TSIO-520-NB29B (N)(R) TSIO-520-NB30B (N)(R) TSIO-520-NB36B (N)(R) TSIO-520-NB38B (N)(R)

649054A27-7 (N) 649054A27-7R (R)

TSIO-520-P1B (N)(R) TSIO-520-P3B (N)(R) TSIO-520-P5B (N)(R) TSIO-520-P6B (N)(R)

649054A16 (N) 649054A16R (R)

TSIO-520-P7B (N)(R) TSIO-520-P8B (N)(R)

649054A16-3 (N) 649054A16-3R (R)

649054A29-6 (N) 649054A29-6R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B

TABLE 1 (CON'T)

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REVISED

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-R4B (N)(R) TSIO-520-R5A (N) TSIO-520-R5B (N)(R) TSIO-520-R9B (N)(R) TSIO-520-R10B (N)(R) TSIO-520-R14B (N)(R) TSIO-520-R6A (N) TSIO-520-R6B (N)(R) TSIO-520-R11B (N)(R) TSIO-520-R15B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A16 (N) 649054A16R (R)

TSIO-520-R7A (N) TSIO-520-R7B (N)(R)

649054A5-1 (N) 649054A5-1R (R)

TSIO-520-R12B (N)(R)

649054A16-3 (N) 649054A16-3R (R)

TSIO-520-R13B (N)(R)

649054A16-4 (N) 649054A16-4R (R)

TSIO-520-T1A (N) TSIO-520-T1B (N)(R) TSIO-520-T1F (N)(R) TSIO-520-T3B (N)(R) TSIO-520-T4B (N)(R)

649054A35 (N) 649054A35R (R)

TSIO-520-UB1B (N)(R) TSIO-520-UB8B (N)(R)

649054A36-9 (N) 649054A36-9R (R)

649054A16-1 (N) 649054A16-1R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-114B 655534-214B 655534-314B 655534-414B 655534-514B 655534-614B 655534-115C 655534-215C 655534-315C 655534-415C 655534-515C 655534-615C 655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA

TABLE 1 (CON'T)

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REVISED

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-UB2B (N)(R) TSIO-520-UB2F (N)(R) TSIO-520-UB3A (N) TSIO-520-UB3B (N)(R) TSIO-520-UB3F (N)(R) TSIO-5200UB6B (N)(R) TSIO-520-UB7B (N)(R) TSIO-520-UB9B (N)(R) TSIO-520-UB23B (N)(R) TSIO-520-UB4A (N) TSIO-520-UB11B (N)(R) TSIO-520-UB13B (N) TSIO-520-UB14B (N) TSIO-520-UB16B (N) TSIO-520-UB21B (N)(R) TSIO-520-UB22B (N)(R) TSIO-520-UB4B (N)(R) TSIO-520-UB4F (N)(R) TSIO-520-UB5A (N) TSIO-520-UB5B (N)(R) TSIO-520-UB5F (N)(R) TSIO-520-UB10B (N)(R) TSIO-520-UB12B (N)(R) TSIO-520-UB20B (R) TSIO-520-UB15B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A36-8 (N) 649054A36-8R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA

649054A36-10 (N) 649054A36-10R (N)

655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA

649054A36-11 (N) 649054A36-11R (N)

655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA

649054A36-12 (N) 649054A36-12R (R)

TSIO-520UB17B (N) TSIO-520-UB18B (N)(R)

649054A36-7 (N) 649054A36-7R (R)

TSIO-520-UB19B (N)

649054A36-13 (N) 649054A36-13R (R)

655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA 655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA 655534-117C 655534-217C 655534-317A 655534-417A 655534-517A 655534-617AA

TABLE 1 (CON'T)

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-520-VB1A (N) TSIO-520-VB1B (N)(R) TSIO-520-VB1F (N)(R) TSIO-520-VB2A (N) TSIO-520-VB2B (N)(R) TSIO-520-VB2F (N)(R) TSIO-520-VB4A (N) TSIO-520-VB4B (N)(R) TSIO-520-VB4F (N)(R) TSIO-520-VB5F (N)(R) TSIO-520-VB6F (N)(R) TSIO-520-VB7F (N)(R) TSIO-520-VB8B (R) TSIO-520-WB1B (N)(R) TSIO-520-WB1F (N)(R) TSIO-520-WB3A (N) TSIO-520-WB3B (N)(R) TSIO-520-WB3F (N)(R) TSIO-520-WB5A (N) TSIO-520-WB5B (N)(R) TSIO-520-WB5F (N)(R) TSIO-520-WB6B (N)(R) TSIO-550-A1B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A37 (N) 649054A37R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 655534-116A 655534-216A 655534-316A 655534-416A 655534-516A 655534-616A

649054A23-2 (N) 649054A23-2R (R)

655534-114C 655534-214C 655534-314C 655534-414C 655534-514C 655534-614C

NOT AVAILABLE

TSIO-550-B1B (N)(R) TSIO-550-B2B (N)(R)

649054A6-1 (N) 649054A6-1R (R)

TSIO-550-C1B (N)(R) TSIO-550-C3B (N)(R) TSIO-550-C4B (N)(R)

649054A6 (N) 649054A6R (R)

TSIO-550-C5B (N)(R) TSIO-550-C8B (N) TSIO-550-C10B (N)

649054A6-5 (N) 649054A6-5R (R)

639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B

TABLE 1 (CON'T)

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIO-550-C6B (N)(R)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A41 (N) 649054A41R (R)

TSIO-550-C7B (N) TSIO-550-C9B (N)

649054A6-4 (N) 649054A6-4R (R)

TSIO-550-E1B (N)(R) TSIO-550-E2B (N)(R) TSIO-550-E4B (R) TSIO-550-E9B (N)(R) TSIO-550-E12B (N)

649054A6 (N) 649054A6R (R)

TSIO-550-E3B (N)(R) TSIO-550-E4B (N) TSIO-550-E13B (N)

649054A6-3 (N) 649054A6-3R (R)

TSIO-550-E5B (N)(R)

649054A6 (N) 649054A6R (R)

TSIO-550-E10B (N)(R) TSIO-550-E11B (N)(R)

649054A6-7 (N) 649054A6-7R (R)

TSIOL-550-A1A (N) TSIOL-550-A1B (N) TSIOL-550-A1G (N)(R) TSIOL-550-A3B (N) TSIOL-550-A5B (N) TSIOL-550-A6B (N) TSIOL-550-A7B (N) TSIOL-550-A8B (N) TSIOL-550-A9B (N)

649054A39 (N) 649054A36R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-119B 639368-219B 639368-319B 639368-419B 639368-519B 639368-619B 639368-114B 639368-214B 639368-314B 639368-414B 639368-514B 639368-614B

TABLE 1 (CON'T)

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ENGINE MODEL/SPEC NUMBER (N)=NEW (R)=REBUILT TSIOL-550-C1B (N)

FUEL SYSTEM PART NUMBERS AND KIT PART NUMBERS 649054A38 (N) 649054A38R (R)

FUEL INJECTOR NOZZLE PART NUMBERS 639368-117C 639368-217C 639368-317C 639368-417C 639368-517C 639368-617C

TABLE 1 (CON'T)

TABLE 1 NOTES 1) For a complete explanation of engine specification numbers see TCM Service Information Letter SIL05-3. 2) The fuel injector nozzle part numbers shown in TABLE 1 indicate the cylinder position in the dash number. For example, a -117C nozzle is for installation in cylinder no.1, a -217C nozzle is for installation in cylinder no.2, etc. These nozzles are NOT interchangeable with the earlier part number nozzles. For example, a P/N 639368-17C nozzle is NOT interchangeable with a P/N 639368-117C nozzle. If the old style part number nozzle is not available, then the entire nozzle set must be replaced.

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TELEDYNE CONTINENTAL

®

CATEGORY 3

AIRCRAFT ENGINE

SERVICE BULLETIN

SB06-5 Technical Portions FAA Approved

Compliance Will Enhance Safety SUBJECT: PURPOSE: COMPLIANCE: MODELS AFFECTED:

Supercedes X30663R1 CRANKSHAFT OIL TRANSFER TUBE INSPECTION AND REPLACEMENT Revise crankshaft inspection, repair and overhaul procedures. During Engine Overhaul or on condition crankshaft repair.

C-125, C-145, O-300, E-165, E-185, E-225; All IO-360; All L/TSIO-360; All O-470; All IO-470; All TSIO-470; All IO-520-A, D, E, F, J, K, L and P; L/TSIO-520-A, AE, AF, C, CE, G, H, M, P, R and T; All GTSIO-520; IO/IOF-550-D, E, F and L.

GENERAL 1. This is an overhaul manual supplement for engine models that have a crankshaft fitted with oil transfer tubes. 2. This supplemental information is to be used when crankshaft repairs are performed in accordance with any of the following overhaul manuals: X30013, X30016, X30019, X30033, X30039A, X30045A, X30574A, X30575A, X30586A, X30588A, X30594A, X30596A or X30596AS1. NOTE: This bulletin contains updates to the Manufacturer's Instructions For Continued Airworthiness as required by FAR43.13. A copy of this bulletin must be inserted into the inspection section of the above listed TCM Overhaul Manuals. INSPECTION Procedure At engine overhaul or whenever the crankshaft is removed from the crankcase, inspect the crankshaft for loose oil transfer tubes using a non-metallic pointed tool (awl). 1. Try to move the oil transfer tubes with the awl to check for movement. 2. Measure each oil transfer tube on both ends using the dimensions given in Figure 3. 3. If oil transfer tubes are secure and conform with the dimensions specifications in Figure 3, proceed with the crankshaft repair procedure in the applicable overhaul manual. 4. Replace loose or non-conforming oil transfer tubes using the procedures contained in this bulletin. NOTE: Teledyne Continental Motors offers factory new crankshafts as an alternative to crankshaft repair.

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PAGE NO 1 of 8

SIL06-5

REVISION

OIL TRANSFER TUBE REMOVAL 1. Place the crankshaft on a secure workbench stand that will allow it to be rotated without damage. 2. Visually inspect the crankshaft oil transfer tube counterbore prior to removal with a 10X magnifying glass. Discard crankshafts exhibiting any of the following indications: •

Handling damage

•

Machine tool damage

•

Corrosion

•

Nicks, dings, scratches or burrs WARNING Do not attempt to drill out the oil transfer tubes. The crankshaft nitrided surface must not be compromised.

3. Remove loose oil transfer tubes using a slide hammer (See Figure 1) fitted with a # 10 X 1.5 inch long self-tapping screw. Turn the puller screw into the oil transfer tube until the threads firmly grip the tubing. Use the slide action of the hammer to remove the oil transfer tube.

Figure 1. Transfer Tube Removal

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PAGE NO 2 of 8

SIL06-5

REVISION

4. Visually inspect the crankshaft oil transfer tube bore after removal with a 10X magnifying glass. Discard crankshafts exhibiting any of the following indications: •

Handling damage

•

Machine tool damage

•

Corrosion

•

Nicks, dings, scratches or burrs

5. Perform a dimensional inspection on the crankshaft oil transfer tube hole. The inside diameter should measure 0.218-0.221 inches. Discard crankshafts with oil transfer tube inside diameters greater than 0.221 inches. WARNING Removing and replacing oil transfer tubes with makeshift tools or unauthorized methods may result in irreparable damage to the crankshaft or future engine malfunction. 3.

OIL TRANSFER TUBE INSTALLATION 1. Ensure the new oil transfer tube is the correct part number and length. Some crankshafts use a different length tube at the #6 Rod Journal (Figure 2). Compare the removed tube length to that of the new tube.

Figure 2. Journal Identification

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PAGE NO 3 of 8

SIL06-5

REVISION

2. Install new oil transfer tube with pre-flared end toward the main journal. See Figure 3 and Figure 7.

10°

0.12

0.25

FLARE TUBES IN PLACE 0.04 0.218 0.221 DIA.

MAIN JOURNAL CRANKSHAFT PIN OIL TRANSFER TUBE PRE-FLARED END

Figure 3. Oil Transfer Tube Installation

3. Using a tool that conforms to the specifications in Figure 4 and a small (not to exceed 12 ounces) ball peen hammer, tap the oil transfer tube until it is firmly seated into the main journal tube bore. CAUTION: Do not use excessive force.

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PAGE NO 4 of 8

SIL06-5

REVISION

0.03125 X 45° 0.375 0.25 MEDIUM KNURL

2.25

4.120 1.25 POLISH

0.50

0.120 SPHERICAL

MATERIAL T00L STEEL - S 5 HDN & DRAW ROCKWELL/C 52-54

0.220

Figure 4. Oil Transfer Tube Seating Tool 4. Using a tool that conforms to the specifications in Figure 5 and a small (not to exceed 12 ounces) ball peen hammer, complete the flare of the tube on the main journal side. CAUTION: Do not use excessive force.

0.03125 X 45° 0.375 0.25 MEDIUM KNURL

2.75

4.625

0.50 X 45° 0.220 ± 0.005 1.50

MATERIAL TOOL STEEL - S 5 HDN & DRAW ROCKWELL/C 52-54

POLISH 0.09375 10°-11°

Figure 5. Oil Transfer Tube Swage Tool

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REVISION

5. Secure the oil transfer tube in the journal with tube clamp illustrated in Figure 6. Install the holding tool at the main journal and screw the ball end into oil transfer tube flare. Tighten only enough to secure the tube in the crankshaft.

1.250

0.625

0.625

1.38R

0.063R TYP.

1

0.750

1.250

SCREW ASSEMBLY

R0.500

R2.000

1/2-13 UNC THROUGH BODY ADAPTER

2

HOLDING TOOL ASSEMBLY

Swivel Screw Carr Lane P/N CL-17-BSS-S 2 Hand Knob Carr Lane P/N CL-40-HK-4A Contact Information: Carr Lane Manufacturing CO. 4200 Carr Lane Ct., P.O. Box 191970 St. Louis, Missouri 63119-7970 USA Phone: 314-647-6200, Fax 314-647-5736 Web Site: www.carrlane.com 1

Figure 6. Oil Transfer Tube Clamp

6. Rotate the crankshaft to access the opposite end of the tube.

7. Using a tool meeting with the specifications in Figure 5 and a ball peen hammer, complete the flare of the tube on the connecting rod journal side. See Figure 3 and Figure 8. CAUTION: Do not use excessive force.

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Figure 7. Installing Oil Transfer Tube in Main Journal

Figure 8. Swage the Oil Transfer Tube in the Crankshaft Pin MO

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FINAL INSTALLATION INSPECTION 1. Inspect the installed tube with a 10X magnifying glass. Oil transfer tube ends must not protrude beyond dimensions shown in Figure 3. The swaged tube ends must not be split. Discard crankshafts with any of the following indications: •

Handling damage

•

Machine tool damage

•

Corrosion

•

Nicks, dings, scratches or burrs

2. Thoroughly wash the crankshaft with solvent. The crankshaft must be free of debris. 3. Perform a crankshaft magnetic particle inspection according to the Overhaul Manual instructions. NOTE: All TCM six cylinder engine crankshafts must be ultrasonic inspected IAW MHS-200 prior to return to service. This inspection must be performed each time the crankshaft is removed for any reason. Reference TCM service bulletin MSB96-10 and FAA AD 97-26-17 for details.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB07-1

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

CONNECTING ROD PISTON PIN BUSHING INSPECTION

PURPOSE:

To provide instructions for inspection of the connecting rod piston pin bushing installation.

COMPLIANCE

MODELS AFFECTED:

At each cylinder removal or anytime piston pin bushing material is identified during routine maintenance procedures.

ALL

GENERAL Teledyne Continental Motors (TCM) has received reports from the field of piston pin bushing material being found in the sump or the oil filter. Piston pin bushings are manufactured from steel-backed bronze and are curved on a radius of approximately 0.62". (Reference Figure 1) If piston pin bushing material is recovered from an engine, (Reference Figure 2) all of the cylinders, pistons, and piston pins must be removed to allow access for inspection of the connecting rods piston pin bushings. In addition, the piston pin bushing must be inspected for condition each time a cylinder is removed for any reason. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA'S) This bulletin contains updates to the manufacturer's Instructions for Continued Airworthiness required under § FAR 43.13(a). A copy of this bulletin must be inserted into the manuals listed in Table 1 of this bulletin until the data is incorporated into the manual by revision or the bulletin is superseded or cancelled. WARNING

New or updated Instructions for Continued Airworthiness may be contained in TCM Service Documents. Service Documents containing updates to the ICA’s that are applicable to the engine or accessories on which work is being performed must be consulted and applicable procedures complied with while performing any installation, maintenance, or overhaul function. Failure in following all published manufacturers ICA’s may result in engine damage, failure and personal injury. INSPECTION If piston pin issues are suspected: 1) Gain access to inspect the piston pin bushings by removing the cylinders and pistons using the instructions contained in the appropriate maintenance or overhaul manual. ISSUED

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2) The piston pin bushing split line (Reference Figure 1) must be positioned within the arc indicated in Figure 3, no closer than 40º to the connecting rod centerline. 3) The piston pin bushing must be visually inspected for any signs of cracks emanating from the piston pin bushing split. (Reference Figure 2) 4) Inspect the piston pin bushing for wear in accordance with the latest revision of bulletin SB00-3. 5) Any piston pin bushing that does not meet the installation criteria in item (2) above or is found cracked per the inspection in item (3) above must be replaced. 6) Any piston pin bushing that exhibits excessive wear when inspected IAW the latest revision of SB00-3 must be replaced before further service. NOTE: Complete connecting rod inspection procedures and piston pin bushing installation procedures are contained in the latest revision of SB00-3. CAUTION: Connecting rod piston pin bushing replacement requires specialized tools and procedures to perform. Connecting rod piston pin bushing replacement must be performed by a shop properly rated to perform the work and using the proper tools and procedures. WARRANTY Warranty for issues found in performance of the inspections contained in this bulletin will only be applied to engines currently covered under the applicable TCM warranty policy.

BUSHING SPLIT LINE PISTON

FIGURE 1 PIN BUSHING SPLIT LINE

FIGURE 1 Typical New Piston Pin Bushing ISSUED

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FIGURE 2 TYPICAL INDICATIONS

P.O. BOX 90 MOBILE, AL 36601 251-438-3411

MISSING MATERIAL

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MANUAL NUMBER X30008 X30010A

MANUAL TYPE OVERHAUL OVERHAUL

X30013 X30019 X30016 X30586A X30622A X30621A OH-22 M-22 X30027 X30594A X30588A X30039A M-11 X30045A X30568A X30634A OH-24 M-24 X30607A X30596A

OVERHAUL OVERHAUL OVERHAUL OVERHAUL OVERHAUL MAINTENANCE OVERHAUL MAINTENANCE OVERHAUL OVERHAUL OVERHAUL OVERHAUL MAINTENANCE OVERHAUL OVERHAUL MAINTENANCE OVERHAUL MAINTENANCE OVERHAUL OVERHAUL

X30672A X30596AS1 X30645A X30033 X30574A

MAINTENANCE OVERHAUL MAINTENANCE OVERHAUL OVERHAUL

X30575A

OVERHAUL

M-18

MAINTENANCE / OVERHAUL OVERHAUL OVERHAUL MAINTENANCE OVERHAUL

X30600A OH-15 OMI-15 X30144

ENGINE MODEL A-65 C-75, C-85, C-90, 0200A,B C-125, C-145, O-300 GO-300 E-165, E-185, E-225 O-470 IO-240 IO-240 IOF-240 IOF-240 IO-346 IO-360 IO-470 IO-520 IO-520 PERMOLD GTSIO-520 IO-550 PERMOLD IO-550 PERMOLD IOF-550 IOF-550 IO-550 SANDCAST L/TSIO-360 EXC RB TSIO-360-MB, SB L/TSIO-360-RB L/TSIO-360-RB TSIO-470 TSIO-520 PERMOLD TSIO-520 SANDCAST TSIO-550

SECTION

TSIOL-550-A TSIOL-550-C TSIOL-550-C TIARA

72-40 18 16 7

SECTION

9 XIII 10 9 IX 72-20 22 18 8 10 IX 72-40 72-40 VI 19 IX 17 19 8 8 72-40 72-40 20 18 20 X 72

16 VIII

72 10

15

16

TABLE 1 This bulletin contains updates to the manufacturer's Instructions for Continued Airworthiness required under § FAR 43.13(a). A copy of this bulletin must be inserted into the manuals listed in Table 1 until the data is incorporated into the manual by revision or the bulletin is superseded or cancelled.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB07-8A

Contains Important Information Pertaining to Your Aircraft Engine.

Supersedes SB07-8 Technical Portions FAA Approved

Compliance Will Enhance Safety

SUBJECT: RECOMMENDED MINIMUM CRUISE RPM LIMITS PURPOSE: To inform operators of the possible long term effects of low engine RPM in cruise conditions. To recommend limitation of minimum engine RPM in cruise. COMPLIANCE: .Upon issuance of this bulletin MODELS AFFECTED: O-470-G; IO-470-N; IO-520-BB, CB, MB, P; IO-550-A, B, C, D, E, F, G, L, M, N, P, R; IOF-550-B, C, D, E, F, G, L, N, P, R; TSIO-520-AE, BB, BE, CE, DB, EB, JB, KB, LB, NB, UB, VB, WB; LTSIO-520AE; TSIO-550-A, B, C, E; TSIOF-550-C, E; TSIOL-550-A, B, C Revision A: To clarify limitations for cruise RPM and add naturally aspirated engines . Teledyne Continental Motors (TCM) has examined recent occurrences of crankshaft counterweight release and consequent engine stoppage with four high time IO and TSIO-520 engine models. Initial investigation and service history lead us to believe that these occurrences are associated with engine operation at sustained cruise engine speeds of less than 2300 RPM. While power settings of less than 2300 RPM are within the recommended cruise range allowed by TCM’s model Specifications, TCM believes that the population of aircraft (equipped with the affected engine models) that operate using the aforementioned low RPM for extended cruise operation is limited. TCM will continue to evaluate the root cause of the counterweight release including any connection with power settings. TCM is not aware of any other confirmed occurrences of this type.

Effective immediately, TCM strongly recommends the following limitation be observed on all the models affected above: Engine cruise RPM settings should be no lower than 2300 RPM. NOTE … This limitation applies only to cruise operation and is not meant to supersede the aircraft manufacturers’ recommendations for other operational modes such as emergency or holding procedures.

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A

Any engine listed in the models affected that has been consistently operated outside the recommended limitation in this bulletin should contact TCM Technical Customer Service at 1-888-826-5465 Option 1 or 1-251-438-3411 x8299 for further information and instructions.

Upon contacting TCM Technical Customer Service, owner/operators must be prepared to provide the following information:      

Aircraft make and model. Aircraft registration number. Engine model(s). Engine serial number(s). Total engine hours since major overhaul or factory new/rebuilt. Aircraft cruise operational profile. o Engine RPM o Engine manifold pressure-Hg” o Fuel flow-PPH or GPH o Average cruise conditions-duration, altitude

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A

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB07-9

Compliance Will Enhance Safety

SUBJECT:

Technical Portions FAA Approved

IO240B Inline Fuel Filter Reorientation

PURPOSE:

To provide instructions for the reorientation of the P/N 656859 fuel filter assembly in the Diamond DA20C1 aircraft. Instructions for Continued Airworthiness (ICA) for the P/N 656859 fuel filter assembly are also provided in this Service Bulletin. COMPLIANCE: Comply at next maintenance event or in conjunction with performance of SIL07-10. MODELS AFFECTED: IO240B13B, 17B, 20B, 21B engines equipped with Altitude Compensating Fuel Systems and IO240 engines modified per SIL05-4A to incorporate a 656859 inline fuel filter

FILTER REORIENTATION INSTRUCTIONS This section contains instructions for the removal of the currently installed P/N 656859A1 fuel filter assembly with mounting bracket and installation of the replacement P/N 656859A6 fuel filter and vertical mounting bracket configuration utilizing EQ7496 Fuel Filter and Hose Kit. This kit provides a new fuel filter with bracket assembly which allows reorientation of the filter utilizing original Camloc locations on the forward apron. New inlet/outlet hoses are furnished installed to assure cleanliness of the replacement filter assembly at installation. Fuel line fittings may be loosened to allow alignment during hose attachment, but are NOT to be disconnected. Caution All fuel system components must be handled with care with any openings sealed with appropriate clean caps and plugs prior to installation or immediately upon removal. The engine, tools and environment must be clean to minimize any potential for fuel system contamination. Fuel system purging instructions must be performed in the sequence provided in this SID.

WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. Referring to the airframe manufacturers maintenance instructions: (a) Remove upper and lower engine cowlings from the aircraft (b) Remove electrical power from the aircraft. (c) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. 1. Disconnect the fuel line from the engine driven fuel pump outlet fitting. The fuel outlet fitting B nut may be loosened to assist in hose removal and alignment for installation of the new pump to filter hose. (Reference Figure 1) Install a cap on the fuel pump outlet fitting to prevent contamination. 2. Disconnect the induction air hose from the throttle body. Install cap plugs or tape on both the throttle body inlet and the induction air hose openings. Disconnect the fuel line from the fuel metering unit inlet fitting. (Reference Figure 2) Install a cap on the fuel metering inlet fitting. ISSUED

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3. Disengage the camlocs that secure the fuel filter mounting bracket to the forward apron assembly. With fuel lines attached, lift the fuel filter assembly vertically removing the fuel filter assembly with hoses, from the aircraft. (Figure 3)

Engine Driven Fuel Pump Fuel Pump Outlet Elbow Fitting

FIGURE 1

Throttle and Control Unit

Metering Unit Inlet Fitting

Figure 2

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P/N 659856A1 Fuel Filter Assembly

Camlocs

Figure 3 4. Modify the existing opening in the forward baffle assembly as referenced in Figure 4. All dimensions in mm’s. See Diamond Service Bulletin DAC1-73-05 NOTE: A rotary tool with a sanding drum is recommended for the baffle modification. Insure that all fuel and air openings are sealed before starting. Carefully clean all surfaces after rework to avoid contamination.

Figure 4 ISSUED

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NOTE: All caution must be exercised during maintenance of the fuel system NOT to allow any contaminants to enter the components, lines and fittings during installation. All surfaces surrounding the area where components are to be installed must be clean and free of all forms of contaminant before and during installation. Components must be flushed and verified to be free of contamination prior to final installation. During Installation: (1) Select the proper size open-end wrenches that will fit the fitting body and hose or tubing end fitting. (2) Torque the hose or tubing end fitting to the specified torque using a properly certified calibrated torque wrench while maintaining sufficient force on the component fitting to prevent twisting and shear loads. (3) Support the last fitting in the assembly on components that contain multiple fittings coupled in one location. (4) DO NOT over torque fittings.

5. Confirm hose and fitting clocking of the fuel pump to inline fuel filter hose. This hose must be installed prior to filter installation as it is not accessible when the filter is attached to the forward apron. When clocking is verified, torque fitting to 135-190 inch pounds using a calibrated torque wrench. See the figure below for clocking. P/N 646644S4Y5.00 Hose assembly

P/N 656859A6 Fuel Filter Assembly. (Mounting Bracket Omitted for Clarity.)

Hose assemblies supplied with the 45º fittings in plane with the fuel filter assembly as shown

P/N 646644S4Y6.50 Hose assembly

FIGURE 5

6. Leaving the inlet and outlet hose attached to the filter, route the new fuel pump to fuel filter line through the forward apron. It will be necessary to guide the fuel line around the back side of the engine driven fuel pump and into the correct position for installation. Assure that that the four lockwired screws are on the ISSUED

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lower side of the filter installation. Attach the fuel filter to the forward apron by engaging the existing Camloc fasteners on bracket. (Reference Figure 6) 7. Restore electrical power to the aircraft. Select the fuel “ON”. 8. Remove the fuel pump outlet fitting protective cap. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel through the fuel pump outlet fitting through a coffee filter into a clean, dry container. If contamination is found, continue to flush until no contaminant is evident. If no contamination is found, remove protective plug from the fuel pump to filter hose and attach hose to the fuel pump outlet fitting. 9. Torque the fuel pump outlet fitting elbow B nut and the fuel pump outlet hose “B” nut to 135-190 Inch-Lbs. 10. Remove the plug from the fuel filter to fuel metering unit inlet hose. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel into a clean, dry container. Inspect the flushed fuel. If contamination is found, locate the source and correct the issue before proceeding further. If no contamination is present, proceed to the next step. 11. Connect the fuel filter outlet line to the metering unit inlet fitting. Torque to 135-190 Inch-Lbs. (Reference Figure 6)

P/N 656859A6 Fuel Filter Assembly

P/N 646644S4Y5.00 Hose Assembly

FIGURE 6 12. Using the fuel boost pump, leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step. 13. Perform the fuel system setup and operation verification in accordance with the instructions and specifications contained in TCM bulletin SID07-3, revision A or later and the instructions contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. Assure that 639464 caps are installed on the fuel metering tee and the manifold tee pressure checking points. Make an engine logbook entry that SB07-9 has been complied with.

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WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. NOTE Pressure altitude must be used when determining fuel system set-up values. To determine pressure altitude prior to take-off, set your altimeter to 29.92 in hg, and the altimeter will indicate your pressure altitude. 14. Using the airframe manufacturers instructions, return the aircraft to its normal configuration.

WARRANTY Contact Teledyne Continental Motors Customer Service at 1-888-826-5465 for part kit availability and labor claim filing instructions to allow completion of the modification section of this Service Bulletin. Please provide the following information to TCM representative at time of contact; 1. 2. 3. 4. 5. 6.

Model and Serial number of the affected aircraft Registration number Engine Serial Number Total time on engine Owner’s Name, Address and Telephone Contact info FBO Name, Address and Telephone Contact info

PARTS REQUIRED P/N EQ7496 Fuel Filter assembly with hoses

1 EA

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Teledyne Continental Motors requires the P/N 656859A6 filter assembly to be inspected after each 200 hours in service using the following instructions and referencing photo 1.

WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. NOTE: All caution must be exercised during maintenance of the fuel system NOT to allow any contaminants to enter the components, lines and fittings during installation. All surfaces surrounding the area where components are to be installed must be clean and free of all forms of contaminant before and during installation. Components must be flushed and verified to be free of contamination prior to final installation.

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Referring to the airframe manufacturer’s maintenance instructions: (a) Remove electrical power from the aircraft. (b) Remove the upper engine cowling from the aircraft (c) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. 1. Disconnect the fuel line from the engine driven fuel pump outlet fitting. The fuel outlet fitting B nut may be loosened but not removed to assist in hose removal and alignment for installation of the new pump to filter hose. (Reference Figure 1) Install a cap on the fuel pump outlet fitting to prevent contamination. 2. Disconnect the induction air hose from the throttle body. Install cap plugs or tape on both the throttle

body inlet and the induction air hose openings. 3. Disconnect the fuel line from the fuel metering unit inlet fitting. (Reference Figure 2) Install a cap on the fuel metering inlet fitting. 4. Disengage the camlocs that secure the fuel filter mounting bracket to the forward apron assembly. With fuel lines attached, lift the fuel filter assembly vertically removing the fuel filter assembly with hoses, from the aircraft. (Figure 3) 5. Remove the P/N 656859A6 filter assembly. Cut the safety wire on the four screws holding the P/N 656855 cover on the inlet side of the fuel filter assembly. Remove the four screws and remove the cover. Remove the P/N MS9021-020 o-ring from the cover and discard. 6. Remove the P/N 656858 filter spring from the filter housing, then remove the P/N 656856 filter disc from the housing. 7. Clean the filter disc, cover and housing ultrasonically or by soaking in lacquer thinner or acetone for several hours. Clean the housing and spring prior to reassembly. Blow the filter disc, housing and spring dry with clean, filtered dry compressed air. If any physical damage is noted to the filter disc, it must be replaced. 8. Install the filter disc and then the spring into the filter housing assembly. Install a new P/N MS9021-020 oring onto the cover. Lubricate the o-ring with clean engine oil and install the cover onto the filter housing assembly. Secure the cover using the four P/N AN500-A8-7 screws and AN960-8 washers. Torque the cover retaining screws to 17.5 to 22.5 In-Lbs. Lockwire the screws in pairs using 0.032” stainless steel lockwire conforming to MS20995 Condition A 9. Reinstall the hoses to filter 656859A6 (Reference Figure 5). Route the fuel pump to fuel filter line through the forward apron. It will be necessary to guide the fuel line around the back side of the engine driven fuel pump and into the correct position for installation. Assure that that the four lockwired screws are on the lower side of the filter installation. Attach the fuel filter to the forward apron by engaging the existing camloc fasteners on bracket. (Reference Figure 6) 10. Restore electrical power to the aircraft. Select the fuel “ON”. 11. Remove the fuel pump outlet fitting protective cap. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel through the fuel pump outlet fitting through a coffee filter into a clean, dry container. If contamination is found, continue to flush until no contaminant is evident. If no contamination is found, remove protective plug from the fuel pump to filter hose and attach hose to the fuel pump outlet fitting. 12. Torque the fuel pump outlet fitting elbow B nut and the fuel pump outlet hose “B” nut to 135-190 inch-lbs. 13. Remove the plug from the fuel filter to fuel metering unit inlet hose. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel into a clean, dry container. Inspect the flushed fuel. If contamination is found, locate the source and correct the issue before proceeding further. If no contamination is present, proceed to the next step. 14. Connect the fuel filter outlet line to the metering unit inlet fitting. Torque to 135-190 Inch-Lbs. (Reference Figure5) Using the fuel boost pump, leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step. ISSUED

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WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. Perform the fuel system verification in accordance with the procedures contained in the latest revision of TCM bulletin SID07-3 and the procedures contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. Assure that all connections are correct and properly torqued. Reinstall the cowlings in accordance with the airframe manufacturer’s maintenance instructions. MS9021-020 O-Ring

656855 Cover

656858 Filter Spring 656856 Filter Disk Or 656851 Cup Filter

656854 Housing

AN500-8-7 Screw 4 Each AN960-8 Washer 4Each

PHOTO 1 FUEL FILTER ASSEMBLY

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-1

Compliance Will Enhance Safety

SUBJECT:

Technical Portions FAA Approved

ROCKER SHAFT INSPECTION AND REPLACEMENT

PURPOSE: To provide instructions for the inspection of P/N 653816 and subsequent cylinder assemblies for the installation of the P/N 654375 rocker shaft and to provide replacement instructions for any P/N 654375 rocker shafts found installed. COMPLIANCE

MODELS AFFECTED:

PART I required at each preflight inspection until completion of PART II. PART II to be completed at the next scheduled maintenance event, no later than the next annual inspection or immediately if oil leakage is noted in PART I.

All C-series engines, O-200-A , O-300-Series, GO-300-series engines

GENERAL All engines listed above, manufactured after November, 1997 and those which have had cylinders replaced after November, 1997 may utilize the P/N 654375 Rocker Shaft and the P/N MS51963-64 retaining screw. Teledyne Continental Motors (TCM) has received reports from the field of some P/N MS51963-64 Rocker Shaft Retaining Screws losing torque, allowing the P/N 654375 Rocker Shaft to chafe the rocker cover. Any listed engine model which was manufactured or had cylinders replaced after November, 1997 must be inspected. All P/N 654375 Rocker Shafts found must be replaced with the P/N 21153 Rocker Shaft. PART I PREFLIGHT INSPECTION INSTRUCTIONS Prior to each flight visually insect all rocker covers at the 3 o’clock and 9 o’clock positions for evidence of oil leakage. If oil leakage is found or evidence of potential damage exists, you must perform PART II of this bulletin prior to further flight. PART II INSPECTION / REPLACEMENT INSTRUCTIONS 1) Using the airframe manufacturers maintenance instructions remove the engine cowlings and engine cooling baffles as necessary to access the cylinder rocker covers. 2) Remove the rocker cover from each cylinder. 3) Inspect each cylinder for the presence of the P/N 654375 Rocker Shaft and the P/N MS51963-64 Rocker Shaft Retaining Screw. (Reference Figure 1 and Figure 2)If the P/N 654375 Rocker Shaft is not installed, no further action is required. Go to step 6. ISSUED

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4) If the P/N 654375 Rocker Shaft is installed proceed as follows: a) Rotate the engine to bring the piston to top dead center. Both valves will be closed. b) Remove and discard the P/N MS51963-64 Rocker Shaft Retaining screw. c) Remove the P/N 654375 Rocker Shaft and retain for return to TCM. d) Reinstall the rocker arms utilizing a new P/N 21153 Rocker Shaft.

P/N 654375 Rocker Shaft

Alignment Notches

P/N MS51963-64 Set Screw FIGURE 1 P/N 654375 ROCKER SHAFT INSTALLATION (ROCKER ARMS REMOVED FOR CLARITY)

P/N 21153 Rocker Shaft

Wide Bevel DO NOT use set screw with the P/N 21153 Rocker Shaft

Machined Surface

FIGURE 2 P/N 21153 ROCKER SHAFT INSTALLATION (ROCKER ARMS REMOVED FOR ILLUSTRATION)

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WARNING The P/N MS51963-64 Rocker Shaft Set Screw MUST NOT be used with the P/N 21153 Rocker Shaft. 5) If the P/N 654375 Rocker Shaft was installed, inspect each Rocker Cover for chafing in the areas as indicated in Figure 3. If damage in the form of metal removal is found, the Rocker Cover must be replaced with a new P/N 40762 Rocker Cover. Acceptable wear pattern is shown in Figure 4.

Visual Inspection Area

FIGURE 3 ROCKER COVER INSPECTION

FIGURE 4 TYPICAL WEAR MARK FLOATING ROCKER ARM SHAFT

NOTE: A wear mark on the Rocker Cover is normal when utilizing a floating Rocker Shaft such as the P/N 21153 and is not an indicator for Rocker Cover replacement. ISSUED

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6) Install each removed Rocker Cover using a new P/N 655706 Rocker Cover Gasket. Torque the Rocker Cover Screws to 55-65 Inch-Lbs. 7) Test run the engine in accordance with the pilots operating handbook and leak check the entire engine. Repair any leaks found prior to returning the engine to service. 8) Reinstall the engine cowlings using the airframe manufacturer’s maintenance instructions. 9) Make logbook entry for compliance with this Service Bulletin.

WARRANTY Warranty coverage will be available as follows; for all engines found to have P/N 654375 Rocker shaft. Rocker cover gaskets and rocker shafts will be available for all engines with 654375 rocker shafts found installed. Rocker covers will be available for all covers worn full circle by the end machining of 654375 rocker shaft. Warranty labor will be available for the inspection and replacement of rocker arms and covers of all engines still within original warranty period as follows: Open cowl models (eyebrows only over cylinders). 3.0 Hours labor Closed cowl models requiring cowl and prop removal. 5.0 hours Closed cowl models requiring cowl removal only. 4.0 hours Engines outside of their original warranty period will receive parts replacement only. Contact TCM Customer Support Technical Services at 1-888-826-5465 for parts shipment, warranty labor questions and general assistance as required.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-12

Contains Important Information Pertaining to Your Aircraft Engine. Compliance will enhance safety.

Technical Portions FAA Approved

SUBJECT: Crankshaft Gear Supersedure PURPOSE: To supersede SANDCAST crankshaft gears part number 536421 and 653631 COMPLIANCE: At the next maintenance requiring complete disassembly of the engine, no later than published TBO. MODELS AFFECTED: ALL O470, IO470, TSIO470, IO520, LIO520, LTSIO520, TSIO520, IO550 and IOF550 SANDCAST engines. By this bulletin, Teledyne Continental Motors announces the mandatory replacement by supersedure of SANDCAST crankshaft gears part number 536421 and 653631. The current replacement crankshaft gear part number is 657175. Replace all 536421 and 653631 crankshaft gears with the current replacement part number, 657175 or subsequent part number. Crankshaft gear replacement to be completed no later than the next engine disassembly or published TBO following the original issue date of this bulletin. The 536421 crankshaft gear measures .565 inches thick (nominal) at the gear tooth area, when measured from the front to the back of the gear. The 653631 crankshaft gear measures .562 inches thick (nominal) at the gear tooth area, when measured from the front to the back of the gear. The 657175 crankshaft gear measures .690 inches thick (nominal) at the gear tooth area, when measured from the front to the back of the gear. This measurement does not include the reduced dimension pilot area on the back of the 657175. Use these measurements to confirm which gear part number is installed. The 657175 gears are in stock and may be ordered through any TCM distributor. To facilitate supersedure of the 536421 and 653631 crankshaft gears, Teledyne Continental Motors, for a limited time, will offer a special price on the purchase of all 657175 (and subsequent part number) gears. The list price of the 657175 crankshaft gear has been reduced to $400.00 (I). A core charge of $200.00 will be charged on separate invoice pending return of the superseded gear 536421 or 653631. Core value will be issued for return of these part number gears only. All returns must be accompanied by engine Model and Serial Number information to confirm engine information and receive core credit. For questions, please call TCM Tech Service at 888-826-5465

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-13

Compliance Will Enhance Safety

SUBJECT:

Technical Portions FAA Approved

INDUCTION SYSTEM HOSE AND CLAMP INSTALLATION

PURPOSE: To provide instruction for the proper installation of induction system hoses and clamps. COMPLIANCE

At every induction system hose installation.

MODELS AFFECTED: All TCM Engines Teledyne Continental Motors has received reports from the field of improper installation of induction system hoses and clamps. Improper installation of induction system hoses and clamps can lead to failure of the induction hose to maintain adequate seal, which can cause loss of engine power. The following instructions must be utilized in the installation of induction system hoses: 1) Each tube or component to be joined incorporates a “bead” at the end or joint of the induction tube. (Reference Figure 1) Care must be taken to ensure the induction tubes are installed squarely and in alignment.

2) Prior to installation, inspect the tubes and/or components to be connected. Any erosion of sealing bead, dents, deep scratches or cracks in the sealing area of the tube or component will cause induction leaks. Any tube or component that exhibits any of these signs must be repaired or replaced prior to installation.

3) See current revision of SIL99-2 for approved assembly lubricants. Slide the induction hose and clamp(s) onto one of the tubes to be joined. The induction hose and clamp(s) must fit onto the tube far enough to allow installation of the tube, hose and clamps without interference.

4) Move the induction hose to position the induction hose over the connection joint of the two tubes. The connection joint and both tube beads are to be positioned in the center of the induction hose. ISSUED

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5) Slide the clamps into place, centering the clamps between the tubing bead and the end of the induction hose to ensure the hose correctly seals the tubes. The ends of the induction hose must extend beyond the clamp(s) on both ends of the induction hose. (Reference Figure 2) 6) Torque the clamps to 25-35 Inch-Lbs.

WARNING Failure to properly install induction system clamps and hoses may lead to failure of the hose to seal, loss of manifold pressure, and loss of engine power

BEAD LOCATION

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FIGURE 1 Typical Induction Tube joint with Tube Bead Seal

Correct Bead Location

Hose Must Extend Beyond Edge of Clamp

Bridged Clamp Assembly

FIGURE 2 ISSUED

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Typical Induction hose installation with “Bridged” clamp assembly

Typical Aftercooler Installation ISSUED

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FIGURE 3 Typical induction system hose installation, unbridged double clamp, hose connector

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-3

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

THROTTLE AND MIXTURE CONTROL ARMS

PURPOSE:

To provide updates to the Instructions for Continued Airworthiness containing inspection criteria and installation instructions for throttle and mixture control arms.

COMPLIANCE

MODELS AFFECTED:

At each routine engine inspection and at any time a throttle or mixture arm is removed for adjustment or replacement.

ALL except FADEC – equipped engines

GENERAL Teledyne Continental Motors currently has two styles of throttle or mixture control arms in use in the field: • The original style control arms were manufactured from a bronze material and featured a non-machined chamfer on one side, which mated to the machined chamfer on the shaft. • The current style throttle or mixture control arms are manufactured from stainless steel and feature a splined chamfer, which interlocks with the matching splined chamfer on the shaft. (REFERENCE FIGURE 1 FOR CONTROL ARM IDENTIFICATION) Note: Teledyne Continental Motors recommends use of the current style stainless steel throttle or mixture levers at the next engine overhaul, component replacement, component repair, or anytime a bronze lever is removed for any reason. INSTRUCTIONS FOR CONTINUED AIRWORTHINESS This Service Bulletin will provide installation instructions and inspection criteria for both bronze and stainless steel throttle and mixture control arms. WARNING

New or updated Instructions for Continued Airworthiness may be contained in TCM Service Documents. Service Documents applicable to the engine or accessories on which work is being performed must be consulted and complied with prior to performing any installation, maintenance, or overhaul function. Failure in following all published manufacturers ICA’s may result in engine damage, failure and personal injury.

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SECTION 1: INSTALLATION INSTRUCTIONS 1) Install the throttle or mixture control arm, as applicable, onto the shaft. Position the lever to allow proper interface with the airframe controls. 2) If installing a bronze control arm, ensure that the chamfer in the control arm is positioned snugly against the splines of the control shaft. 3) If installing a stainless steel control arm, ensure that the formed splines on the control arm are interlocked with the splines on the shaft. 4) Lubricate the threads on the shaft with clean 50 weight engine oil. 5) Install the lock nut and torque to 100-120 inch-pounds. 6) Check the control arm after proper torque application to ensure there is not any free play between the control arm and the shaft. 7) If any free play is noted after installation, remove the control arm and inspect for the cause.

Bronze Control Arm

Stainless Steel Control Arm

Non-Machined Chamfer. Splines Formed at Installation

Machined Chamfer. Splines Formed at Manufacture

FIGURE 1 THROTTLE AND MIXTURE ARM IDENTIFICATION

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Correct Installation Chamfered Edge Installed Against Splines

Incorrect Installation Non-Chamfered Edge Installed Against Splines

FIGURE 2 BRONZE THROTTLE OR MIXTURE ARM INSTALLATION SECTION 2: INSPECTION INSTRUCTIONS 1) At initial installation and at every 100 hour or annual inspection, inspect the control arm for looseness, free play on the shaft, and proper installation. 2) If any looseness or free play is found, the control arm must be removed for inspection of the control arm and shaft. 3) If the control arm is found to be installed incorrectly the control arm must be removed and replaced and the shaft must be inspected for condition. 4) Inspect removed control arms. Any control arm found with worn or damaged splines must be replaced. 5) Inspect the shaft splines in accordance with FIGURE 4 any time the control arm is removed. If damage or wear is found on shaft splines the component must be removed and repaired or replaced. Note: Teledyne Continental Motors recommends use of the current style stainless steel throttle or mixture levers at the next engine overhaul, component replacement, component repair, or anytime a bronze lever is removed for any reason.

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REVISION

Splines must be well formed without deformation or material loss.

FIGURE 3 NEW STAINLESS STEEL CONTROL ARM AND SHAFT 6) Damage may consist of: a) Rolled edges on the control shaft splines b) Stripped or missing splines on the control arm or the control shaft. c) Excessive wear on the splines of the control arm or the control shaft. Splines must be well defined with no visible distortion or missing material. WARNING

Any control arm or shaft exhibiting damage must be replaced prior to further service using the procedures contained in the applicable Maintenance or Overhaul Manual and this Service Bulletin.

Worn splines caused by under torque at installation.

Rolled Edges and missing material

FIGURE 4 CONTROL ARM AND SHAFT SPLINE INSPECTION ISSUED

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SID08-4

Compliance Will Enhance Safety

Technical Portions FAA Approved

SUBJECT:

FUEL INJECTION SYSTEM CONTAMINATION

PURPOSE:

To provide guidelines to prevent contamination of Teledyne Continental Motors (TCM) fuel injection systems during installation and maintenance.

COMPLIANCE: Anytime a TCM continuous flow fuel injection system component is removed for replacement or repair. MODELS AFFECTED:

All with TCM Continuous Flow Fuel Injection Systems

Teledyne Continental Motors has continued to receive fuel injection system components from the field which have been contaminated with foreign material during installation or maintenance procedures. It is imperative that fuel injection system components be kept free from contamination during all installation and maintenance procedures. The following guidelines must be followed during fuel injection system maintenance: • • • • • •

All caution must be exercised during reassembly of the fuel system to NOT allow any contaminants to enter the components, lines and fittings during installation. All surfaces surrounding the area where components are to be installed must be clean and free of all forms of contaminant before and during installation. All hose assemblies must be flushed and verified to be free of contamination prior to installation. All fuel system component and lines must be capped and remain capped until flushed and ready for installation. The engine, tools and environment must be clean to minimize any potential for fuel system contamination. All fuel system components, regardless of their source, must be purged at time of installation. WARNING

Fuel system contamination may lead to fuel system component damage, erratic engine operation, loss of power, or engine shutdown.

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FUEL SYSTEM PURGING PROCEDURES 1. Fuel Pump Installation a. Install fuel pump using the latest revision of the applicable engine maintenance or overhaul manual. b. Remove the protective cap from the fuel inlet line. Direct the fuel inlet line into a clean bucket. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the fuel pump inlet hose into a clean, dry container. c. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. d. Remove the fuel pump inlet fitting cap and install the inlet fuel line using the installation instructions contained in the latest revision of the applicable engine maintenance or overhaul manual. e. Remove the cap from the fuel outlet line and install the line using the applicable engine maintenance or overhaul manual. (If line is installed or partially installed, the line will have to be removed to facilitate the flush process.) f. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel through the fuel pump into a clean, dry container. If the fuel pump is equipped with a mixture control, operate the mixture control slowly through its full range of motion several times during the flushing procedure. g. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. h. If the fuel pump and associated lines are verified to be free from contamination, complete the fuel pump installation and setup procedures in accordance with the latest revision of the applicable maintenance manual, overhaul manual, and service bulletin SID97-3. 2. Fuel Control Unit a. Install the fuel control unit using the latest revision of the applicable engine maintenance or overhaul manual. b. Remove the protective cap from the fuel control inlet line. Direct the fuel control inlet line into a clean bucket. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the fuel control inlet hose into a clean, dry container. c. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. d. Remove the cap from the fuel control inlet line and install the line using the applicable engine maintenance or overhaul manual. e. Remove the cap from the fuel control outlet. Install the fuel control outlet line using the applicable engine maintenance or overhaul manual. (If line is installed or partially installed, the line will have to be removed to facilitate the flush process.) ISSUED

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f. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the fuel control inlet hose into a clean, dry container. It the fuel control is equipped with a mixture control, operate the mixture control slowly through its full range of motion several times during the flushing procedure. g. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. h. If the fuel control unit and associated lines are verified to be free from contamination, complete the fuel control unit installation, additional fuel system component installation if required, and setup procedures in accordance with the latest revision of the applicable maintenance manual, overhaul manual, and service bulletin SID97-3. 3. Fuel Manifold Valve a. Install the fuel manifold valve using the latest revision of the applicable engine maintenance or overhaul manual. b. Remove the protective cap from the fuel manifold valve inlet line. Direct the fuel manifold valve inlet line into a clean bucket. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the fuel control inlet hose into a clean, dry container. c. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. d. Remove the cap from the fuel manifold valve inlet and install the line using the applicable engine maintenance or overhaul manual. e. Install the fuel injector lines. Torque the each fitting at the manifold valve to 55-60 InLbs. f. Utilizing the airframe boost pump, flush fuel from the fuel injector lines into appropriate, clean, and dry containers. g. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. h. If the fuel manifold valve and associated lines are verified to be free from contamination, complete the fuel manifold valve installation, additional fuel system component installation if required, and setup procedures in accordance with the latest revision of the applicable maintenance manual, overhaul manual, and service bulletin SID97-3. 4. Bypass Fuel Filter (Where Installed) a. Install the bypass fuel filter assembly using the latest revision of the applicable engine maintenance or overhaul manual b. Remove the protective cap from the bypass fuel filter inlet line. Direct the fuel inlet line into a clean bucket. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the bypass fuel filter inlet hose into a clean, dry container

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c. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. d. Remove the cap from the bypass fuel filter inlet line and install the line using the applicable engine maintenance or overhaul manual. e. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the bypass fuel filter inlet hose into a clean, dry container. f. Inspect the flushed fuel. If free from contamination, proceed to the next step. If contamination is found, locate the source and correct the issue before proceeding further. g. If the bypass fuel filter and associated lines are verified to be free from contamination, complete the bypass fuel filter installation, additional fuel system component installation if required, and setup procedures in accordance with the latest revision of the applicable maintenance manual, overhaul manual, and service bulletin SID97-3.

NOTE: Operational verification of the engine fuel system in accordance with the latest revision of SID97-3 is required any time one of the following circumstances occurs: (1) at engine installation, (2) during 100 hour and annual inspections, (3) whenever a fuel system component is replaced or adjusted, (4) when changes occur in the operating environment.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-6

Compliance Will Enhance Safety

SUBJECT:

®

PRECISION AIRMOTIVE, LLC MANDATORY CARBURETOR SERVICE BULLETIN MSA-13

Technical Portions FAA Approved

PURPOSE: To provide notification to affected owners of the issuance of Precision Airmotive, LLC, Mandatory Carburetor Service Bulletin MSA-13, “Replacement of Carburetor Floats With New Foam Floats”. COMPLIANCE

MODELS AFFECTED:

Initial Inspection required within 30 days of 1/30/2008. For carburetors found to be affected, 30 day recurring inspection is required until float replacement. is performed. Float replacement must occur prior to December 31, 2008.

All models of TCM engines equipped with Marvel-Schebler, Facet, or Precision Airmotive carburetor. Includes Rolls Royce carburetor equipped models.

GENERAL Precision Airmotive, LLC, has issued Mandatory Carburetor Service Bulletin MSA-13 dated January 30, 2008, concerning model MA-3PA, MA-3SPA, and MA-4-5 carburetors as installed on the above listed engines. The affected carburetor models may have been manufactured by Marvel-Schebler, Facet, or Precision Airmotive. Precision Airmotive Mandatory Service Bulletin MSA-13 must be performed on the above listed engines in accordance with the instructions contained in the attached service bulletin. For additional information concerning Precision Airmotive Mandatory Service Bulletin MSA-13 contact Precision Airmotive at (360) 651-8282.

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MANDATORY

Service Bulletin

14800 40th Avenue NE MARYSVILLE, WASHINGTON 98271 FAA-PMA FACILITY #PQ111NM

Fuel Systems

Bulletin No.: MSA-13 Date:

SUBJECT:

1/30/08

REPLACEMENT OF CARBURETOR FLOATS WITH NEW FOAM FLOATS

NOTE: This service bulletin supersedes and replaces Service Bulletin MSA-1 SECTION 1 - PLANNING INFORMATION A. EFFECTIVITY: All aircraft with Precision Airmotive/Facet/Marvel-Schebler Float Carburetors, which contain floats manufactured by Precision Airmotive or Facet. This bulletin does not apply to carburetors containing floats manufactured by other FAA-PMA approved sources. Continued airworthiness instructions for those non Precision Airmotive/Facet floats should be obtained from the manufacturer. B. REASON: Service difficulties inherent with the brass and the advanced polymer floats currently approved for use by the FAA on Precision Airmotive/Facet/Marvel-Schebler carburetors and the introduction and service history of a new foam float have led to the release of this bulletin. In the case of the brass floats, several service issues are known. For example, because of the long life of these carburetors there have been instances where the float hinge point has been allowed to wear to the point where the float pontoons can contact the walls of the float bowl. This can lead to a hole in the float which will allow fuel to enter the float and thereby reduce the buoyancy of the float, which could lead to flooding or poor idle performance (and possible engine stoppage at idle). In addition, over time the brass floats can also develop leaks through the seam, allowing fuel to enter the float and thereby reducing the buoyancy of the float. In the case of the advanced polymer floats, there is also a possibility of leaks through the welded seam. This allows a portion of the float to fill with fuel and thereby reduce the buoyancy of the float, which could lead to flooding or poor idle performance. In the vast majority of incidents, the condition was identified by flooding or poor idle performance on the ground. In some cases, there were no operational difficulties at all. In many of these cases there was sufficient service history to indicate that the carburetor had not been overhauled by a qualified repair station within 10 years as required by Service Bulletin MSA-3, and/or had not been properly repaired after prior reports of flooding. Precision Airmotive has developed and incorporated a new foam float, and there is now sufficient service history and test data to conclude that the new floats will not develop these same service issues. Page 1 of 2

Precision Airmotive Service Bulletin MSA-13 C. COMPLIANCE: The carburetor must be inspected within 30 days and at 30 day intervals until the float is updated. Prior to December 31, 2008, all carburetors not already in compliance must be updated to use the current foam float, part number 30-860, 30-862, or 30-864 depending upon application. If the carburetor shows any signs of flooding, the float should be replaced immediately. SECTION 2 - ACCOMPLISHMENT INSTRUCTIONS A. INSPECTION: Within the next 30 days the carburetor should be inspected to determine if a new foam float has been installed. The new floats have been in production since November of 2005. If your carburetor has been replaced or repaired since that date, use one of the following methods to verify that the carburetor contains a new foam float. 1. If the carburetor was manufactured, overhauled, or rebuilt by Precision Airmotive the nameplate will have a box titled “IC” with a number. If the “IC” number is 15 or higher, the carburetor contains a new foam float. 2. If the carburetor was overhauled or repaired by a third party, the paperwork should be reviewed to determine if a new foam float, part number 30-860, 30-862, or 30-864 was installed. The carburetor should also be inspected for signs of flooding (see SIL MS-12). Carburetors that show signs of flooding should be removed and sent to a qualified repair station for repair and replacement of the float. This inspection should be repeated every 30 days until the float has been replaced by a new foam float. NOTE: As required by Service Bulletin MSA-3, all carburetors must be overhauled every 10 years or at engine TBO whichever comes first. If the carburetor in question does not meet these requirements, it should be removed and sent for overhaul immediately. The float should be replaced as a part of the overhaul. B. ACTION: If the carburetor does not contain a new foam float it should be removed and sent to a qualified repair station prior to December 31, 2008 to be updated with a new foam float, in accordance with the current release of overhaul manual #MSAFSM. Alternatively, the carburetor may be replaced with a new, overhauled, or rebuilt carburetor that contains the new foam float. C. IDENTIFICATION: Carburetors that have been manufactured, overhauled, or rebuilt by Precision Airmotive, are identified with an IC number of 15 or higher when they contain the new foam float. For all other carburetors, the letters “FF” should be stamped on the nameplate once it has been verified that the carburetor contains float part number 30-860, 30-862, or 30-864. Repair stations that install these floats should stamp the letters “FF” on the nameplate when the update is done.

Page 2 of 2

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-7

Compliance Will Enhance Safety

SUBJECT:

®

PRECISION AIRMOTIVE, LLC MANDATORY CARBURETOR SERVICE BULLETIN MSA-14

Technical Portions FAA Approved

PURPOSE: To provide notification to affected owners of the issuance Precision Airmotive, LLC, Mandatory Carburetor Service Bulletin MSA-14 “Carburetor Throttle Body to Bowl Screw Inspection”. COMPLIANCE

MODELS AFFECTED:

Within the next 50 hours of engine operation and at each 100 hours of engine operation thereafter, or anytime fuel stains are evident.

All models of TCM engines equipped with Marvel-Schebler, Facet or Precision Airmotive carburetor. Includes Rolls Royce carburetor equipped models.

GENERAL Precision Airmotive, LLC, has issued Mandatory Carburetor Service Bulletin MSA-14 dated February 07, 2008, concerning model MA-3PA, MA-3SPA, and MA-4-5 carburetors as installed on the above listed engines. The affected carburetor models may have been manufactured by Marvel-Schebler, Facet, or Precision Airmotive. Precision Airmotive Mandatory Service Bulletin MSA-14 must be performed on the above listed engines in accordance with the instructions contained in the attached service bulletin. For additional information concerning Precision Airmotive Mandatory Service Bulletin MSA-14 contact Precision Airmotive at (360) 651-8282.

ISSUED

REVISED

PAGE NO REVISION TM

MO 05

DAY 28

YEAR 2008

MO

DAY

YEAR

T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

1 of 1 SB08-7

Original

MANDATORY

Service Bulletin

14800 40th Avenue NE MARYSVILLE, WASHINGTON 98271 FAA-PMA FACILITY #PQ111NM

Fuel Systems

Bulletin No.: MSA-14 Date:

SUBJECT:

2/7/08

CARBURETOR THROTTLE BODY TO BOWL SCREW INSPECTION (Reference Lycoming SB 366)

MODELS AFFECTED: All engines equipped with Marvel-Schebler, Facet, or Precision Airmotive updraft carburetor models MA-3A, MA-3PA, MA-3SPA, MA-4SPA, MA-4-5, MA-45AA, MA-5, MA-6, and MA-6AA. TIME OF COMPLIANCE:

Within the next 50 hours of engine operation and at each 100 hours of engine operation thereafter, or anytime fuel stains are evident.

Instances have been reported of leakage past the gasket between the bowl assembly and throttle body of the carburetor, evidenced by fuel stains in the area of the leak. Leakage of this type may be accompanied by loose screws that attach the bowl and throttle body. See Figure 1 for illustrative example of the throttle body attaching screws. INSTRUCTIONS FOR COMPLIANCE: 1. Check the carburetor for evidence of fuel stains on the outside of the bowl along the parting line. 2. Check for movement between the throttle body and bowl. 3. Check each throttle body to bowl attaching screw for looseness by attempting to move the screw and/or locktab washers with your fingers. CAUTION Do not attempt to turn the screw with a screwdriver. Turning the screw with a screwdriver may compromise the lock washers and increase the likelihood that the screws will become loose. 4. If there is evidence of fuel stains, movement between the throttle body and bowl, or the throttle body to bowl attaching screws are loose then remove the carburetor in accordance with the applicable engine and airframe service manuals. Send the carburetor to a qualified repair station for troubleshooting and repair. 5. Reinstall the carburetor in accordance with the applicable engine and airframe service manuals. Inspect the engine installation for damaged or worn motor mounts, and/or evidence of out of balance conditions. Page 1 of 2

Precision Airmotive Service Bulletin MSA-14

6. Make an appropriate logbook entry showing compliance with this Service Bulletin. If after compliance with this Service Bulletin there is continued fuel leakage, or if there are other conditions not specifically described in this Service Bulletin then contact the engine and/or aircraft manufacturer’s product support department.

Figure 1. Example of Throttle Body to Attaching Screws

Page 2 of 2

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB08-8B

Compliance Will Enhance Safety

SUBJECT:

Technical Portions FAA Approved

Slick Service Bulletin SB2-08A

PURPOSE: Notification, support of inspections required by Slick Bulletin SB02-8 Rev A , Corrected Copy COMPLIANCE: As detailed in the bulletin revision also includes a final compliance to end repetitive inspection MODELS AFFECTED: All engines equipped with Slick 4300/6300 magnetos and Lasar 4700/6700 magnetos.

GENERAL Unison Industries has issued Rev A , Corrected Copy to SLICK Service Bulletin SB028 dated 07-01-2008. The revision concerns inspections of specific magneto models as listed above with a mandatory inspection compliance that ends need for repetitive inspection. The affected magnetos may have been installed on various TCM model engines. Inspection is required within 50 hours of the bulletin issuance, then every 100 hours of operation or annual inspection following. Assure that the inspections are carried out as recommended. QUESTIONS ? Contact Unison Piston Products Technical Support Hotline at 904-739-4081 Unison Technical Publications Web-site: www.unisonpubs.com WARRANTY If your engine is within the original full coverage warranty period as stated in your written warranty, contact TCM Technical Services at 1-888-826-5465, option 2 Beyond the full coverage period as stated above, contact the Unison Hotline for assistance.

ISSUED

REVISED

PAGE NO REVISION TM

MO 06

DAY 16

YEAR 2008

MO 04

DAY 10

YEAR 2009

T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama  251-438-3411

© 2009 TELEDYNE CONTINENTAL MOTORS, INC.

1 of 1 SB08-8

B

SB2-08A SLICK Service Bulletin

(Corrected Copy)

UNISON PROPRIETARY INFORMATION The information contained in this document is Unison proprietary information and is disclosed in confidence. It is the property of Unison and shall not be used, disclosed to others or reproduced without the express written consent of Unison. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by U.S. export control laws. Unauthorized export or re-export is prohibited. TO: Aircraft manufacturers, distributors, dealers, engine overhaul facilities, owners and operators of Slick Aircraft Products aircraft magnetos. SUBJECT: Mandatory inspections on all Slick 4300/6300 and LASAR™ 4700/6700 magnetos MAGNETO MODELS AFFECTED: • Slick and LASAR™ magnetos with serial numbers beginning with 0610XXXX through 0804XXXX. • Magnetos which have had the cam, or the cam as part of the contact point assembly kit, replaced between October 1, 2006 and May 11, 2008. ENGINE MODELS AFFECTED: Engines utilizing Slick and LASAR™ magnetos. AIRFRAME MODELS AFFECTED: Aircraft utilizing Slick and LASAR™ magnetos. BACKGROUND INFORMATION: Field reports indicate premature wear of breaker point cam in the serial number range listed in MAGNETO MODELS AFFECTED. Premature cam wear can cause excessive timing drift, causing low magneto output power. COMPLIANCE: All magnetos that have had a cam, or the cam as part of the contact point assembly kit, replaced between October 1, 2006 and May 11, 2008, and all magneto models in the specified serial number range noted in MAGNETO MODELS AFFECTED. Inspect affected magnetos within the next 50 hours of the effective date of this Service Bulletin. Then, inspect every 100 hours thereafter or annual inspection, whichever comes first. See Detailed Instructions for Service Bulletin ending compliance information. PROOF OF COMPLIANCE: Appropriate logbook entries. PARTS REQUIRED PER BULLETIN: Replace magneto or M3611 cam as required. TOOLS REQUIRED PER BULLETIN: Slick T-100 Tool Kit, magneto timing light, T-300 SynchroLASAR™ and standard shop tools as applicable. UNISON PROPRIETARY INFORMATION – Subject to the restrictions on the cover or first page ISSUED MO DAY YR

REVISED MO DAY YR

05

07

02

08

01

08

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 2008 Unison Industries, LLC

PAGE NO.

REVISION

1 of 2

A

SLICK Service Bulletin

SB2-08A (Corrected Copy)

WEIGHT CHANGE: None. REQUIRED SERVICE LITERATURE: Refer to the following literature as applicable when performing the detailed instructions contained in this bulletin: Slick 4300/6300 Magneto Maintenance and Overhaul Manual L-1363 LASAR™ 4700/6700 Magneto Maintenance and Overhaul Manual L1503 Slick Service Bulletin SB3-08, Mandatory inspections on all Slick 4300/6300 and LASAR™ 4700/6700 magnetos WARRANTY INFORMATION: If damage or premature wear listed in this Service Bulletin is discovered during inspection, and the magneto is within Unison's 1-year warranty period, the magneto may be returned through your point of sale for warranty replacement. For magnetos outside the 1-year warranty period in which the replacement cam, or the cam as part of the contact point assembly kit has failed, the cam may be returned under warranty through your point of sale. DETAILED INSTRUCTIONS: 1. Check engine timing per engine operator's manual. If engine to magneto timing is retarded more than 4° from base timing (nominal engine manufacturer's timing), cam must be replaced per the applicable Maintenance and Overhaul Manual. 2. Service Bulletin ending compliance can be documented after the cam has been replaced by one manufactured May 12, 2008 or later (controlled by manufacturerdated packaging) and an appropriate logbook entry has been made. 3. For magnetos that have not had the cam replaced, Service Bulletin ending compliance can also be documented if, after 200 hours of magneto operation, there has been no significant engine to magneto timing drift as identified in step 1 above. Record an appropriate logbook entry.

Unison Piston Products Technical Support Hotline: 904-739-4081 Unison Technical Publications Web-site: www.unisonpubs.com

UNISON PROPRIETARY INFORMATION – Subject to the restrictions on the cover or first page ISSUED MO DAY YR

REVISED MO DAY YR

05

07

02

08

01

08

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, LLC

PAGE NO.

REVISION

2 of 2

A

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB09-2

Contains Important Information Pertaining to Your Aircraft Engine.

Technical Portions FAA Approved

Compliance Will Enhance Safety

SUBJECT: Volare Carburetors, LLC SB1 Service Bulletin, COMPLIANCE: At any time that parts are required for repair or overhaul of any Volare Carburetor used on a TCM engine as listed. MODELS AFFECTED: A65, A75, C75, C85, C90, C125-2, 2H, C145-2 TCM O200-A,B,C,D and Rolls Royce O200-A, B , O240 TCM O300-A,B,C,D , GO300-A,C,D,E, O470-A,J,K,L,R,S,U.

General: Volare Carburetors, LLC has issued Service Bulletin SB-1 dated February 1, 2009. This bulletin contains specific concerns and instructions concerning the use of UNAUTHORIZED parts in Volare’s Float Carburetors. No specific inspections are required for this informational bulletin. TCM recommends support and compliance with this manufacturer’s bulletin. Any questions concerning this Bulletin or other specific Volare’ Carburetor questions should be directed to: Volare’ Carburetors, LLC Customer Service by phone: 336-446-0002 Customer service by email: [email protected]

ISSUED

REVISED

PAGE NO REVISION TM

MO 03

DAY 17

YEAR 2009

MO

DAY

YEAR

T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama  251-438-3411

© 2009 TELEDYNE CONTINENTAL MOTORS, INC.

1 of 1 SB

Original

 

Volare Carburetors LLC

Bulletin No. SB-1 Date: February 1, 2009

Flight Safety Service Bulletin

Subject: Use of UNAUTHORIZED Parts in Volare’s Float Carburetors

1. Applicability: This Flight Safety Service Bulletin (SB) applies to all aviation carburetors manufactured by Volare Carburetors LLC (“Volare”), and its predecessors Precision Airmotive Corporation, Facet Aerospace Products Company, and Marvel-Schebler (Borg Warner) (all collectively referred to hereafter as “Volare Float Carburetors”). 2. Reason: Volare is issuing this SB to remind owners, operators, over-haulers, and repairers, of Volare Float Carburetors of the possible adverse consequences resulting from the use of UNAUTHORIZED parts in Volare Float Carburetors. 3. Background: Some owners of Volare Float Carburetors have yet to replace superseded carburetor parts or have allowed installation of replacement carburetor parts made by various manufacturers not associated with or licensed by Volare to manufacture or distribute such replacement parts. Volare currently manufactures some carburetor parts that supersede parts made by Volare’s predecessors because such superseded parts are obsolete, have been removed from service due to service difficulties, service bulletins, service letters or instructions, airworthiness directives or for other reasons. NonVolare parts have not been designed or tested under the same performance criteria upon which FAA granted approval to Volare Float Carburetors. Volare and its predecessors have hundreds of thousands of hours of service experience with Volare Float Carburetors that the manufacturers of such replacement parts do not. 4. Description: Genuine Volare Float Carburetors contain only non-superseded parts manufactured by or on behalf of Volare and its predecessors in accordance with the strict tolerances, manufacturing processes and rigorous inspection requirements contained in Volare’s detailed FAA-approved specifications, drawings, and inspection requirements. Because no superseded parts or parts manufactured by others meet these exacting standards, all such replacement parts are UNAUTHORIZED. 5. Voiding of Warranty and Waiver of Liability: The use of UNAUTHORIZED replacement parts in Volare Float Carburetors constitutes a modification and/or alteration of such aviation carburetors voiding all warranties express or implied, to the extent permitted by law. Distributed by                                                                                               1 of 1 

 

 

a. Volare expressly disclaims any and all responsibility and liability for any aviation carburetor containing UNAUTHORIZED parts to the extent permitted by law. b. The installation of UNAUTHORIZED parts in Volare Float Carburetors constitutes a complete and total waiver to the extent permitted by law of any and all rights the operator may have had to hold Volare responsible or liable for the malfunction or failure of such a modified and/or altered aviation carburetor. c. To the extent permitted by law, the owner, operator and/or overhaul facility or repairer responsible for installation of UNAUTHORIZED parts in Volare Float Carburetors shall bear the sole responsibility and full liability for any damages of whatever nature, injury, or death arising from any malfunction or failure of such a modified and/or altered aviation carburetor.

Distributed by                                                                                                                                                  2 of 2 

 

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB09-3

Contains Important Information Pertaining to Your Aircraft Engine.

Technical Portions FAA Approved

Compliance Will Enhance Safety

SUBJECT: Volare Carburetors, LLC SB2 Service Bulletin, Required Replacement of Foam and Hollow Floats COMPLIANCE: Volare’s recommendation is for all Foam and Hollow Floats in service be replaced by a new Blue Epoxy float. See Service bulletin attached MODELS AFFECTED: A65, A75, C75, C85, C90, C125-2, 2H, C145-2 TCM O200-A,B,C,D and Rolls Royce O200-A, B , O240 TCM O300-A,B,C,D , GO300-A,C,D,E, O470-A,J,K,L,R,S,U.

General: Volare Carburetors, LLC has issued Service Bulletin SB-2 dated February 1, 2009. This bulletin contains specific recommendations to replace all Foam and Hollow floats in service by June 1, 2009. TCM recommends support and compliance with this manufacturer’s bulletin. Any questions concerning this Bulletin or other specific Volare’ Carburetor questions should be directed to: Volare’ Carburetors, LLC Customer Service by phone: 336-446-0002 Customer service by email: [email protected]

ISSUED

REVISED

PAGE NO REVISION TM

MO 03

DAY 17

YEAR 2009

MO

DAY

YEAR

T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama  251-438-3411

© 2009 TELEDYNE CONTINENTAL MOTORS, INC.

1 of 1 SB09-3

Original

 

Volare Carburetors LLC

Bulletin No. SB-2 Date: February 1, 2009

Flight Safety Service Bulletin

Subject: Required Replacement of Foam and Hollow Floats 1. Applicability: This Flight Safety Service Bulletin (SB) applies to all aviation carburetors manufactured by Volare Carburetors, LLC (“Volare”), and its predecessors Precision Airmotive Corporation, Facet Aerospace Products Company, and Marvel-Schebler (Borg Warner) (all collectively referred to hereafter as “Volare Float Carburetors”) not equipped with a solid, blue epoxy float having one of the following part numbers: 30-860, 30-862, and 30-864, dependent on carburetor model. 2. Reason: Service difficulties affecting foam floats and hollow floats, whether made of brass or plastic, necessitate their replacement with solid, blue epoxy floats. Volare is issuing this Flight Safety Service Bulletin to warn owners, operators, over-haulers, and repairers of Volare Float Carburetors (all collectively referred to hereafter as “owner”) of the possible adverse consequences from failing to replace foam and hollow floats with a solid, blue epoxy float. Foam floats may deteriorate in certain fuels and fuel additives. Brass 3. Background: floats, regardless of manufacturer, may crack, leak, corrode, and/or mechanically fail. White plastic hollow floats may leak. Deteriorated, leaking, or broken floats can negatively affect engine performance, regardless of the identity of the manufacturers of such floats. Volare and its immediate predecessor Precision Airmotive have worked arduously to address these issues by developing the first solid, blue epoxy composite float. This float is impervious to the fuels and fuel additives used in the aviation industry today. The solid, blue epoxy float is not a “foam” float. It is not a thermoplastic. It has no soldered or riveted joints. Being solid, it cannot fill with fluid and sink, even if pierced. The float is essentially chemically inert. The stainless steel bracket is cast securely into the float body and is not subject to separation in normal use. This float design has been in production for several years. It is installed in thousands of carburetors, including carburetors sold by Volare and its predecessor to current engine manufactures since its introduction. There are no known cases of failure or malfunction of this design. 4. Indications of a leaking float: Hard starting, the need for excessive leaning, flooding, fuel leaking from the carburetor, excessive fuel consumption and/or or poor idle performance or difficulty in stopping the engine with the mixture cut-off control may indicate a deteriorating or damaged float and/or flooding carburetor. However, the absence of these symptoms is not reason to ignore this Flight Safety Service Bulletin. Distributed by                                                                                                                                                      1 of 1 

 

 

5. Compliance: In order to maintain flight safety, within 30 days of the date of issuance of this Flight Safety Service Bulletin, each owner of a Volare Float Carburetor not equipped with a solid, blue epoxy float is requested and strongly encouraged to inspect the carburetor and to re-inspect the carburetor at 30-day intervals thereafter until the float is replaced by a solid, blue epoxy float. Failure to follow this advice may result in engine malfunction, damage, injury or death. Inspect the carburetor for any signs of flooding and other indicators of a 6. Instructions: possible deteriorating or damaged float including those mentioned in this bulletin. (See Marvel-Schebler bulletin SIL MS-12.) Remove from service prior to further flight any carburetors exhibiting signs of flooding or possible float deterioration or damage. In addition, take the following steps: a. Determine if a solid, blue epoxy float is installed in the carburetor: i. Every Volare manufactured or serviced carburetor is equipped with a solid, blue epoxy float unless the float was replaced with an unauthorized float subsequent to Volare’s release of the carburetor. (See Volare SB-1 warning against the use of unauthorized parts in Volare Float Carburetors.) ii. If Precision Airmotive manufactured, overhauled, or rebuilt the carburetor after November 2005, and the IC number on the carburetor’s data tag is 15 or higher, the carburetor is equipped with a solid, blue epoxy float, unless the float was replaced with an unauthorized float subsequent to Precision’s release of the carburetor. iii. If at any time Precision Airmotive performed more limited carburetor service (such as repair or testing without overhauling or rebuilding) and it cannot be conclusively determined from maintenance or other records that a solid, blue epoxy float is installed, there is no assurance that the carburetor contains a solid, blue epoxy float. iv. It is each owner’s and operator’s responsibility to make a positive determination regarding what type float is installed in his carburetor and take appropriate action based on that determination. While we believe the information in paragraphs ii and iii is correct and regardless of any error(s) that may be contained in those paragraph, it is the owner/operators responsibility to make a positive determination and confirm that a solid, blue epoxy float is installed. If a positive determination cannot be made or there is doubt as to whether the carburetor contains a solid, blue epoxy float, the carburetor must be partially disassembled to the extent necessary to make a positive determination. Refer to the appropriate carburetor Service Manual for disassembly and reassembly instructions and the aircraft maintenance manual for removal and installation instructions. b. Volare urges each owner to install a solid, blue epoxy float in any Volare Float Carburetor not so equipped prior to June 1, 2009. All carburetors must be overhauled or rebuilt every 10 calendar years after purchase or last overhaul or rebuild, or at engine overhaul, whichever comes first (See SB MSA-3). If the carburetor does not meet these requirements it should be sent to Volare for overhaul or rebuilding, including installation of a solid, blue epoxy float (if not already installed) at no extra charge. c. NEVER install a solid, blue epoxy float in any carburetor containing parts not manufactured by Volare, Precision Airmotive, Borg-Warner, or Marvel Schebler as the float and or carburetor may not function properly. (See Volare Service Bulletin SB-1.) Distributed by                                                                                                                                                    2 of 2 

 

 

7. Identification/Marking: Upon determining that that a carburetor has a solid, blue epoxy float, an owner must stamp the letters “FF” on the carburetor data tag. An IC number of 15 or higher or the letters “FF” stamped on the data plate by Volare indicates the installation of a solid, blue epoxy float in carburetors serviced by Volare Carburetors, providing that an unauthorized float has not been subsequently installed. 8. Service and Parts Availability: Carburetors may be sent to Volare for float replacement and/or other servicing to include installation of a solid, blue epoxy float (if not already installed) at no extra charge, regardless of the identity of the manufacturer of the float in the carburetor when it arrives at Volare. Replacement float kits and other genuine Volare replacement parts are available from Volare. 9. Voiding of Warranty and Waiver of Liability: The owner of any Volare Float Carburetor not equipped with a solid, blue epoxy float after June 1, 2009 is hereby notified that such carburetors contain UNAUTHORIZED parts. An owner’s failure to install a solid, blue epoxy float prior to June 1, 2009, failure to inspect the carburetor in accordance with this bulletin, or operation of a carburetor containing any float other than a solid, blue epoxy float after June 1, 2009, voids any otherwise applicable warranty and constitutes a complete and total waiver to the extent permitted by law of any and all rights the owner, operator and/or service facility or repairer may have had to hold Volare responsible or liable for the malfunction or failure of such an aviation carburetor. The owner, operator and/or service facility or repairer responsible for installation of UNAUTHORIZED parts in Volare’s aviation carburetors shall bear the sole responsibility and full liability for any damages of whatever nature, injury, or death arising from any malfunction or failure of such a modified and/or altered aviation carburetor. An owner’s purchase of a solid, blue epoxy float constitutes an agreement to not install that float in any carburetor containing UNAUTHORIZED parts (as set forth in SB-1). Owners of carburetors containing UNAUTHORIZED parts assume all responsibility for the operation of such carburetors recognizing that such operation may result in engine malfunction, damage, injury or death. As Volare stated in SB-1: a. Volare expressly disclaims any and all responsibility and liability for any aviation carburetor containing UNAUTHORIZED parts to the extent permitted by law. b. The installation of UNAUTHORIZED parts in Volare Float Carburetors constitutes a complete and total waiver to the extent permitted by law of any and all rights the operator may have had to hold Volare responsible or liable for the malfunction or failure of such a modified and/or altered aviation carburetor. c. To the extent permitted by law, the owner, operator and/or overhaul facility or repairer responsible for installation of UNAUTHORIZED parts in Volare Float Carburetors shall bear the sole responsibility and full liability for any damages of whatever nature, injury, or death arising from any malfunction or failure of such a modified and/or altered aviation carburetor. Volare is a customer-service oriented company committed to technical 10. Safety First: innovation in pursuit of aviation safety. While Volare has no authority to compel owners to act responsibly and take prudent action to insure their own safety and the safety of others, Distributed by                                                                                                                                                    3 of 3 

 

 

Volare believes compliance with this Flight Safety Service Bulletin is essential to protect against failures with unacceptable consequences. Volare strongly warns owners of the inherent risks involved in using any float other than a solid, blue epoxy float in any Volare Float Carburetor and strongly encourages owners to comply with this Flight Safety Service Bulletin. Pictorial Examples of Carb floats REQUIRING REPLACEMENT

MA White Float (REPLACE)

HA White Float (REPLACE)

Brass Float (REPLACE)

MA Brown/Beige Foam (REPLACE)

MA Brown/Beige Foam (REPLACE)

MA Black Foam (REPLACE)

Pictorial Examples of GOOD (Blue Epoxy) Carb FLOATS

GOOD Small MA Float (BLUE)

GOOD HA Float (BLUE)

GOOD Large MA Float (BLUE)

Distributed by                                                                                                                                                    4 of 4 

 

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB09-4A

Contains Important Information Pertaining to Your Aircraft Engine.

Technical Portions FAA Approved

Compliance Will Enhance Safety

SUBJECT: Crankcase inspection for “Permold” engines equipped with Air Conditioner systems installed from 1998 to present. PURPOSE: To issue instructions for a required crankcase inspection at the forward Air Conditioner bracket attachment boss To require replacement of the Air Conditioner bracket on all affected models listed below COMPLIANCE: At next maintenance event, no later than the next 100 hr or Annual inspection MODELS AFFECTED: IO520-BA, BB IO550-B, G, P, R TSIO520-BE, L, LB, UB, WB TSIO550-A, B, C, E, G All affected engines equipped with TCM upper rear mounted, factory Air conditioning bracket and “Thinner Rib” crankcase (see page 5)

BACKGROUND TCM has confirmed reports of cracks in a rib of some Permold crankcases that are equipped with TCM supplied air conditioning compressor brackets. The rib extends from the 11:00 o’clock position of the number 1 cylinder to the forward air conditioner compressor bracket attachment boss. (See Figures 5 and 6) There are two crankcase rib configurations, a “thinner rib” and a “thicker rib”. These two rib configurations are shown in Figures 5 and 6. The cracks occur in the “thinner rib” crankcases near the forward air conditioner compressor bracket attach bolt point. Figure 3 exhibits a crack indication in a “thinner rib” crankcase. This service bulletin requires inspection of the “thinner rib” configuration for cracks and replacement of the air conditioning compressor bracket on all “thinner rib” crankcases. The TCM supplied brackets are part of an EQ (equipment) kit that includes all parts to enable installation of an air conditioning compressor system by aircraft OEMs and other installers. See Figure 1 for a typical installation on an IO550B model engine. The cracks in the thinner rib are in the “Non-critical” area of the crankcase as identified in Figure 4 of this bulletin and prior in Service Bulletin M90-17. Figure 4 shows an illustration of the areas designated as critical and non-critical.

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© 2009 TELEDYNE CONTINENTAL MOTORS, INC.

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Mounting Bracket

FIGURE 1 Compressor installation

Right Magneto

Forward

FIGURE 2 General Area

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FIGURE 3 Compressor bracket attachment bolt boss crack indication

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FIGURE 4 Crankcase 1-3-5 half Critical area depicted in white Non-critical area depicted in shaded area Forward A/C bracket attach point

FIGURE 5 Thinner Rib (Approximate thickness 3/8”)

FIGURE 6 Thicker Rib (Approximate thickness 3/4” )

CRANKCASE INSPECTION “Thicker rib” crankcases as pictured in Figure 6 require NO INSPECTION No inspection is required on the thicker rib crankcases. Make a log book entry that this Service Bulletin is Not Applicable by crankcase rib thickness. No further action is required on these “thicker rib” crankcase engines. All “thinner rib” crankcases, as pictured in Figure 5 MUST BE INSPECTED. Recurring inspection is required each 50 hours of operation until the air conditioner bracket is replaced with the superseding bracket as listed on Page 6. Replacement with the superseding air conditioner bracket will remove the inspection requirements of this Service Bulletin.

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Visual Inspection Criteria       

Inspection may normally be completed without removal of the air conditioning bracket or right magneto Clean the pictured area (Figure5) to remove any debris utilizing Stoddard solvent or mineral spirits Utilizing an adequate light source and 10X magnification device, visually inspect the outside of the forward A/C bracket attach point boss as shown in Figure 5 Inspect the rib at the front air conditioner bracket attach point of bracket up to the Right Magneto flange attachment opening and magneto lower attachment clamp ( See Figures 2,3) If any crack indication is found or if question of crack exists, proceed to the following Dye-penetrant inspection to assist in measurement of crack. If no crack is found, make a log book entry to include the inspection date, engine total time, results of inspection and the next 50 hour recurring inspection time When the air conditioner bracket is replaced by the superseding bracket, make a logbook entry to include the replacement date, engine total time, results of inspection and compliance with Service Bulletin SB09-4

2. Dye-penetrant inspection NOTE: Dye-penetrant inspection must be performed by a properly qualified mechanic in accordance with the dye-penetrant manufacturer’s instructions. Use “Magnaflux® Portable Spotcheck Kit” or equivalent. These kits can be purchased through many aviation industry distributors. 

Inspection may normally be completed without removal of air conditioner bracket or right magneto as shown in Figure 7



Using Dye-penetrant “Cleaner/Remover”, thoroughly clean the area between the A/C bracket base and Magneto as shown in Figure 5



Spray the “Penetrant/Dye” onto the clean/dry area as illustrated in Figure 7. Allow the “Penetrant/Dye” enough time to set in accordance with the manufacturer’s instructions.



Remove the excess “Penetrant Dye” and clean the area where the “Penetrant/Dye” was applied in accordance with the manufacturer’s instructions.



Spray the “Developer” onto the clean/dry area as illustrated in Figure 7. Allow the “Developer” enough time to dwell for the determination of the existence of a crack, in accordance with the manufacturer’s instructions.



If a crack is present, its appearance and location will be similar to that shown in Figure 3 and Figure 7. See following criteria for cracks to determine what

specific further action is required 

Please report any crack located to TCM Customer support (see page 6)

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Crack inspection criteria Critical (white) and Non-critical (shaded) areas are illustrated in Figure 4. If a crack is observed in the non-critical (shaded) areas less than two (2) inches in length, it should be re-inspected for crack progression and signs of oil leakage at the next 50 hours of operation. If no crack progression is observed and no additional cracks are evident, continue to re-inspect at regular intervals not to exceed 100 hours duration or at Annual inspection. If a crack is observed in any of the non-critical (shaded) areas more than two (2) inches in length or if a previously observed crack has progressed to two (2) or more inches in length, remove the engine and repair or replace the crankcase or prior to further flight. If any crack is observed in a critical (white) area, remove the engine and repair or replace the crankcase or prior to further flight. SUMMARY - Reasons for Crankcase Repair or Replacement A. B. C.

Any crack in the critical (White) area. Any crack two (2) inches or more in length in the non-critical (shaded) area. Any size crack that is leaking oil (not seeping).

Make an appropriate log book entry indicating compliance with this bulletin. Include engine total time in service, method of compliance (visual, dye-penetrant, other) appearance of crack, time for recurring inspection and date completed.

FIGURE 7 Example of Dye-penetrant inspection area ISSUED

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Air Conditioner Bracket Replacement TCM has superseded the Air Conditioner bracket for all affected engine models. All brackets installed on “Thinner Rib” crankcases must be replaced with the superseding number. The superseding bracket, required hardware and installation instructions are included in a new EQ installation kit for ease of procurement The new air conditioning bracket replacement kit is Part Number EQ7530 and includes the following material: 1 ea 657627 Bracket, Freon Compressor 1 ea 657629 Spacer, 1.00 O.D.X .375 Long 2 ea MS90728-65 Screw-Hex .38 X 1.75 Long 2 ea 24239 Washer-.375 Plain 5 ea 643956-20 Shim Idler Sheave to Spacer (rear) 5 ea 646064-20 Shim Driver Sheave to Spacer 1 ea 657653 Instruction Drawing- Freon Comp Bracket EQ7530 kits may be ordered through any TCM distributor WARRANTY All engines that are within published Teledyne Continental Motors Warranty coverage by type of engine, should contact TCM Customer Support at 1-888-826-5465 for any questions or concerns on this issue. Warranty coverage examples: HBC three years or 1000 operating hours from date of initial delivery; TCM Factory New one year parts and labor warranty, two additional years parts only or 1000 operating hours; TCM Factory Rebuilt, one year parts and labor or 500 operating hours; Platinum Engines two years parts and labor warranty, three additional years parts only to published TBO. The following labor will be allowed for all engines within warranty coverage, as above; Inspection of crankcase: 1.0 hours Additional time allowed if magneto must be removed to confirm crankcase condition: 1.5 hours Replacement of Air Conditioner Bracket: 4.0 hours Warranty coverage for compliance with this bulletin will be accepted only through June 1st, 2010 for all claims filed in accordance with the warranty criteria above.

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No claims of warranty compensation for work accomplished on engines beyond the coverage criteria outlined above will be considered.

TCM Customer Support may be reached via email at [email protected] Or tcm.technical @teledyne.com Please have engine serial number, date of installation or date placed in service, aircraft serial and registration number ready at the time of call to customer service.

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB09-5

Contains Important Information Pertaining to Your Aircraft Engine.

Technical Portions FAA Approved

Compliance Will Enhance Safety

SUBJECT: Volare Carburetors, LLC SB4 Service Bulletin, Carburetor Bowl to Float Clearance COMPLIANCE: 1.Volare recommendation for visual inspection of all MA carburetors prior to each flight and when indications of a sticking float are present. 2. Within 100 hours or 90 days after the bulletin date March 13, 2009 perform float inspection and take action as required by paragraph 4 of Volare’SB-4 MODELS AFFECTED: A65, A75, C75, C85, C90, C125-2, 2H, C145-2 TCM O200-A,B,C,D and Rolls Royce O200-A, B , O240 TCM O300-A,B,C,D , GO300-A,C,D,E, O470-A,J,K,L,R,S,U.

General: Volare Carburetors, LLC has issued Service Bulletin SB-4 dated March 13, 2009. This bulletin contains specific recommendations to inspect and replace all affected Brass floats in service all Marvel Schebler, Facet, Precision and Volare carburetors (includes all MS style carburetors) TCM recommends support and compliance with this manufacturer’s bulletin. Any questions concerning this Bulletin or other specific Volare’ Carburetor questions should be directed to: Volare’ Carburetors, LLC Customer Service by phone: 336-446-0002 Customer service by email: [email protected]

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T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama  251-438-3411

© 2009 TELEDYNE CONTINENTAL MOTORS, INC.

1 of 1 SB09-5

Original

Volare Carburetors, LLC

Bulletin No. SB-4

125 Piedmont Avenue Gibsonville, N.C. 27249, USA

Revision: Original

Date: March 13, 2009

Subject: BOWL CLEARANCE – MA- SERIES CARBURETORS Applicability: This Service Bulletin (SB-4) applies to MA-2, MA-3, MA-4, MA-4-5, MA-4-5AA, MA-5, MA-5AA, MA-6 and MA-6AA model float carburetors manufactured by Volare Carburetors LLC (“Volare”), and its predecessors Precision Airmotive Corporation, Facet Aerospace Products Company, and Marvel-Schebler (Borg Warner) (hereinafter “Volare”) that are equipped with a brass float assembly. 1. Reasons: Warning: Failure to follow this advice may result in engine malfunction, damage, injury or death. Reports of sticking, leaking and/or worn floats have been received, see Figure 1. The specified float/bowl clearance MUST exist to ensure proper operation. 2. Operational indications of insufficient float clearance: Fuel leaks from the carburetor, hard starting, rich idle mixture, black smoke in the exhaust, excessive magneto drop, engine running roughly, difficulty stopping the engine with the mixture control, or partial or complete loss of engine power. 3. Compliance: a.

PRIOR TO EACH FLIGHT AND AT ANY OTHER TIME DURING ENGINE OPERATION, if any of the indications in paragraph 2 are observed, then the inspections and corrective actions described in paragraph 4 must be performed before further engine operation or before the next flight, unless the root cause of the operational indication is verified to be something other than the carburetor.

b.

WITHIN 100 HOURS OF OPERATION OR 90 DAYS after the date of this Service Bulletin, which ever comes first, perform the inspections and corrective actions (if required) contained in paragraph 4 of this Service Bulletin.

4. Instructions: This inspection must be conducted each time the bowl is removed. Remove the bowl in accordance with Instruction E-1000 or E-1002 contained in Volare Float Replacement Kit 666-1000 or Kit 666-1002, as appropriate by carburetor model. Distributed by

SB-4_O 03/13/09 Pg 1 of 4

With the clearance tool M-510 or M-513 (dependent on model) in place, orient the carburetor body with one pontoon uppermost, see Figure 2. Check the clearance between the float pontoon and the bowl wall. A .081 inch gage pin (models MA-2, MA-3 & MA-4), or a .051 gage pin (models MA-4-5, MA-4-5AA, MA-5, MA-5AA, MA-6 and MA-6AA) must pass between the lower surface of the upper pontoon and the throttle bore wall and between the lower surface of the lower pontoon and the lower bowl wall without touching either pontoon. Reorient the carburetor so that the other pontoon is uppermost, see Figure 3. Repeat the clearance check. If, as the gage pin is moved along between the float and the bowl wall the gage pin contacts either pontoon, float clearance is inadequate and the float assembly must be replaced. Install new parts as necessary. Torque and safety the cover screws and test the carburetor in accordance with instructions contained in the appropriate Carburetor Service Manual (MSAFSM) and Instructions E-1000 and E1002, appropriate to the model. Note: Instructions E-1000 and E1002 apply only to the installation of solid blue epoxy floats. The float clearance requirements in this Service Bulletin apply to all Volare carburetors to which this bulletin is applicable, i.e., carburetors equipped with brass floats, regardless of the manufacturer of the float and MUST be adhered to. This Service Bulletin is not applicable to carburetors equipped with solid, blue epoxy floats, Volare part numbers 30862 and 30-864. i.

ii.

iii.

Volare manufactured or serviced carburetors are equipped with a solid, blue epoxy float unless the float was replaced with an unauthorized float subsequent to Volare’s release of the carburetor. If Precision Airmotive manufactured, overhauled, or rebuilt the carburetor after November 2005, and the IC number on the carburetor’s data tag is 15 or higher, the carburetor is equipped with a solid, blue epoxy float unless the float has been replaced with an unauthorized float subsequent to release of the carburetor by Precision. While Volare believes the information in paragraphs i and ii is correct, and regardless of any error(s) that may be contained in those paragraphs, it is the owner’s/operator’s responsibility to make a positive determination that a solid, blue epoxy float is installed or to comply with this service bulletin. Where necessary, carburetors must be partially disassembled to make a positive determination. Refer to the aircraft maintenance manual for carburetor removal, installation and adjustment instructions.

5. Identification/Marking: Upon completion of this Flight Safety Service Bulletin, stamp the letters “FC” (1/8 inch tall (nominal) characters) on the flange adjacent to the throttle shaft, see Figure 6. 6. Service and Parts Availability: Float clearance tools M-510 and M-513 and replacement float and parts kits can be ordered from Tempest/Volare distributors. Distributed by

SB-4_O 03/13/09 2 of 4

7. Voiding of Warranty and Waiver of Liability: An owner’s/operator’s failure to inspect and where necessary replace the float assembly in accordance with this bulletin, or operation of a carburetor which is non-compliant the clearance requirements set forth in this bulletin, or operation of a carburetor in which other than genuine Volare approved parts are installed, voids any otherwise applicable warranty and constitutes a complete and total waiver to the extent permitted by law of any and all rights the owner, operator and/or service facility or repairer may have had to hold Volare responsible or liable for the malfunction or failure of such an aviation carburetor. The owner/operator and/or service facility or repairer that returns a carburetor that is non-compliant with this service bulletin to service shall bear the sole responsibility and full liability for any damages of whatever nature, injury, or death arising from any malfunction or failure of such a non-compliant, modified and/or altered aviation carburetor. 8. Safety First: Volare is a customer-service oriented company committed to technical innovation in pursuit of aviation safety. While Volare has no authority to compel owners to act responsibly and take prudent action to insure their own safety and the safety of others, Volare believes compliance with this Service Bulletin is essential to protect against failures with unacceptable consequences. Volare strongly warns owners of the inherent risks involved in operating an airplane with a float installation having non-conforming float to bowl clearance and strongly encourages owners to comply with this Service Bulletin.

Distributed by

SB-4_O 03/13/09 3 of 4

SPAN

GAGE PINS

A

PER CARB

GAGE

MODEL

PIN

.051” MA-45/AA MA-5/AA MA-6/AA

Floats with Rubbing Wear – FEB 2009 Fig. 1

.081” MA-2

SPAN A

GAGE PIN

MA-3

GAGE PINS

B

MODEL

Installed

.051”

MA-4

SPAN

PER CARB

Carb Orientation 1, Check Spans A & B Fig. 2

MA-45/AA MA-5/AA MA-6/AA

.081 ”

N

SPAN B

Wear

MA-2

from

MA-3

Rubbing

MA-4

Carb Orientation 2, Check Spans A & B Fig. 3

Example: Wear from Rubbing on Large MA Float Fig. 4 Either Location acceptable

Wear from

FC

Rubbing

Example: Wear from Rubbing on Small MA Float Fig. 5

FC

Large

Small MA

MA

Carb

Carb

Conformance with this SB-4 ‘FC’ Stamp Locations Fig. 6

Distributed by

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB09-6A

Contains Important Information Pertaining to Your Aircraft Engine.

S/S SB08-6 and SB09-6 Technical Portions FAA Approved

Compliance Will Enhance Safety

SUBJECT: Volare’ Carburetors, LLC SB-5 Rev A Service Bulletin PURPOSE: Adds the Model HA-6 Carburetor to the list of Applicable Carburetors. Announces the supersedure of Precision Airmotive Bulletin MSA-13 by Volare’ Carburetors, LLC Service Bulletin SB-2 COMPLIANCE: Upon receipt of Volare’ SB-5 Rev A See bulletin copy attached

MODELS AFFECTED: A65, A75, C75, C85, C90, C125-2, 2H, C145-2 TCM O200-A,B,C,D and Rolls Royce O200-A, B , O240 TCM O300-A,B,C,D , GO300A,C,D,E, O470-A,J,K,L,R,S,U.

General: Volare’ Carburetors, LLC has issued Service Bulletin SB-5 Revision A dated May 1, 2009 that revises the listing of applicable carburetors. The HA-6 carburetor is added to the list carburetors for float inspection. The carburetor model HA-6 is utilized on Lycoming engines only. This bulletin is issued as information only to maintain currency and continuity in support of Vendor bulletin issuance. Any questions concerning this Bulletin or other specific Volare’ Carburetor questions should be directed to: Volare’ Carburetors, LLC Customer Service by phone: 336-446-0002 Customer service by email: [email protected]

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© 2009 TELEDYNE CONTINENTAL MOTORS, INC.

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Volare’ Carburetors, LLC

Service Bulletin: SB-5

125 Piedmont Avenue Gibsonville, N.C. 27249, USA

Revision: A Date: June 1st , 2009

Subject – SUPERSEDED SERVICE BULLETIN MSA-13 1.

Applicability: MA-2, MA-3, MA-4, MA-4-5, MA-4-5AA, MA-5, MA-5AA, MA-6, MA-6AA, and HA-6 model float carburetors manufactured by Volare Carburetors LLC (“Volare”), and its predecessors Precision Airmotive Corporation, Facet Aerospace Products Company, and Marvel-Schebler (Borg Warner) (hereinafter “Volare”) that are not equipped with a solid, blue epoxy float. Note: Volare (and Precision) floats, part numbers 30-860, 30-862 and 30-864, are NOT FOAM floats. Volare (and Precision) floats are solid, blue epoxy floats.

2.

Reason: WARNING: Failure to follow this advice may result in engine malfunction, damage, injury or death. Precision Service Bulletin MSA-13 is superseded and replaced by Volare Service Bulletin SB-2.

3.

Compliance: Comply with Volare Service Bulletins Nos. SB-2 & SB-4. Precision Service Bulletin MSA-13 should be marked “No Longer Active – Replaced by Volare Service Bulletin No. SB-2.”

4.

Voiding of Warranty and Waiver of Liability: An owner’s failure to inspect and, where necessary, replace float in accordance with Service Bulletins Nos. SB-2 & SB-4, or operation of a carburetor containing a float that does not conform to the requirements of Service Bulletins Nos. SB-2 & SB-4, voids any otherwise applicable warranty and constitutes a complete and total waiver to the extent permitted by law of any and all rights the owner, operator and/or service facility or repairer may have had to hold Volare responsible or liable for the malfunction or failure of such an aviation carburetor. The owner, operator and/or service facility or repairer responsible for installation of UNAUTHORIZED parts in Volare’s aviation carburetors shall bear the sole responsibility and full liability for any damages of whatever nature, injury, or death arising from any malfunction or failure of such a modified and/or altered aviation carburetor. An owner’s purchase of a solid, blue epoxy float constitutes an agreement to not install that float in any carburetor containing UNAUTHORIZED parts (as set forth in Volare SB-1). Owners of carburetors containing UNAUTHORIZED parts assume all responsibility for the operation of such carburetors recognizing that such operation may result in engine malfunction, damage, injury or death.

Distributed by 

SB‐5_A  06/01/09  1 of 2 

 

As Volare stated in SB-1: a. Volare expressly disclaims any and all responsibility and liability for any aviation carburetor containing UNAUTHORIZED parts to the extent permitted by law. b. The installation of UNAUTHORIZED parts in Volare Float Carburetors constitutes a complete and total waiver to the extent permitted by law of any and all rights the operator may have had to hold Volare responsible or liable for the malfunction or failure of such a modified and/or altered aviation carburetor. c. To the extent permitted by law, the owner, operator and/or overhaul facility or repairer responsible for installation of UNAUTHORIZED parts in Volare Float Carburetors shall bear the sole responsibility and full liability for any damages of whatever nature, injury, or death arising from any malfunction or failure of such a modified and/or altered aviation carburetor. 5. 

Safety First:  Volare  is  a  customer‐service  oriented  company  committed  to  technical  innovation in pursuit of aviation safety. While Volare has no authority to compel owners to act  responsibly and take prudent action to insure their own safety and the safety of others, Volare  believes  compliance  with  this  Service  Bulletin  is  essential  to  protect  against  failures  with  unacceptable  consequences.    Volare  strongly  warns  owners  of  the  inherent  risks  involved  in  operating an airplane with a hollow brass or plastic float or with a foam float, regardless of the  manufacturer  of  such  floats,  and  strongly  encourages  owners  to  comply  with  this  Service  Bulletin. 

Distributed by 

 

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TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 3

SERVICE BULLETIN Compliance Will Enhance Safety

SB643B SUPERSEDES SERVICE BULLETINS SB632A , SB643 and SB643A FAA APPROVED

SUBJECT:

MAINTENANCE INTERVALS FOR ALL TCM AND BENDIX AIRCRAFT MAGNETOS AND RELATED EQUIPMENT

PURPOSE:

Required maintenance of TCM and Bendix Aircraft Magnetos and Related Equipment

EQUIPMENT AFFECTED:

TCM and Bendix S-20, S-200, S-1200, D-2000 and D-3000 Magnetos, Ignition Harnesses, Ignition Switches and Starting Vibrators.

General Information: The following information constitutes the manufacturer’s Instructions for Continued Airworthiness and outlines required maintenance, inspection, cleaning and overhaul intervals of the TCM and Bendix magnetos and related equipment listed under "Equipment Affected". Detailed Instructions: 1. 100 HOUR, ANNUAL INSPECTION, OR PROGRESSIVE MAINTENANCE. A. Magneto-to-engine timing checks must be conducted at the shortest of these intervals. Should the magneto-to-engine timing require adjustment due to exceeding the limits specified by the engine manufacturer, a visual inspection of the magneto contact assemblies must be performed. Follow procedures in the PERIODIC MAINTENANCE section of the latest revision of the applicable Service Support Manual, included in Form X40000 Master Service Manual. If internal magneto components require replacement or adjustment, the magneto must be removed from the engine.

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B. Ignition Switches must also be functionally tested at the shortest of these intervals. This inspection may be accomplished by performing a "Preflight Magneto RPM Drop" test in accordance with the Aircraft Manufacturer's Pilot's Operating Handbook. Switch action must be smooth and free from sticking. For key type Switches, keys must be removable only in the "OFF" position and the switch must function in accordance with the requirements of the latest revision of Service Bulletins No. 636 and 653. C. Also at the shortest of these intervals, all Ignition Harness spark plug terminals must be removed from spark plugs, cleaned and inspected. Clean Harness spark plug terminals following procedures in CLEANING section of the latest revision of the applicable Service Support Manual, included in Form X40000 Master Service Manual. Replace all parts found to be broken, brittle, cracked or burned, then lubricate and reinstall Harness following procedures in ASSEMBLY section of the applicable Service Support Manual.

REVISED DAY YEAR 06

2005

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

©2005 Teledyne Continental Motors, Inc.

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B

D. Spark plug condition has a major effect on the continued airworthiness of the engine and its ignition system. Therefore, the importance of proper spark plug maintenance cannot be overemphasized. At the shortest of these intervals, all spark plugs must be inspected and maintained in accordance with the spark plug manufacturer's instructions. 2. IMPULSE COUPLING INSPECTION. A. Magnetos equipped with snap-ring impulse couplings must be inspected for wear at 500 hour intervals as specified in the latest revision of the applicable Service Support Manual, PERIODIC MAINTENANCE Section, Paragraph 6.2.2. B. Magnetos with riveted impulse couplings must be inspected for wear at 100 hour intervals as specified in the latest revision of Service Bulletin MSB645. 3. 500 Hour Inspection. A.

B.

MO 02

Magnetos, regardless of engine manufacturer application, must be inspected every 500 hours as outlined in the PERIODIC MAINTENANCE section contained in the latest revision of the applicable Service Support Manual, Paragraph 6.2.3. Also, all Ignition Harness outlet plates, covers or cap assemblies must be cleaned and inspected at the same time. Clean grommets following procedures found in the CLEANING section contained in the latest revision of the applicable Service Support Manual. Replace all parts found to be broken, brittle, cracked or burned, then lubricate and reinstall harnesses following procedures found in the ASSEMBLY section contained in the latest revision of the applicable Service Support Manual.

ISSUED DAY YEAR 25

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4. Engine Overhaul or Four Year Interval. A. Magnetos are electro-mechanical devices that use rotating parts and are subject to the same service treatment, environmental conditions and wear as the engine. Therefore, magnetos must be overhauled when the engine is overhauled. Also at engine overhaul, Ignition Harnesses must be replaced. Ignition switches and starting vibrators must be inspected and tested for airworthiness in accordance with all current service information at engine overhaul. B. Severe environmental conditions, engine over-speeds, sudden stoppage, immersion and other unusual circumstances may require complete or partial engine overhaul prior to the overhaul time recommended by the engine manufacturer. The magneto is an integral part of the engine and is subject to the same deterioration as the engine under the abnormal conditions listed above. In such circumstances the magneto, regardless of "In Service" time, must be overhauled with particular attention focused on all rotating parts, bearings and electrical components. C. In addition to the requirements listed above, magnetos must be overhauled or replaced at the expiration of five years since the date of original manufacture or last overhaul, or four years since the date the magneto was placed in service, whichever occurs first, without regard to accumulated operating hours. Also at this time all related components, including the High Tension Ignition Harness, Starting Vibrator Assembly and Ignition Switch Assembly, must be inspected for airworthiness in accordance with the procedures contained in the latest revision of their respective Service Support Manual.

REVISED DAY YEAR 06

2005

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

©2005 Teledyne Continental Motors, Inc.

2 of 2

B

®

TELEDYNE CONTINENTAL

IGNITION SYSTEMS

SERVICE BULLETIN

CATEGORY 3

SB650

Compliance Will Enhance Safety

FAA APPROVED SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED: COMPLIANCE:

STOP PIN PROCEDURES To revise stop pin replacement procedures. All TCM and Bendix S-21, S-23 and S-25 Series magnetos (which are equipped with impulse couplings and stop pins). At next overhaul, or whenever Stop Pin Replacement is necessary.

GENERAL INFORMATION: Due to the sizing of the hole that takes place when a stop pin is pressed into the aluminum housing, the practice of simply replacing stop pins in holes from which a stop pin has been removed is not suitable. Owing to the difficulty in visually determining which holes have had stop pins previously installed, all holes are subject to the following measurements prior to stop pin installation. DETAILED INSTRUCTIONS: Any time magneto assembly requires installation of a stop pin into any stop pin hole for any reason, perform the following measurements to determine suitability of the housing for standard or oversize stop pin installation. See Figure 1 for identification of standard and oversize stop pins. 1.

To determine if a stop pin hole has been machined for use with stop pin: Attempt to insert a .2800 inch gage-pin into hole. If hole does not accept .2800 inch gage-pin, hole has not been machined for stop pin installation. Do not attempt to install a stop pin in this hole. If the hole accepts a .2800 inch gage-pin, continue measurements.

2.

For use of standard size stop pin (P/N 10-56513 for S-21 and S-23 Series Magnetos, and P/N 10-79011 for S-25 Series Magnetos), hole must accept .2800 inch gage-pin as detailed in step 1, and .2820 inch gage-pin must not be able to be inserted into hole more than .120 inch below face of housing stop pin hole boss. If .2820 inch gage-pin can be inserted more than .120 inch below face of housing stop pin hole boss, continue measurements.

3.

For use of oversize stop pin (P/N 10-400602 for S-21 and S-23 Series Magnetos, and P/N 10400603 for S-25 Series Magnetos), hole must accept a .2820 inch gage pin more than .120 inch below face of housing stop pin hole boss, and a .2840 gage-pin must not be able to be inserted deeper than .120 inch below face of housing stop pin hole boss. If all conditions of this step are not met, hole is too large to be used for stop pin installation. Therefore, replacement of the housing is required.

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FIGURE 1 STOP PIN IDENTIFICATION

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®

TELEDYNE CONTINENTAL

IGNITION SYSTEMS

SERVICE BULLETIN

CATEGORY 3

SB651

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

CAPACITOR INFORMATION AND INSTALLATION FOR D-2000 AND D-3000 SERIES MAGNETOS.

REASON FOR BULLETIN:

To provide information and instructions when troubleshooting difficulties associated with capacitors in the D-2000 and D-3000 Series Magnetos, and to provide revised installation instructions for these capacitors. WARNING High resistance or discontinuity between the capacitor and the remainder of the magneto will result in destruction of the contact assembly, loss of ignition, and loss of engine power.

EQUIPMENT AFFECTED: COMPLIANCE:

All Bendix D-2000 Series Magnetos and all Bendix and TCM D-3000 Series Magnetos. Whenever described symptoms are encountered and whenever capacitors are installed.

GENERAL INFORMATION: Field reports indicate a widespread lack of understanding regarding the function of the capacitor in the operation of the D-2000 and D-3000 Series Magnetos, and regarding the remedies for symptoms associated with the capacitor circuit. The capacitor is an integral part of the magneto which serves the electrical function of point arc suppression. The capacitor is always specified in the magneto bill-of-materials. Every spare D-3000 Series Magneto Unit supplied by Teledyne Continental Motors includes two capacitors and attaching hardware. Replacement of a D-2000 or D-3000 Series Magneto Unit is not complete without also replacing the capacitors. Apparently this relationship is occasionally overlooked because the capacitors in a D-2000 or D-3000 Series Magneto are installed in the harness cover. When a magneto is removed from an engine for replacement, its capacitors are sometimes left on the engine with the separated harness. If the reason for the original magneto's removal originated in the capacitor circuit, but the capacitors are not changed, the same symptoms can be expected to recur with the replacement magneto. For the capacitor to function, it must be electrically connected to the magneto. Capacitor connections are made at two principal places: Through the lead wire to the flag terminal and the contact assembly, and from the capacitor case to the harness cover to the magneto housing ground. (The "P-lead" terminal connection, where the capacitor is connected to the wire to the magneto switch, is not part of this discussion.) While it is straightforward to inspect the flag terminal connection and its associated lead, the equally important ground return path for the capacitor is often overlooked. If either the ground return path or the flag terminal lead path presents high resistance, arcing will occur at the points. Arcing causes the points to overheat, which also overheats the spring to which one of the points is attached. The nylon cam follower then melts where it bears against the hot spring. The decreased height of the melted cam follower causes the point clearance to decrease and the magneto-to-engine timing to drift late. Whenever this condition is

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discovered, the magneto must be removed from the engine, and both the contact assembly and the capacitor must be replaced. In the D-2000 and D-3000 Series Magnetos, the capacitor ground return path begins at the capacitor case. The capacitor case has a threaded area for a nut and a lockwasher to fasten the capacitor to the harness cover. The cover is then fastened to the magneto housing by four hold-down screws, allowing a ground return path through the housing-to-cover mating surfaces as well as through these screws. Original Bendix and TCM D-2000/D-3000 harness covers and all D-2000 and D-3000 Series Magneto housings are made from a magnesium alloy. Improper application of surface treatments, paints, thread locking compounds, brightening materials, gasket materials, and threaded fastener torque, singularly or in combination, can cause the capacitor to become insulated from magneto ground. Likewise, given enough time without the required preventive maintenance, the effects of moisture, heat, contamination, and a corrosive environment can serve to insulate the capacitor from magneto ground. Teledyne Continental Motors Ignition Systems Service Bulletin 643 specifies required maintenance intervals for all TCM and Bendix aircraft magnetos and related equipment, including D-2000 and D3000 Series Magnetos. Although these are the maximum intervals allowed, operators may choose to schedule maintenance at intervals shorter than those specified in SB643. DETAILED INSTRUCTIONS: 1. Whenever magneto-to-engine timing is found to be later (closer to piston top dead center) than the limit specified by the engine manufacturer, prior to disassembling any ignition system component, use an ohmmeter capable of 0.1 milliohm resolution (such as Fluke model 8840A digital multimeter, John Fluke Manufacturing Co, P. O. Box C-9090, Everett, WA, 98206) to measure resistance between each capacitor threaded area and an unpainted area on the magneto housing. If this resistance is greater than 3 milliohms, the capacitor must be removed from the magneto system assembly and the corresponding contact assembly must be examined. If the contact assembly cam follower is found to be melted where it bears against the point spring, both the contact assembly and the capacitor must be discarded. If the cam follower is not found to be melted, the capacitor must be inspected per GENERAL OVERHAUL paragraph 7.2.5, in the D-3000 Series Maintenance Manual, Form X42003 or later revision, before it can be reinstalled as described below. NOTE... A new cam follower has a straight edge where it bears on the point spring. If melting has occurred, the edge deforms to match the shape of the spring. Sometimes melting also causes the follower thickness to bulge and/or the material to darken at the bearing area. 2. Whenever maintenance affords access, inspect the contact assemblies. Any contact assembly found with the cam follower melted where it bears against the point spring must be removed and replaced, and its corresponding capacitor must also be removed and replaced. 3. At the 500 hour inspection as specified in SB 643, check magneto-to-engine timing in accordance with the engine manufacturer's instructions prior to removing any ignition system component from the engine. If magneto-to-engine timing is found to be later than the limit specified by the engine manufacturer, comply with paragraph 1, above.

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4. Capacitor Installation: a. Ensure each capacitor to be installed is the correct part number for the magneto. Despite similarities in appearance, capacitors for D-2000/D-3000 Series Magnetos have differing capacitance values and boot configurations depending on the number of cylinders the magnetos fire. Capacitor applications are as follows: Magneto Number Of Cylinders

Capacitor Part Number

4

10-382807

6

10-382681

8

10-382681-1

b. Ensure capacitor mounting surface inside the harness cover is clean and free of corrosion. If necessary, brighten harness cover in the inside capacitor mounting area with ONLY a clean, fresh nylon scouring pad. c. Using ONLY a different clean fresh nylon scouring pad, remove contamination and corrosion from capacitor case shoulder and threads as necessary. See Figure 1 d. Form capacitor leads as shown in Figure 1. e. Install the two capacitors in their respective places in the harness cover. Secure each capacitor with lockwasher and nut, centering the boot nipple between the harness silicone grommets. Apply 60 to 70 inch pounds torque to each nut. NOTE... To ensure correct alignment of capacitor boot nipple, the harness cover and capacitor may be temporarily mounted onto a magneto while the capacitor securing nut is tightened. 5. Assemble Harness Cover to Magneto: NOTE... Spray grommets with a film of MS-122N/CO2 TFE Release Agent. (Available from Miller-Stephenson Chemical Company, P. O. Box 950, Danbury, CT, 06813) Do not spray distributor block. NOTE... Harness cover is secured to both D-2000 and D-3000 Series Magnetos with four screws and four washers. Early D-2000 Series Harness covers with eight screw holes which have not been modified in accordance with SB 605A to fill in the four center screw holes must be replaced with new covers. a. In order to ensure a good ground return path, ensure harness cover and housing mating surfaces are free of corrosion, paint, and gasket/sealing materials. Use ONLY a clean fresh nylon scouring pad to brighten these surfaces. Also ensure threads in housing are free of corrosion and thread locking compounds. Use a 10-32 tapered tap, followed by a nylon brush and air blast to clean the threads. b. For pressurized magnetos only, position gasket on magneto mating surface. c. Position harness cover so that witness marks align with witness marks on magneto housing. Install capacitor lead flag terminal onto the inside spade terminal of the corresponding contact assembly: Connect LEFT capacitor lead to the contact assembly farthest from the witness marks and data plate; Connect RIGHT capacitor lead to the contact assembly nearest to the witness marks and to the data plate. Fully seat flag terminals straight onto the spade terminals.

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d. Position cover onto magneto, ensuring each grommet slides into its corresponding distributor block outlet tower. e. Install one screw and washer at each of the four locations on the cover. Draw screws down evenly. For pressurized magnetos, ensure gasket is positioned properly and apply 40 to 45 inch pounds torque to each screw. For unpressurized magnetos, apply 30 to 35 inch pounds torque to each screw. f.

Using Fluke model 8840A digital multimeter or equivalent, measure the resistance between each capacitor threaded area and an unpainted area of the magneto housing. If this resistance exceeds 3 milliohms, the source of high resistance must be eliminated before the magneto can be returned to service.

FIGURE 1 TYPICAL D-2000 / D-3000 CAPACITOR

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®

TELEDYNE CONTINENTAL

IGNITION SYSTEMS

SERVICE BULLETIN

CATEGORY 3

SB652 FAA APPROVED

SUBJECT: REASON FOR BULLETIN:

IMPULSE COUPLING CONFIGURATION AND MAINTENANCE FOR ALL TYPE D6LN-2031 MAGNETOS. To require parts list conformity, and to emphasize required maintenance. WARNING In the affected applications, use of the early "standard spring" impulse coupling, or use of the standard spring in conjunction with the "heavy spring" impulse coupling components, may lead to hard starting of the engine and accelerated wear of the battery, starter solenoid, starter motor, and other engine components.

EQUIPMENT AFFECTED:

MAGNETO TYPE NUMBER: D6LN-2031 MAGNETO PART NUMBERS: 10-382560-11 10-382560-13 NOTE... This Service Bulletin applies to all serial numbers of Type D6LN2031 magnetos, regardless of data plate color. Production and rebuilding of these magnetos ended in September 1982. All affected units were built by Bendix, not by TCM. NOTE... If maintenance records indicate a "heavy spring" impulse coupling has been installed as specified in Table 1, the magneto is in compliance with this Service Bulletin.

COMPLIANCE:

Prior to completion of the next 100 hour inspection, annual inspection, progressive maintenance inspection, magneto overhaul, or the expiration of four calendar years since impulse coupling spring replacement, whichever comes first.

GENERAL INFORMATION: The original impulse coupling for the D6LN-2031 magnetos included the same spring used in all other contemporary Bendix impulse couplings. However, because the D6LN-2031 turns slower than any other contemporary magneto relative to crankshaft speed (3/4 to 1, versus 1 to 1 or 1.5 to 1), and because the spring has only 90 degrees to wind between snaps (all other contemporary designs have 180 degrees), and because the rotating magnet in the D-2000 Series Magneto is heavier than other contemporary designs, starting performance was not as good as was experienced with other magnetos, especially in cold weather. In order to improve starting performance the "heavy spring" impulse coupling, including revised designs

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for the body, spring, and cam assembly subcomponents, was first used in production around June, 1978. This Service Bulletin requires the replacement of all "standard spring" impulse couplings which remain in service, and that only "heavy springs" (P/N 10-400042) be used in the affected equipment. DETAILED INSTRUCTIONS: 1. Remove the magneto from the engine. Compare the part number marked on the body to the part number shown in Table 1. If another part number body is installed on the magneto, the entire impulse coupling assembly must be replaced with new parts as detailed in Table 1. In this circumstance, do not replace the body, spring, or cam assembly as individual pieces. The impulse coupling must be replaced as a unit. TABLE 1 IMPULSE COUPLING PARTS FOR TYPE D6LN-2031 MAGNETOS DESCRIPTION

P/N

P/N

Magneto

10-382560-11

10-382560-13

Impulse Coupling Assemblies: (includes body, spring and cam assembly)

10-400325

10-400326

. Body

10-382952

10-382961

. Spring

10-400042

10-400042

. Cam Assembly

10-400167-13

10-400167-12

NOTE...Use of interim heavy spring impulse coupling assemblies (P/N's 10-382953, 10-382962), interim heavy spring (10-382941), and corresponding riveted cam assemblies (10-349357-8, 10349357-9), is permissible so long as such parts meet all conditions of SB 623A, SB 643, and MSB 645. 2. Whenever the impulse coupling is disassembled for any reason, the spring must be replaced with a new P/N 10-400042 spring. NOTE... Heavy Springs (P/N 10-400042) may be identified by their nominal thickness: 0.042 in. Standard Spring P/N 10-51324 is nominally 0.031 inches thick. 3. Magnetos must be overhauled at the time of engine overhaul or at the expiration of four calendar years, whichever comes first. Refer to TCM Ignition Systems Service Bulletin 643. The impulse coupling spring is among the items which must be replaced 100% in order for the magneto to be considered overhauled. NOTE... Many engines currently using impulse couplings may be converted to Shower-of-Sparks technology as detailed in Service Information Letter 648.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB653

SERVICE BULLETIN Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

HOT MAGNETO TEST

PURPOSE:

To provide test procedure to ensure the integrity of the magneto grounding circuit.

EQUIPMENT AFFECTED:

All ignition systems utilizing TCM or Bendix magnetos and/or ignition switches on all aircraft types.

GENERAL INFORMATION: Magneto ignition systems must be tested in the following manner to ensure magnetos are grounded after engine shutdown in order to avoid engine ignition from movement of the propeller. DETAILED INSTRUCTIONS: 1. Prior to engine shut-down, and prior to performing any maintenance on the engine, perform the Magneto RPM drop-off Test as detailed in the Pilot’s Operating Handbook (Normally found under Preflight Engine Run-Up Procedures). 2. If no RPM drop is noted when a magneto is individually selected, either the magneto selected is timed far in advance of the magneto, or a discontinuity exists between the other magneto primary circuit and airframe ground. Either condition must be remedied before further flight and before moving the propeller by hand. 3. Stop the engine using normal procedures as detailed in the Pilot’s Operating Handbook.

WARNING THE ENGINE MAY INADVERTENTLY EXPERIENCE IGNITION OR START-UP ANY TIME THE PROPELLER IS MOVED. INJURY, DEATH OR DAMAGE TO PROPERTY MAY RESULT. 4. If there is evidence of discontinuity in the magneto grounding circuit, inspect circuit connections for cleanliness and tightness, inspect wire and fed-through capacitors (whether mounted inside or outside the magneto) for continuity, and inspect switch (es) for correct electrical operation. Repair or replace malfunctioning parts as necessary as specified in the appropriate service manual. NOTE . . . Do not use an ohmmeter or continuity tester to troubleshoot the magneto grounding circuit with the magneto connected, as false continuity to ground will be read through the points or coil primary windings. Instead, position the magneto shaft so that the points are open, and use a magneto timing light to troubleshoot the magneto grounding circuit with the magneto connected.

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TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 3

SB654A

SERVICE BULLETIN Compliance Will Enhance Safety

FAA APPROVED

SUBJECT: IMPROVED CAPACITOR, P/N 10-400604, FOR CERTAIN SHORT COVER S-20 AND S-200 SERIES MAGNETOS. REASON FOR BULLETIN: EQUIPMENT AFFECTED:

COMPLIANCE:

To announce the availability of an improved capacitor and to require its use in affected magnetos. All new and rebuilt magnetos of the following part numbers: MAGNETO PART NUMBER

MAGNETO TYPE NUMBER

MAGNETO PART NUMBER

MAGNETO TYPE NUMBER

10-500556-1

S6RSC-25

10-600606-1

S6RSC-201

10-500556-3

S6LSC-25

10-600606-3

S6LSC-201

10-500556-101

S6RSC-25P

10-600656-1

S6RSC-205

10-500556-103

S6LSC-25P

10-600656-3

S6LSC-205

Any time capacitor is replaced or at next magneto overhaul, whichever occurs first.

GENERAL INFORMATION: Field reports indicate that affected magnetos installed on TCM TSIO-360-E, EB, F, FB, KB and LTSIO-360-E, EB, KB engines may suffer lead breakage due to vibration. Lead breakage will cause the magneto to run intermittently or quit. A capacitor with an improved lead/terminal connection is now available. This capacitor was introduced on factory production P/N 10-500556-103 magnetos with manufacturing numbers L099417D and above and for all other affected magneto P/N's with manufacturing numbers F049602D and above. (Refer to SIL642 to interpret manufacturing numbers.) New and rebuilt magnetos built prior to the manufacturing numbers listed have the old capacitor installed. DETAILED INSTRUCTIONS: 1. Remove capacitor P/N 10-349276 and replace with capacitor P/N 10-400604 in accordance with applicable disassembly and assembly instructions in S-20/S-200 Series Service Support Manual, Form X42002-1. 2. To indicate installation of P/N 10-400604 capacitor in magnetos built prior to the manufacturing numbers detailed under GENERAL INFORMATION, stamp letter G, approximately 1/8 inch high, in lower right corner of the Magneto Data Plate.

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A

NOTE... Magnetos P/N 10-500556-103 with capacitor P/N 10-400604 installed in the field under the original issue of this Service Bulletin are identified by change letter AB stamping. Reidentification of these magnetos is not required. WARRANTY CONSIDERATION: All affected equipment will be covered by the TCM Gold Medallion Warranty or Ignition Systems Warranty as applicable, subject to its terms and conditions. Warranty claims may be filed through any TCM Distributor. Up to 1.8 hours labor will be allowed per magneto installed on an engine. Up to 1.0 hours labor will be allowed per magneto not installed on an engine. EQUIPMENT PUBLICATIONS: Insert a copy of this Service Bulletin into S-20/S-200 Series Service Support Manual, Form X42002-1.

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A

TELEDYNE CONTINENTAL

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SB658

Compliance Will Enhance Safety SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED: COMPLIANCE:

CATEGORY 3

FAA APPROVED

DISTRIBUTOR GEAR MAINTENANCE To emphasize the value of the use of correct materials and practices relevant to magneto distributor gears. All Bendix and TCM S-20, S-200, S-1200, D-2000, and D-3000 Series Magnetos. Any time maintenance is performed on the distributor gear, any time the magneto is installed on the engine, and any time any condition described below is experienced.

GENERAL INFORMATION: Although Bendix and TCM have previously published detailed service instructions and introduced technological advances for distributor gears, field reports indicate that breakage of distributor gear teeth continues to occur. Gear service life cannot be maximized unless operators perform required maintenance using proper procedures and correct materials. The following instructions consolidate new and previous data to focus attention on this issue. DETAILED INSTRUCTIONS: 1. WARNING...DO NOT USE ANY GEAR HOLDING TOOL AS AN AID WHILE ASSEMBLING THE MAGNETO OR WHILE TIMING THE MAGNETO TO THE ENGINE. SUCH TOOLS ARE UNNECESSARY, AND USING THEM MAY CAUSE HIDDEN DAMAGE TO THE DISTRIBUTOR GEAR. SUCH DAMAGE MAY CAUSE MAGNETO FAILURE, AND SUBSEQUENT ENGINE FAILURE, INJURY, OR DEATH MAY RESULT. 2. Anytime maintenance affords access to the distributor gear, inspect the gear according to the latest applicable service manual and the requirements of this bulletin. Anytime cleaning is required, clean only in accordance with published cleaning procedures as described in the latest applicable magneto service manual. Use only the correct make-up of parts associated with the distributor gear as detailed in the latest Illustrated Parts List chapter of the applicable Magneto Service Manual. When installing magneto pressurization fittings or similar items, ensure that such fittings will not interfere with the gear under any operating conditions.

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3. Always use the latest configuration distributor gears available. In S-20 and S-200 series Magnetos, the earlier gears using "Captivated Washers" were superseded beginning in 1978. Beginning with the 1989 S-20/S-200 Service Manual, the earlier gears were required to be replaced no later than at the next magneto overhaul, which MUST occur before the intervals defined in the latest revision of SB643 have expired. Therefore, the earlier gears MUST now be replaced at the next opportunity when maintenance allows access to the gear, not later than the next required inspection or magneto overhaul, whichever occurs first. For S-1200 series magnetos, all distributor gears without a date code and all distributor gears with date codes 75 (1975) through 78 MUST be replaced no later than next magneto overhaul (Refer to the latest revision of SB643) with a distributor gear with a date code of 79 or higher. All D-2000 and D-3000 series magnetos MUST have laser-welded distributor gears which display marks as required by the latest revisions of SB617B, SB618, and SB619. (Ref. AD 82-11-05, and 81-12-06 R1) 4. Re-lubricate distributor block bushings using 10-391200 lubricant and correct procedures only at intervals not to exceed 500 hours time-in-service or four calendar years from date of factory shipment, whichever comes first. Also re-lubricate distributor gear teeth using 1027165 grease and correct procedures at the same interval. Procedures for re-lubrication are included in the applicable Magneto Service Manual. 5. Ensure distributor block bushing is not contaminated with any solvent or distributor block coating compound following bushing re-lubrication. 6. Follow all Engine and Airframe Manufacturer's instructions regarding engine cooling, including but not limited to installation and maintenance of engine baffles, operation of cowl flaps, cold weather pre-heating procedures, and post-flight turbocharger cool-down procedures. If an engine has been operated at an oil temperature in excess of gauge red line for any period, the distributor gear in each magneto on that engine MUST be inspected for browned color and/or missing or damaged teeth before further flight. Any gear which is browned in color, and/or has any broken or missing teeth MUST be replaced with a serviceable gear prior to next engine start. 7. Follow all Engine Manufacturer's instructions regarding magneto installation, including but not limited to condition of magneto drive gear and related parts, and correct seating of magneto on drive pad. 8. Ventilation of the magneto is essential for continued airworthiness, as the magneto generates contaminants through normal operation. Unpressurized magnetos use vent plugs to ensure fresh air is introduced into the magneto during operation. Pressurized magnetos are connected to a pressure air source and use a calibrated orifice to maintain a pressure differential with ambient air pressure and also to ensure flushing of contaminated air from within the magneto. If the vent plug(s) or orifice is blocked, the contaminants collect inside the magneto. Any distributor gear which has operated for any period in an unvented magneto MUST be discarded and replaced with a serviceable gear prior to further flight, and the distributor block MUST be replaced or completely cleaned, inspected, and re-lubricated as required by the applicable magneto service manual. 9. Following any engine kickback event during start, shut the engine down and investigate the cause of the kickback. If troubleshooting does not indicate another cause for the kickback, inspect all distributor gear teeth for damage. Although it is unlikely that a kickback could cause gear tooth damage, engine kickback may be a symptom of missing or broken distributor gear teeth.

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10. Any distributor gear found to have any cracks, any missing or broken teeth, brown discoloration, or chalky or crazed surface, MUST be discarded and replaced with a serviceable distributor gear prior to next engine start. AFFECTED PUBLICATIONS: Insert a copy of this Service Bulletin into the appropriate section of all affected magneto Service Support Manuals.

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TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

SERVICE BULLETIN

SB659

Compliance Will Enhance Safety SUBJECT: REASON FOR BULLETIN: EQUIPMENT AFFECTED: COMPLIANCE:

CATEGORY 3

FAA APPROVED

MAGNETO IMPULSE COUPLING STOP PIN INSTALLATION. Provide stop pin replacement instructions. All TCM and Bendix S-1225 and S-1227 Series Magnetos utilizing impulse couplings and stop pins. At next overhaul, or whenever stop pin replacement is necessary.

GENERAL INFORMATION: Impulse coupling stop pins are provided as service parts only in an oversize dimension. Refer to Figure 1. If impulse coupling stop pins require replacement the following inspection must be performed. DETAILED INSTRUCTIONS 1. Prior to installation of an oversize replacement impulse coupling stop pin, dimensionally inspect the stop pin hole in the magneto flange. The stop pin hole minimum diameter for its entire depth is .2485". The stop pin hole may have a maximum diameter of .2495" from its opening to a depth not exceeding .120". 2. If the stop pin hole does not exceed the specified dimension, a replacement stop pin P/N 10349438R may be installed. WARNING INSTALLATION OF SALVAGED, STANDARD SIZE IMPULSE COUPLING STOP PINS IS NOT PERMITTED AND WILL RESULT IN THE STOP PIN NOT HAVING THE CORRECT INTERFERENCE FIT. 3. Scrap and destroy all flanges that have stop pin holes exceeding the specified dimension. AFFECTED PUBLICATIONS: Insert a copy of this Service Bulletin into the latest revision of the S-1200 Series High Tension Magneto Service Support Manual.

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FIGURE 1 S-1200 STOP PIN IDENTIFICATION

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TELEDYNE CONTINENTAL

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IGNITION SYSTEMS

SERVICE BULLETIN

CATEGORY 3

SB660

Compliance Will Enhance Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

POSSIBLE MALFUNCTION IN CERTAIN PUST-TO-START IGNITION / STARTER SWITCHES

PURPOSE:

To advise of the potential for uncommanded starter engagement and consequent propeller rotation as a result of malfunction in some Push-To-Start Ignition/Starter Switches, and to provide corrective action.

COMPLIANCE:

At the next and each subsequent 100 hour, annual, or progressive inspection, (whichever occurs most often) inspect affected switches for proper function. If improper function is found, replace the switch prior to further flight. NOTE: All TCM Ignition switches, regardless of the part number, date code or manufacturing number are to be functionally tested in accordance with the latest revision of TCM Ignition Systems Service Bulletin SB653 to insure the integrity of the magneto grounding circuit.

EQUIPMENT AFFECTED:

Push-To-Start Ignition/Starter switches, part numbers 10-357210-1 (with key), and 10357240-1 (with lever) with the following date codes or manufacturing numbers ONLY: 1. Units built by Bendix: date codes 8049 (1980, 49th week) and later. 2. 2. Units built by TCM: all manufacturing numbers up to but not including H0192-H (August 1, 1992). Refer to SIL642 to interpret manufacturing numbers. NOTE... 10-357210-1 switches are supplied individually or as part of a kit, such as but not limited to 10-357210-9 (Switch supplied with three keys) and 10-357210-10 (Switch with matching door lock set). All such kits have base part number 10-357210 followed by a suffix number. NOTE... Switch part number and date code or manufacturing number appear on the side of the aluminum switch housing. Switches built prior to 1976, outside the affected date code range, are not marked with any date code. Similar switches with functions other than Push-to-Start carry different part numbers and are not affected by this bulletin.

GENERAL INFORMATION: Field reports and examination of a returned switch indicate that affected switches, under certain circumstances, may allow a "short circuit" condition between the "BAT" terminal (Battery/Bus Power) and the "S" terminal (Starter Solenoid) when the switch is in the OFF position. If this occurs, uncommanded propeller rotation may result any time the Aircraft Battery Master Switch is in the ON

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position and the Ignition/Starter Switch is in the OFF position.

WARNING DO NOT PLACE OBJECTS OR PERSONS IN THE PATH OF PROPELLER ROTATION. DAMAGE, INJURY, OR DEATH MAY RESULT.

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This condition is the result of internal damage to the Ignition/Starter Switch which may be caused by incorrect operation. In some affected switches, this action makes and then breaks continuity to the starter solenoid, resulting in overheating and insulation breakdown. Damage to the switch, however, is not evident until the switch is rotated to the OFF position. Correct operation of the Push-to-Start Switch requires rotating the key or lever FULLY clockwise to the START position, THEN pushing in on the key or lever to engage the starter. If the starter cannot be engaged in the normal manner, discontinue the start procedure and investigate the cause of the difficulty. DO NOT rock the key or lever to hunt for a position to engage the starter, as repeated make-and-break of the inductive DC circuit will cause overheating and consequent damage. Because only some units of affected equipment will make continuity when the key or lever is pushed in and rotated clockwise the first few degrees from the BOTH position, only those switches that display this condition must be replaced. A continuity lamp/buzzer or similar device is used for this test because the condition may occur too quickly to actuate the starter solenoid and starter motor. Because wear may be a factor for all affected equipment, recurrent inspections are required. DETAILED INSTRUCTIONS 1. With the Aircraft Battery Master Switch OFF, and the Ignition/Starter Switch OFF, attach a continuity lamp/buzzer, timing light, or similar device across the BAT and S terminal as shown in Figure 1.

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2. If continuity is indicated with the Ignition/Starter Switch in the OFF position, remove and replace the switch. 3. If continuity is not indicated with the Ignition/Starter Switch in the OFF position, rotate the Ignition/Starter Switch key or lever clockwise to the BOTH position. Push in firmly on the key or lever and slowly rotate it toward the START position. 3.1 Normal function occurs if continuity is indicated ONLY as the key or lever approaches the full clockwise START position. 3.2 The Switch must be removed and replaced prior to further flight if continuity is indicated, however briefly, as the key or lever is rotated the first few degrees away from the BOTH position. If this happens, it is expected that continuity will be broken as the key or lever continues clockwise rotation, and continuity will be indicated again as the key or lever approaches the full clockwise START position.

WARNING WHENEVER A MAGNETO P-LEAD WIRE OR GROUND WIRE IS DISCONNECTED FROM THE SWITCH, THE MAGNETOS ARE IN A "HOT" CONDITION. THE ENGINE MAY INADVERTENTLY EXPERIENCE IGNITION OR START-UP ANY TIME THE PROPELLER IS MOVED. DEATH, INJURY, OR DAMAGE TO PROPERTY MAY RESULT. 4. Make a logbook entry for each action in compliance with this Service Bulletin.

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

SUBJECT: TWO-WIRE MAGNETO TACHOMETER BREAKER CONTACT (POINTS) ASSEMBLY PART NUMBER 10-400507 PURPOSE:

SB663A Technical Portions FAA Approved

To advise of procedures to ensure the integrity of the tachometer circuit in certain Teledyne Continental Motors (TCM) Ignition Systems Magnetos.

COMPLIANCE: All affected magnetos must be inspected and maintained per the instructions contained in this bulletin at each magneto overhaul, 500 hour inspection, each time the magneto tachometer breaker points are serviced or replaced, or at any time a component that utilizes the magneto tachometer breaker points exhibits abnormal operation. Additionally, any affected part number magneto between serial numbers D05DA001 to D06JA001 or between serial numbers E05DA001 to E06JA001 must be inspected per this service bulletin at the next scheduled maintenance visit. (See Figure 4 for initial compliance marking requirements applicable to above listed serial number magnetos only.) MODELS AFFECTED:

For a list of the affected magneto part numbers see Table 1.

MODEL NUMBER S4LN-21 S6LN-25 S4LN-204 S6LN-204 S4LSC-21T S6LSC-25T S4LSC-204T S6LSC-204T

PART NUMBER 10-51360-47 10-79020-11, 10-79020-17 10-163046-6 10-163050-12 10-500514-201, BL-500514-201 10-500556-203, BL-500556-203 10-600644-201, BL-600644-201 10-600646-201, BL-600646-201

TABLE 1 AFFECTED MAGNETO MODEL AND PART NUMBER MATRIX

GENERAL Teledyne Continental Motors (TCM) has developed procedures to ensure the integrity of the tachometer circuit. The tachometer breaker assembly P/N 10-400507 (supersedes P/N 10-361631) is designed to be insulated from the magneto ground when it is installed in the magneto. The following maintenance procedures must be followed at each magneto overhaul, 500 hour inspection, each time the tachometer points are replaced, or any time the magneto tachometer circuit exhibits abnormal operation. ISSUED

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SB663

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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS This Service Bulletin contains updates to the manufacturer’s Instructions for Continued Airworthiness (ICA) as required by FAR 43.13(a). A copy of this bulletin must be inserted into the specified locations in the manuals listed in TABLE 2 until the manual is updated or the bulletin is superseded or cancelled. MANUAL NUMBER SECTION SECTION X-42002-1* S-20 / S-200 SERIES 6 9 HIGH TENSION MAGNETOS *Also included in the X40000 TCM Ignition Systems Master Service Manual TABLE 2 MANUAL REFERENCE CHART

INSPECTION AND ASSEMBLY PROCEDURES 1. Parts Assembly: Figure 2 depicts the correct current configuration of parts, assemblies and wiring in the magneto breaker compartment of the affected magnetos. (a) Inspect the P/N 10-361639 tachometer insulating bushings for cracks, crushing or other damage. Current bushings use phenolic material that is laminated in an annular (circular) pattern. (Reference Figure 1) (b) Any bushing found to have parallel laminations as shown in Figure 2 must be replaced before further service. (c) Set tachometer contacts to .016 - .022 clearance on the high lobe of the cam. Apply 8-10 inch-pounds torque to the retaining screws. (d) Visually inspect the P/N 10-361639 phenolic insulating bushings for damage after torque application. Any damaged bushings must be replaced before further service. (e) Washer P/N 10-14268 is used under the screw at the adjusting slot in the P/N 10-400507 tachometer contact assembly. The washer is thicker and wider to spread the clamping load evenly to the bushing that bridges the slot. (f) Washer P/N 10-400566 is used under the screw at the pivot hole in the P/N 10-400507 tachometer contact assembly. This washer is smaller to ensure electrical insulation from the tachometer assembly. The insulating bushing is supported on all sides by the breaker support. 2. The breaker compartment features four wires that must be assembled properly to ensure continued reliable service: the coil primary wire, the two tachometer wires, and the capacitor wire. (See FIGURE 2.) Whenever access allows, inspect wires to ensure that they are free of cuts or chafing damage. Wires must be routed as shown in FIGURE 2 to ensure that they do not interfere with the rotating cam and associated parts during operation, and to ensure that no wire is pinched between the breaker cover and distributor housing at assembly. Any excess coil wire may be protected by bending it away from the cam. Coil and capacitor wires feature insulation that is relatively soft. Indentations on the insulation on these parts are normal and expected. Any exposed wire strands is cause for replacement. Replace damaged parts as necessary. The two tachometer wires use a short length of tubing as an assembly aid: the position of the tubing at

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assembly is unimportant. Either tachometer wire may pass through either hole in the bushing in the breaker compartment cover. 3. Whenever access allows, inspect the wiring terminals (Flag Terminals) for integrity as shown in Figure 3. 4. Hi-Pot insulation integrity test. (a) As applicable, disconnect magneto tachometer wires from all airframe circuits in accordance with airframe manufacturer’s instructions. (b) Using Slaughter Model 1305 Dielectric Breakdown Tester * (or equivalent) set to 500V, apply 500V to each tachometer wire and ground. No indication of dielectric breakdown is permissible. (c) Replace all tachometer breaker assemblies or related components that indicate any dielectric breakdown in accordance with the latest revision of S-20/S-200 Series High Tension Magneto Service Support Manual, form X42002-1, dated November 1993 and installation requirements detailed above. Repeat Hi-Pot test following parts replacement. (d) Reattach magneto tachometer wires to airframe wires in accordance with the latest Airframe manufacturer’s instructions. * Slaughter Model 1305 Dielectric Breakdown Tester available from: Slaughter Company, Inc. 28105 N Keith Drive Lake Forest, IL 60045 USA Ph: 800-504-0055 Email: [email protected]

PARALLEL LAMINATIONS

ANNULAR LAMINATIONS

FIGURE 1 P/N 10-361639 PHENOLIC BUSHING INSPECTION ISSUED

REVISED

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10-35936-7 SCREW 10-14268 WASHER (.375”OD x .169”id x .032” THICK) 10-361639 BUSHING INSULATING

10-382585 CONTACT ASSEMBLY 10-35936-7 SCREW 10-14268 WASHER

PRIMARY WIRE TO COIL 10-357165-1

(2EA)

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10-35936-7 SCREW 10-400566 WASHER (.309”OD x .174”ID X .016” THICK CAPACITOR

10-35936-7 10-35936SCREW 7 SCREW

FIGURE 2 BREAKER COMPARTMENT ASSEMBLY AND WIRING WIRE COLORS IN FIGURE 2 ARE FOR ILLUSTRATION OF ROUTING ONLY AND DO NOT INDICATE ACTUAL WIRE COLORS.

WIRE STRANDS AND INSULATION WIRE STRANDS AND INSULATION MUAST BE VISIBLE IN THIS AREA MUST BOTHBOTH BE VISIBLE IN THIS AREA

NO LOOSE, NICKED, SCRAPED OR CUT STRANDS (THIS AREA) WIRE BARREL SEAM CLOSED WITH NO CONDUCTOR STRANDS SHOWING

BELLMOUTH MUST BE VISIBLE

NOT USED

NO DAMAGE TO MATING AREA

NO EXCESSIVE WIRE BARREL FLASH

CONDUCTOR ENDS FLUSH TO OR SLIGHTLY BEYOND END OF WIRE BARREL

FIGURE 3

PAINT DOT IN LOCATION AS SHOWN

FIGURE 4 Initial compliance identification. Applicable to designated serial number range only. NOTE: Initial compliance does not preclude recurring compliance performance in accordance with the recurring inspection requirements of this bulletin.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB94-11

SERVICE BULLETIN Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

OIL PUMP GASKET P/N 643749

PURPOSE:

To notify customers of incorrectly cut oil pump gaskets.

COMPLIANCE:

On receipt of bulletin.

MODELS AFFECTED: O-470-U, IO-470-K, IO-520, IO-550, TSIO-520 series engines using oil pump assemblies with integral oil filter adapters. This type of oil pump has the oil filter adapter cast as a part of the complete pump housing. Oil pump part numbers 643716A3, 643717, 643717-1, 643778, 643778-1, 653538A2, 653538A3, 653542 and 653553.

There have been reports from the field that some oil pump gaskets part number 643749 may have been incorrectly cut during manufacture. The affected gaskets may not adequately cover the machined orifice in the accessory case that provides access to the gallery plug for the 1-3-5 crankcase half. The part number 643749 gasket is sold individually and as a part of gasket set part numbers 646546A1 and 646548A1. This gasket may also be sold either individually or as a part of a gasket set provided by an after market parts supplier. Gaskets and gasket sets purchased between October 22, 1993 and February 1, 1994 are suspect. Figure 1 represents a correctly cut gasket P/N 643749, Figure 2 represents a incorrectly cut gasket P/N 643749. The area of concern is noted in Figure 2 by the arrow. Check all inventory of individual gaskets and those contained in gasket sets in stock. Figure 3 represents an actual size gasket that can be used to verify correctly cut P/N 643749 gaskets that are in stock. Contact Teledyne Continental Motors by FAX at (205) 433-2325 after verifying inventory. All incorrectly cut gaskets must be returned to Teledyne Continental Motors. Engines assembled with incorrectly cut gaskets may exhibit low or fluctuating oil pressure. Please contact your Teledyne Continental Motors Representative if a low or fluctuating oil pressure report is received. Compliance with this service bulletin is covered by TCM's Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB94-13

Compliance Will Enhance Safety

Supersedes M87-7 FAA APPROVED

SUBJECT:

PISTON RING SET, PART NUMBER 649226

PURPOSE:

To notify customers of the possibility of oversize rings in standard ring sets.

COMPLIANCE: MODELS AFFECTED:

Prior to utilization of subject ring sets.

E-185, E-225, O-470, IO-470 and TSIO-470 model engines.

It has been noted that some part number 649226 ring sets may contain rings that are .015" oversize. The affected ring sets are identified by the date code "CE" (March 1994), stamped adjacent to the ring set part number on the package. Piston rings are individually marked on the upper surface, either STD (standard), .005, .010 or .015. These ring sets are also contained in cylinder kit part numbers 653443A3, 653443A3BP, 653443A5, 653443A5BP, 653444A4, 653444A4BP, 653455A2 and 653455A2BP. These affected cylinder kits which may be in customer inventory, must be inspected for suspect ring sets. Cylinder kits found to contain ring sets with oversize rings must have the ring set returned to TCM through the TCM Distributor from which the kit was purchased. All part number 649226 ring sets in customer inventory must be inspected for date code "CE" and those identified as such must be inspected to determine that all rings in the set are marked "STD". Any ring set found to contain oversize rings must be returned to TCM through the TCM Distributor from which the ring set was purchased. Standard cylinder bores that are operated using oversize piston rings will exhibit cylinder wall scoring and an increase in oil consumption due to improper ring end gaps. Suspect cylinders should be inspected with a borescope or other suitable method for signatures of scoring. Cylinders that have abnormal scoring signatures will require removal and repair or replacement. Cylinder removal and installation must be accomplished in accordance with the applicable TCM Overhaul Manual. During piston and cylinder build up, the piston ring end gaps and side clearances must be verified for proper values prior to final assembly. These required specifications are listed in the "Table of Limits" section of the applicable TCM Overhaul manual and TCM service bulletin M8811 or current revision as applicable. Compliance with this service bulletin is covered by the TCM Gold Medallion Warranty Policy, subject to its terms and conditions.

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NONE

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB94-2

Compliance Will Enhance Safety

Supersedes M87-7 FAA APPROVED

SUBJECT:

OIL FILTER ADAPTER MOUNTING STUD

PURPOSE:

To announce parts availability and to provide inspection and replacement instructions for new oil filter adapter studs. The new 653489 and 653490 oil filter adapter studs utilize an incomplete thread that provides a positive mechanical stop to prevent the stud from being installed or moving too deep in the adapter housing.

COMPLIANCE:

Replacement of the oil filter adapter stud P/N 632373 with P/N 653489 or P/N 653490, as applicable, is required when: 1. The stud is found to be loose or installed beyond the stud setting height limits set forth in this service bulletin; or 2. The oil filter adapter is removed from the engine; or 3. The engine is overhauled.

MODELS AFFECTED:

ALL IO346, IO360, L/TSIO360, O470, IO470, IO520, TSIO520, GTSIO520, IO550, TSIO550 AND TSIOL550 engines that incorporate TCM supplied oil filter adapter housings.

Engines and adapters that were purchased from TCM after December 2, 1993 are in compliance with this service bulletin. Verification of compliance can be determined by the "S" stamped in the adapter housing. TCM has received field reports that the oil filter mounting stud on the oil filter adapter housing of some engines have become loose allowing the stud to screw into the housing and provide less than the specified stud extension. To correct this situation, TCM has incorporated new design oil filter mounting studs. These studs are designed with an incomplete thread which ensures proper installation depth by providing a positive mechanical stop. The IO360 and L/TSIO360 model engines will now utilize the new P/N 653489 mounting stud. This stud is yellow chromate treated and can be identified by its gold color and length of 1.160". All other affected engine models will use the new P/N 653490 mounting stud that is black in color and has a length of 1.420". NOTE . . . The installation of the P/N 653489 and P/N 653490 studs can be verified by an "S" stamped in the adapter housing. See Figure 2. The P/N 632373 mounting stud that is to be replaced has a plain steel color and has a length of 1.440".

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

INSPECTION AND REPLACEMENT INSTRUCTIONS 2.

At the next and each subsequent oil filter change interval, remove the oil filter and inspect the oil filter adapter mounting stud for security and proper setting height of .500" to .700" as indicated in Figure 1. NOTE . . . Each time a used filter is removed, inspect for foreign material. Using the Champion CT-470 "Oil Filter Can Cutter", open the used oil filter and remove the pleated paper from the center tube. Inspect between the folds for metal particles. WARNING . . . A large amount of metal is an indication of excessive wear and/or impending failure and must be investigated to determine the source and must be corrected before further flight.

FIGURE 1 2.

When the stud requires replacement as directed by the "COMPLIANCE" set forth above, proceed as follows.

3.

Remove the old stud P/N 632373 and inspect the threads in the adapter housing for damage. Replace the adapter housing assembly if any thread damage is evident.

4.

Clean the adapter housing threads thoroughly to remove any remaining thread adhesive and oil.

5.

Install the applicable new stud (P/N 653489 or P/N 653490, see above) and confirm that the incomplete thread on the stud stops at the first thread in the adapter housing and does not continue into the housing below the minimum .500" extension. See Figure 1. Replace the adapter housing assembly if the extension is less than the .500" minimum.

6.

After checking for the proper extension height, remove the stud from the adapter. Clean the threads of the adapter housing and stud with Loctite "Primer T" (TCM P/N 646944) and allow to dry.

7.

Apply a line of Loctite "271" (TCM P/N 646941) along the large threads (.8125-16) of the stud and install into the adapter finger tight to 30 in/lbs of torque. Check for proper stud extension length per Figure 1.

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FIGURE 2

8.

Stamp a .125 inch high "S" in the location indicated in Figure 2 and allow the parts to cure for a minimum of 30 minutes prior to installing the filter.

9.

Make a log book entry showing compliance with this service bulletin.

Warranty action required to comply with this bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. OIL FILTER INSTALLATION 1.

Check oil sump for proper oil level.

2.

Lubricate the oil filter gasket with a thin film of Dow Corning 4 (DC 4) Compound.

3.

Torque the filter to 16 - 18 ft/lbs.

4.

Run the engine until operating temperatures are reached. Shut down the engine and check for leaks. All oil leaks must be eliminated before further flight.

5.

Check oil sump for proper oil level and safety wire the oil filter.

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AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB94-3A

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

INDUCTION SYSTEM HOSE AND CLAMP REPLACEMENT

PURPOSE:

Field reports indicate that there have been isolated instances of the P/N 642917-2 induction hose detaching from the induction tube due to improper positioning by maintenance personnel. Therefore, we have superseded the hoses and clamps with ones that have an increased length to improve the coupling of the induction system. WARNING . . . Loss of induction system coupling will result in a loss of turbo boost and subsequent loss of engine power.

COMPLIANCE:

MODELS AFFECTED:

Within the next 100 hours of operation from the date of issuance of this bulletin or next annual inspection, which ever occurs first. The following TCM Factory New and Rebuilt were assembled in compliance with this service bulletin: TSIO-520-BE TSIO-550-A TSIO-550-B TSIO-550-C

(NEW) (REBUILT) (NEW) (NEW) (NEW)

Serial # 528522 and subsequent. Serial # 273762-R and subsequent. Serial # 801017 and subsequent. Serial # 802054 and subsequent. Serial # 802513 and subsequent.

All rebuilt TSIO-550-A, B and C model engines built after February15, 1994 were assembled in compliance with this service bulletin. INSPECTION INSTRUCTIONS

1. Remove engine cowling and components necessary to gain access to the hoses and clamps that secure the left and right induction tubes located between the turbocharger compressor outlet and aftercooler inlet. See Figure 1. Reference the applicable airframe manufacturer's maintenance manual for cowling and component removal and installation instructions. 2. Measure the four hoses and clamps and record their lengths. The old P/N 642917-2 hose has a length of 2.440 to 2.560 inches. The new P/N 642917-4 hose has a length of 2.940 to 3.060 inches. The old P/N 629163-5 clamp has a length of 1.870 to 1.890 inches. The new P/N 629163-7 clamp has a length of 2.370 to 2.390 inches. 3. Any of the four subject hoses or clamps that do not conform to the "new" hose and clamp dimensions listed in paragraph 2 must be replaced.

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23

95

P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 2 SB94-3A

A

REPLACEMENT INSTRUCTIONS The following instructions must be accomplished on both the left and right induction tube hoses and clamps located between the turbocharger compressor outlet and aftercooler inlet. See Figure 1. 1. Loosen the worm screws on each clamp. 2. Position the hoses on the induction tube to facilitate the removal of the induction tube. Remove the induction tube and discard the old hoses, clamps and heat shield. 3. Clean the turbocharger compressor outlet, aftercooler inlet and induction tube with stoddard solvent and wipe clean with a dry cloth. 4. Install the new hoses P/N 642917-4, clamps P/N 629163-7 and heat shield P/N 646568 onto the induction tube. 5. Properly position the induction tube between turbocharger compressor outlet and the aftercooler inlet. 6. Position the hoses evenly on the parts to be coupled so that the space between the induction tube, turbocharger compressor outlet and aftercooler inlet is located in the center of the hose length. Properly position the heat shield. 7. Tighten each clamp evenly and torque to 35 to 45 inch pounds to insure positive sealing and retention of the hose. DO NOT over torque the clamp as this can result in damage to the clamp and/or hose. 8. Reinstall components and cowling that were removed, in accordance with the applicable airframe manufacturer's maintenance manual. Make a log book entry as to compliance with this service bulletin. Warranty action required to comply with this bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims must be filed through a TCM Distributor.

ISSUED MO

DAY

03

16

REVISED YEAR 94

TELEDYNE CONTINENTAL MOTORS

MO

DAY

YEAR

05

23

95

P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

2 of 2 SB94-3A

A

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Contains Useful Information Pertaining To Your Aircraft Engines’ Service Documents

CATEGORY 5

SB94-7 FAA APPROVED

SUBJECT:

CHRANKSHAFT FLANGE TIMING MARKS

PURPOSE:

TCM Quality Assurance has identified a small number of crankshafts that were marked with incorrect timing marks that must be removed to prevent magneto timing from being set with reference to these marks. Magneto timing that is set utilizing these incorrect marks will advance timing by a maximum of three degrees. WARNING Engines that are operated with advanced timing exhibit higher than normal oil and cylinder head temperature and have a reduced margin of safety from detonation! Engines that are manufactured by TCM have magneto timing set by the use of a timing disc and top dead center locator as required in TCM Service Bulletin SB94-8. However, it is required that the affected engines and service crankshafts listed below are inspected for correct magneto timing and the incorrect timing marks removed. This bulletin provides inspection and rework instructions for these crankshafts.

COMPLIANCE:

MODELS AFFECTED:

The inspection portion of this bulletin is required within the next 25 hours of operation on engines that contain affected crankshafts to verify correct magneto to engine timing. The rework procedures are required no later than the next annual or 100 hour inspection. O-470-J, K, L, M R, S & U. IO-470-D, E, F, J, K, M, S, U & V. IO-520-A, D, E, F, J, K & L. TSIO-520-AF, C, G, H, M, P, R, & T. Service crankshaft assembly part numbers 649133, 649134, 649135, 649138, 649141 and 652039 that were shipped from TCM on June 7, 1994 through July 13, 1994, identified with serial numbers F079401N through F209406N are affected. The crankshaft assembly part number is not identified on the crankshaft. The crankshaft serial number is located on the crankshaft flange, adjacent to the timing marks.

MO 09

ISSUED DAY YEAR 14

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 4

The following engines must be inspected and have the timing marks removed utilizing the procedures set forth in this service bulletin: ENGINE ...................

SERIAL NUMBER

O-470-L ....................

069797-R, 069798-R

O-470-R ...................

288234-R thru 288238-R, 288247-R.

O-470-S....................

269302-R.

O-470-U ...................

286846-R, 286847-R.

IO-470-V...................

171096-R, 171097-R.

IO-520-A...................

112716-R.

IO-520-D ..................

293050-R thru 293055-R, 293057-R thru 293059-R, 293061-R, 293066-R, 293078-R.

IO-520-F...................

291201-R, 291202-R, 291204-R, 291205-R, 291208-R, 291209-R, 291212-R, 291216-R, 291217-R.

IO-520-L ...................

294518-R thru 294521-R, 294524-R.

TSIO-520-C..............

178429-R, 178432-R.

TSIO-520-G..............

216045-R.

TSIO-520-H..............

217316-R.

TSIO-520-M .............

291572-R thru 291575-R, 291578-R.

TSIO-520-P ..............

278680-R, 278683-R.

TSIO-520-R..............

293522-R, 293524-R, 293526-R, 293528-R, 293531-R, 293536-R, 293537-R, 293539-R.

TSIO-520-T ..............

239405-R.

INSPECTION PROCEDURE 1.

Affected crankshafts and engines listed above must have the correct magneto to engine timing verified within the next 25 hours of operation. The timing must be verified by using the procedure prescribed in TCM Service Bulletin SB94-8. If affected service crankshafts have not been assembled in an engine, remove the timing marks as instructed in the "REWORK INSTRUCTIONS" set forth in this bulletin.

REWORK INSTRUCTIONS 1.

Remove the propeller and associated parts to gain access to the crankshaft flange timing marks.

2.

Correct crankshaft flange timing marks are illustrated in Figure 1. If the crankshaft is marked correctly, verify magneto timing and make a log book entry as to compliance with this service bulletin.

3.

If incorrect crankshaft flange timing marks are found as illustrated in Figure 2, proceed as follows.

4.

Remove degree numbers and marks by buffing with 180 grit emery cloth. Do not remove the TC mark. Maximum depth of buffing is .002 inch. Buffed area must be smooth with no sharp edges.

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5.

Apply a thin film of aluminum color, enamel spray paint to the buffed area. Allow sufficient time for the paint to dry. Reworked crankshaft flange timing marks will appear as illustrated in Figure 3.

6.

Install the propeller and associated parts in accordance with the airframe manufacturers instructions.

7.

Verify and set magneto timing as indicated in TCM Service Bulletin SB94-8.

8.

Make a log book entry as to compliance with this service bulletin.

Warranty action required to comply with this bulletin is covered by the TCM Gold Medallion Warranty, subject to its terms and conditions. Warranty claims may be filed through any TCM Distributor.

MO 09

ISSUED DAY YEAR 14

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PAGE NO REVISION

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB95-2

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

INSPECTION AND MAINTENANCE OF ENGINE CONTROL CABLES AND LINKAGE.

PURPOSE:

TCM has received reports and examined damaged components of fuel systems. These components consist of linkage and levers used on the throttle and fuel control, fuel pumps, carburetors and related assemblies. Our examination revealed that this damage is caused by lack of lubrication and/or improper installation or maintenance of these components. Therefore, it is required that the inspection and maintenance instructions set forth in this service bulletin be complied with at the specified intervals. The following instructions are general guidelines which are intended for all TCM model engines. WARNING FAILURE TO COMPLY WITH THE INSTRUCTIONS SET FORTH IN THIS SERVICE BULLETIN CAN RESULT IN FUEL SYSTEM LINKAGE AND/OR RELATED COMPONENT DAMAGE AND SUBSEQUENT LOSS OF ENGINE POWER.

COMPLIANCE:

1. At the next and each subsequent 100 hour, progressive and/or annual inspection. 2. Anytime a lever/linkage actuated component of the fuel system is removed, adjusted or cleaned.

MODELS AFFECTED:

All TCM engine models.

INSPECTION PROCEDURE The correct installation and maintenance of engine control cable attaching hardware and fuel system component levers and linkages cannot be overemphasized. The use of specified attachment procedures is required to assure proper operation and to prevent abnormal wear. 1. Inspect the operation of each engine related control, including the throttle, mixture, propeller, carburetor heat and alternate air controls as applicable. Make certain that each control has full limit of travel and that no binding or excessive play caused by worn parts or improper installation is evident. 2. Inspect all engine control cables for proper routing and security as specified in the applicable airframe manufacturer's instructions. Inspect cables for signs of damage or wear that can be caused by chafing and heat distress.

MO 04

ISSUED DAY YEAR 21

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MO

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PAGE NO REVISION

1 of 4 SB95-2

3. Replace all control cables, levers, link rods and attaching hardware that are found to be damaged or worn. Engine related levers, link rods and attaching hardware must be installed in accordance with the instructions provided in the applicable engine overhaul manual. Consult the airframe manufacturer and/or their published instructions for routing and attachment of the various engine related control cables. WARNING CONNECTIONS REQUIRING TORQUED FASTENERS MUST NOT EXHIBIT ANY MOVEMENT OR MOTION BETWEEN COMPONENTS. SUCH MOVEMENT MAY CAUSE ABNORMAL WEAR RESULTING IN COMPONENT MALFUNCTION OR FAILURE AND SUBSEQUENT LOSS OF POWER. CONTROL LUBRICATION Damage and wear to the actuating components of engine control systems can be attributed to improper (or the lack of) lubrication. During scheduled and unscheduled maintenance, engines are normally cleaned using a solvent or soap solution pressure wash. This tends to remove lubrication from fuel system levers, linkages and bushings. Therefore, it is necessary that these areas be lubricated after engine cleaning and during scheduled maintenance as follows: 1. Inspect the pivot points of the levers and linkages for dirt, wear and rust. Replace any component found to exhibit damage or abnormal wear. See Figures 1 and 2. Direct cleaning of these areas may be necessary to remove contamination and/or a buildup of old grease or oil. After cleaning with clean solvent or soap solution, dry each area using compressed air. 2. Apply LPS 2, PERMATEX "Maintain" Lubricant or equivalent to each pivot point, including throttle shaft bushings. If parts such as a lever or link rod are to be replaced or reassembled, initial lubrication must be accomplished using SHELL #5 grease or LUBRIPLATE #630AA or equivalent. 3. Consult the airframe manufacturer and/or their published instructions concerning aircraft engine control cable attach point inspection, repair, installation and lubrication. After proper installation and lubrication have been accomplished, verify that: a. Each control has full limit of travel and that the required safeties are in place; b. No binding of levers or linkages occurs; and c. Control movement is unrestricted by contact with other parts or components that are located in close proximity. Check fuel system flow (after fuel system component and linkage installation) and adjust as required in accordance with TCM Service Bulletin M89-10 or current revision as applicable.

WARRANTY COVERAGE Not applicable.

MO 04

ISSUED DAY YEAR 21

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MO 04

ISSUED DAY YEAR 21

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MO 04

ISSUED DAY YEAR 21

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PAGE NO REVISION

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety

SUBJECT: INSPECTION

ALTERNATOR/GENERATOR DRIVE COUPLING

CATEGORY 3

SB95-3B TECHNICAL PORTIONS ARE FAA APPROVED

PURPOSE:

Field reports and inspection of coupling assemblies have revealed parts that are severely worn or damaged. This bulletin requires inspection of affected alternator couplings to preclude the possibility of coupling failure.

COMPLIANCE:

Alternator/generator drive couplings used on the affected engines with more than 500 hours total time in service must be inspected in accordance with the instructions set forth in this bulletin within the next 25 hours of operation and every 500 hours thereafter. Affected drive coupling assemblies with less than 500 hours total time in service must be inspected upon the accumulation of 500 hours and every 500 hours thereafter.

MODELS AFFECTED:

All C-75, C-85, C-90, C-115, C-125, C-145, E-165, E-185, E-225, O-200, O-300, GO-300, GIO-300, IO-240, IO-360, TSIO-360 and LTSIO-360 model engines that utilize alternator/generator drive couplings described in this bulletin.

A. INSPECTION OF COUPLING ASSEMBLY - SEE FIGURE 1. 1. Remove engine cowling and other airframe components as necessary to allow the removal of the alternator or generator. 2. Remove the alternator or generator and discard the gasket and attaching hardware. 3. Identify the type of drive coupling that is installed on the alternator or generator. See Figures 1 and 2. If one piece coupling P/N 635796 (see Figure 2) is installed, refer to section B for inspection and testing of one piece coupling. If coupling assembly (see Figure 1) is installed, proceed as follows. 4. Remove P/N MS24665-151 cotter pin and discard. Mount the alternator coupling gear in the protected jaws of a vise, only tight enough to loosen and remove P/N 530412 nut. 5. Remove coupling assembly parts 531325 gear, P/N 530407 sleeve, P/N 632050 bushings and 653982 retainer. Do not remove P/N 653983 hub unless replacement is required. Discard bushings and retainer. Inspect nut, gear and sleeve for wear and damage and replace if necessary.

MO 05

ISSUED DAY YEAR 10

95

MO 10

REVISED DAY YEAR 21

PAGE NO REVISION

1 of 3 SB95-3

05 P.O. Box 90 Mobile Alabama • 251-438-3411

© 2005 Teledyne Continental Motors, Inc.

B

NOTE: Certain applications call for the use of the P/N 626543 bushings. In those applications, the P/N 632050 bushings can be used as a substitution. However, the P/N 626543 bushings must NOT be used in those applications that specify the use of the P/N 632050 bushings. 6. Install new replacement P/N 653982 retainer and two P/N 632050 bushings into the P/N 653983 hub on the alternator shaft. Bushings must be installed as indicated in Figure 1. Install P/N 530407 sleeve, P/N 531325 gear and P/N 530412 nut. 7. Clamp the alternator and hub assembly gear into the protected vise jaws only tight enough the torque the nut. Torque the P/N 530412 nut to 175 inch pounds. Torque may be increased to a maximum of 200 inch pounds to align castellated nut with the cotter pin hole. If alignment cannot be achieved with torque between 175 - 200 inch pounds, replace nut. Do not over or under torque! Install new P/N MS24665-151 cotter pin and secure in accordance with TCM Service Information Letter SIL93-15 or current revision as applicable. 8. Reinstall alternator/generator using new gasket and specified attaching hardware. Torque attaching nuts to 180 - 220 inch pounds. 9. Reattach airframe components and cowling in accordance with the airframe manufacturer's instructions. Perform a leak check run on the engine and repair any leaks prior to returning the aircraft to service. 10. Make a log book entry, "Performed TCM Service Bulletin SB95-3B, compliance required again upon accumulation of 500 operating hours from this date." and return aircraft to service. B. INSPECTION AND TESTING OF ONE PIECE COUPLING - SEE FIGURE 2. The P/N 635796 single piece coupling is designed to slip when abnormal torque is required to rotate the alternator/generator. This can prevent internal engine damage in the event of an alternator/generator seizure. The one piece coupling may be substituted for the coupling assembly shown in Figure 1. Inspect the one piece coupling for shearing or tearing of the elastomeric (rubber) element. Replace coupling if damage is observed. The following test must be performed at engine overhaul or when slippage is suspected. 1. With the coupling removed from the alternator/generator, place the coupling body in the protected jaws of a vise. 2. Figure 3 provides necessary dimensions to produce a tool for checking coupling slippage torque. 3. Install the tool over the coupling gear and apply 100 inch pounds of torque. No slippage can occur at or below 100 inch pounds of torque. Replace couplings that fail this test. 4. Install serviceable or replacement couplings in accordance with section A, paragraphs 7, 8 and 9. WARRANTY: None.

MO 05

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MO 10

REVISED DAY YEAR 21

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05 P.O. Box 90 Mobile Alabama • 251-438-3411

B

653982 RETAINER

653983 HUB

FIGURE 1

FIGURE 2

FIGURE 3

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REVISED DAY YEAR 21

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3 of 3 SB95-3

05 P.O. Box 90 Mobile Alabama • 251-438-3411

B

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB95-7

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

MANIFOLD VALVE COVER INSPECTION

PURPOSE:

To provide inspection and rework procedures for Teledyne Continental Motors fuel manifold valves. The INSPECTION INSTRUCTIONS contained in this service bulletin must be included as a part of routine inspection and maintenance of all TCM fuel injected engine models. A copy of this bulletin must be inserted into the TCM Fuel Injection Overhaul Manual Form # X30593 to indicate the current manifold valve attaching hardware and installation procedures. WARNING FAILURE TO IDENTIFY AND CORRECT FUEL SYSTEM LEAKS CAN RESULT IN LOSS OF ENGINE POWER AND/OR ENGINE COMPARTMENT FIRE.

COMPLIANCE: 1. At each scheduled maintenance interval or whenever fuel flow fluctuation is encountered, inspect the fuel manifold valve in accordance with the INSPECTION INSTRUCTIONS set forth in this service bulletin. 2. If evidence of fuel leakage is observed at the manifold valve cover, prior to further flight, rework the manifold valve in accordance with the REWORK INSTRUCTIONS set forth in this service bulletin. MODELS AFFECTED:

All TCM fuel injected engine models.

INSPECTION INSTRUCTIONS 1. With engine cowling removed as instructed by the aircraft manufacturer, inspect the fuel manifold valve (and all other fuel system components) for signs of fuel stains. WARNING STAND CLEAR OF THE PROPELLER ARC WHILE PERFORMING THE FOLLOWING INSPECTION. 2. Pressurize and inspect the engine fuel system as follows: a. Aircraft fuel selector .. ON. b. Mixture control ......... FULL RICH. c. Throttle control ........ FULL OPEN. d. Aircraft master switch .. ON.

MO 12

ISSUED DAY YEAR 08

95

MO

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PAGE NO REVISION

1 of 3 SB95-7

e. Place a suitable container under the induction system drain(s). f.

While additional personnel observes the fuel manifold valve, (and all other fuel system components) engage the aircraft fuel boost pump for 5 seconds and verify fuel flow indication on the aircraft fuel flow gage.

g. Inspect all fuel system components and lines for leaks. h. Repair fuel leaks prior to further flight. If fuel leakage is noted at the manifold valve cover to body mating surfaces, perform the following rework procedure. REWORK PROCEDURE Parts required for the upright and inverted valves are listed in Figures 1 and 2. 1. UPRIGHT VALVES - See Figure 1. a. Remove manifold valve cover safety wire. b. Remove one screw and discard. c. Install one set of attaching hardware as indicated in Figure 1. Torque to 22 to 26 inch pounds. d. Repeat steps b and c replacing the attaching hardware in a crisscross pattern until all four sets have been replaced. e. Safety wire using approved practices outlined in TCM Service Bulletin SIL93-15 or current revision as applicable. 2. INVERTED VALVES - See Figure 2. a. Aircraft fuel selector valve - OFF. b. Disconnect fuel manifold valve vent line, fuel inlet line, gage reference line (where used) and nozzle distribution lines. Remove manifold valve from engine and retain attaching hardware. c. Remove manifold valve mounting bracket/cover safety wire. d. Remove one screw and discard. e. Install one set of attaching hardware as indicated in Figure 2. Torque to 22 to 26 inch pounds. f.

Repeat steps d and e replacing the attaching hardware in a crisscross pattern until all four sets have been replaced.

g. Safety wire using approved practices outlined in TCM Service Bulletin SIL93-15 or current revision as applicable. h. Reinstall manifold valve, attaching hardware and fuel lines in the reverse order of their removal and torque to the values as indicated in TCM Service Bulletin M92-15 or current revision as applicable. 3. Check fuel system for leaks as set forth in the "INSPECTION INSTRUCTIONS" section of this bulletin. Warranty action required to comply with this service bulletin is covered by the Gold Medallion Warranty, subject to its terms and conditions.

MO 12

ISSUED DAY YEAR 08

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MO

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2 of 3 SB95-7

UPRIGHT VALVES FIGURE 1

INVERTED VALVES FIGURE 2 MO 12

ISSUED DAY YEAR 08

95

MO

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PAGE NO REVISION

3 of 3 SB95-7

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB96-11B

Compliance Will Enhance Safety

FAA APPROVED Supersedes SB96-11A, SB96-11, M84-16

SUBJECT:

PROPELLER STRIKES LOCKS.

AND

HYDRAULIC

PURPOSE:

PURPOSE: PART I: PROPELLER STRIKE INCIDENTS: Provides definition of propeller strike and foreign object damage (FOD), possible resulting damage that can occur from such incidents and required inspections and corrective actions mandated by TCM to return the engine to service. PART II: HYDRAULIC LOCK: Provides definition of hydraulic lock, the conditions that can lead to a hydraulic lock event, how to prevent it, and the inspection and corrective actions mandated by TCM to return the engine to service.

COMPLIANCE:

PART I: Anytime a propeller strike incident occurs, perform the inspections set forth in this Service Bulletin prior to further engine operation. PART II: As set forth in the instructions contained in PART II.

MODELS AFFECTED:

All Teledyne Continental Motors (TCM) engine models.

PART I - PROPELLER STRIKE INCIDENTS A propeller strike is: (1) any incident, whether or not the engine is operating, that requires repair to the propeller other than minor dressing of the blades as set forth in Part I, B of this Service Bulletin or (2) any incident while the engine is operating in which the propeller makes contact with any object that results in a loss of engine RPM. Propeller strikes against the ground or any object, can cause engine and component damage even though the propeller may continue to rotate. This damage can result in catastrophic engine failure. A. PROPELLER STRIKE INSPECTIONS. Following any propeller strike, complete disassembly and inspection of all rotating engine components is mandatory and must be accomplished prior to further flight. Inspect all engine driven accessories in accordance with the manufacturer’s maintenance instructions. Prior to any ground operation of the engine assure that the propeller flange and the crankshaft flange area are free of any crack indications. In addition to the engine component inspection MO 09

ISSUED DAY YEAR 10

96

MO 07

REVISED DAY YEAR 07

2008

PAGE NO REVISION

1 of 5 SB96-11 P.O. Box 90 Mobile Alabama • 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

B

requirements set forth in the appropriate overhaul manual, the following inspection procedures must be accomplished: 1. The crankshaft must be inspected by magnetic particle inspection. All crankshaft surfaces must be cleaned free of sludge, paint or any other substance that could mask reliable magnetic particle inspection indications. 2. Connecting rods, gears, and all other steel internal engine parts must be magnetic particle inspected. 3. The crankcase must be stripped and fluorescent penetrant inspection performed, paying particular attention to the forward crankcase bearing support and adjacent structure. 4. Connecting rod bolts and nuts must be replaced regardless of condition. 5. On counterweight equipped engines, replacement of all counterweight pins, bushings, end plates and snap rings is required regardless of their condition. Counterweight bushing bores in both counterweights and crankshaft must be inspected in accordance with the criteria contained in the latest revision of SB00-3. 6. Inspect all engine-driven accessories in accordance with the accessory manufacturer's instructions.

B. MINOR FOREIGN OBJECT DAMAGE (FOD) INSPECTION. For instances where the propeller is damaged by a small foreign object during operation, such as a small stone, inspection and repair must be accomplished in accordance with the propeller manufacturer's published instructions. Any time foreign object damage requires propeller removal for repairs other than minor dressing of the blades the incident is considered a propeller strike and must be inspected as outlined in paragraph “A” above.

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96

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REVISED DAY YEAR 07

2008

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2 of 5 SB96-11 P.O. Box 90 Mobile Alabama • 251-438-3411

B

PART II - HYDRAULIC LOCK

WARNING OVER PRIMING CAN CAUSE A FLOODED INTAKE RESULTING IN A "HYDRAULIC LOCK" EVENT AND SUBSEQUENT ENGINE MALFUNCTION OR FAILURE. IF YOU OVER PRIME, OR FLOOD YOUR ENGINE, MAKE CERTAIN THAT ALL FUEL HAS DRAINED FROM THE INTAKE MANIFOLD AND/OR CYLINDER PRIOR TO ATTEMPTING ENGINE STARTING. WARNING MODIFICATION OF OR DEVIATION FROM THE ORIGINAL INTAKE MANIFOLD DESIGN MAY RESULT IN INSUFFICIENT DRAINAGE OF THE INTAKE MANIFOLD, RESULTING IN AN INCREASED POTENTIAL FOR HYDRAULIC LOCK. ALL INTAKE MANIFOLD DRAINS MUST BE PROPERLY PLACED, AND OPERATIONAL. A. GENERAL INFORMATION Hydraulic lock is defined as a condition in which a volume of liquid, equal to or greater than the clearance volume of the combustion chamber, is drawn into the cylinder during starting. This liquid, being incompressible, restricts piston travel during the compression stroke. Damage only occurs after the preceding cylinder or cylinders in the firing order have fired, thereby providing the required force to drive the piston of the fluid filled cylinder through the compression stroke. Most hydraulic lock events in horizontally opposed aircraft engines are due to fuel accumulation in the induction system and/or cylinder assembly and usually occur in one of the forward cylinders. Over priming prior to or during engine starting will allow fuel to accumulate in the induction system or cylinder faster than the system drains can evacuate it. Other causes of hydraulic lock can be attributed to: 1. Restricted or clogged induction system drains or cylinder intake port drain(s). 2. Extended operation of the electric boost pump: a. During failed engine start. b. Following loss of power during ground operation. c. Following momentary engine shutdown. d. During single engine operation for training purposes on twin engine aircraft. 3. Over priming and attempting engine start with the aircraft parked on an incline that negates the effective operation of the drain system. 4. A failure to drain oil from cylinders that have been preserved.

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REVISED DAY YEAR 07

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B

Damage from a hydraulic lock can be extensive. Engine components such as connecting rods, cylinder assemblies, pistons, piston pins, crankcase and crankshaft can be damaged due to the extreme stress. Subsequent failure of these components can occur if the instructions set forth in this service bulletin are not followed. B. PRECAUTIONS PRIOR TO AND DURING STARTING 1. Owners, operators and maintenance personnel must become familiar with the type, operation, total number and location(s) of the fuel drain(s). This information is provided in the Aircraft Manufacturer's or STC holder's Maintenance and/or Flight Manual. NOTE:

Verify that the boost pump switch(es) are in the "OFF" position prior to turning the master switch on.

Each time the engine is manually primed, or the electric boost pump is energized for fuel system leak check or for priming before or during engine start, observe the following precautions: a. Fuel priming must be accomplished in accordance with the instructions specified by the Aircraft Manufacturer or STC holder and only with a properly functioning drain system. b. Prime and start engine(s) while the aircraft is positioned on a level surface. c. Prime only as long as required to achieve a stabilized fuel flow or pressure indication and in no case exceed the Aircraft Manufacturer or STC holder's limitations. d. If prolonged priming or inadvertent operation of the boost pump has occurred, verify visually that fuel is running from the system drains. Starting must not be attempted until all fuel has drained from the induction system. e. If fuel draining is not noticed during priming, discontinue priming and remove, repair or replace drain(s), associated hoses and hardware in accordance with the Aircraft Manufacturer's instructions. Make certain that the system drains are functioning properly and that fuel drains from the system prior to engaging the starter. 2. If the engine has been in storage and/or preserved, drain all preservative oil in accordance with the latest revision of the TCM Service Bulletin concerning engine preservation prior to engine operation.

C. SYSTEM DRAIN INSPECTION At each scheduled maintenance interval, perform the following inspection to ensure that the drain(s) function properly:

WARNING DO NOT ROTATE THE PROPELLER OR ALLOW ANY PERSONNEL TO STAND IN THE AREA OF THE PROPELLER ARC WHILE PERFORMING THE FOLLOWING INSPECTION. 1. Perform a normal engine start priming sequence in accordance with the Aircraft Manufacturer or STC holder's instructions.

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2. Observe the drain location(s) in the engine cowling and make certain that fuel drains from each. NOTE:

On some installations, drains are located in the induction system where fuel draining will not be observed during priming. In this case, the drain must be inspected as necessary to determine that it is functioning properly.

3. Remove, clean or replace any drain that does not function properly. D. INDICATIONS OF POSSIBLE HYDRAULIC LOCK In the event the operator starts an over-primed/flooded engine, hydraulic lock may result. Indications of hydraulic lock are difficult to detect since the engine will not normally exhibit any unusual operation once the fuel-air mixture stabilizes. Therefore, the operator must be cognizant of the fact that a hydraulic lock can occur anytime an attempt to start an overprimed/flooded engine occurs. In the event that the operator starts an over-primed/flooded engine or suspects a hydraulic lock has occurred, he must make certain that the inspection procedures in Section E are followed.

E. INSPECTION PROCEDURES FOR SUSPECTED HYDRAULIC LOCK. In the event of a suspected hydraulic lock, perform the following inspection: 1. Remove all cylinders and connecting rods in accordance with the applicable TCM Overhaul Manual. Inspect the connecting rods in accordance with applicable TCM Overhaul Manual. 2. If all rods meet the criteria specified by TCM, reassemble the engine in accordance with the overhaul manual. 3. If any connecting rod does not meet TCM acceptance criteria, remove and disassemble the engine to allow inspection of the crankcase and crankshaft in accordance with the applicable TCM Overhaul Manual. Replace any part that does not meet Overhaul Manual inspection criteria. Replace each non-conforming connecting rod and its associated piston, piston pin and cylinder assembly. NOTE: Any parts that require replacement must be destroyed to prevent future installation. 4. Reassemble the engine in accordance with the applicable TCM Overhaul Manual and return the aircraft to service.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB96-12

Compliance Will Enhance Safety

FAA APPROVED Supersedes M89-17

SUBJECT:

CONTINUED CYLINDERS.

AIRWORTHINESS

INSTRUCTIONS

FOR

TCM

PURPOSE:

In addition to the instructions provided in TCM Overhaul Manuals, Maintenance Manuals and Service Bulletins, TCM has established the following inspection criteria to assist in achieving the optimum service life from cylinder assemblies. Cylinder cores received from the field often exhibit non-TCM approved repairs, external damage and maintenance neglect which can cause a reduction in service life with possible catastrophic results. Compliance with this Service Bulletin will help identify and prevent conditions, repairs, misuse and damage to cylinders which are known to adversely affect cylinder airworthiness. This Service Bulletin requires removal from service any cylinder that exhibits unauthorized repairs or types of damage described in this Service Bulletin.

COMPLIANCE:

PART I - At the next scheduled maintenance interval and then at each subsequent annual inspection thereafter, inspect each cylinder as set forth in PART I. PART II - Each time a cylinder is removed for engine or cylinder overhaul, the inspection instructions set forth in PART II must be accomplished in addition to the requirements provided in the applicable TCM Service Bulletins, Maintenance and Overhaul Manuals.

MODELS AFFECTED:

All TCM engine models.

PART I - ANNUAL INSPECTION REQUIREMENTS. Each annual inspection must include the following inspection procedures which will help identify internal or external structural discrepancies developing or present in the cylinder assembly. They consist of: (A) VISUAL INSPECTION, (B) COMPRESSION CHECK, and (C) LEAK CHECK. After inspection is completed and appropriate corrective action (as required) has been accomplished, make a log book entry as to compliance with this Service Bulletin. A. VISUAL INSPECTION 1. An external inspection of each cylinder assembly will help identify conditions that could progress to the point of adversely affecting the airworthiness of the cylinder. Remove the cowling and inspect the cylinder barrels and cylinder heads as outlined below. It should not be necessary to remove the induction system, exhaust system or inter-cylinder baffles for purposes of this inspection. Prior to any cleaning of the engine, carefully inspect each cylinder assembly as follows:

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a. Cylinder Barrel.Using an inspection light and mirror, thoroughly inspect the cylinder barrel including the cylinder barrel fins and the areas between and adjacent to the fins for cracks, sharp indentations, chafing damage and pitting. This visual inspection must include a detailed external inspection of the areas of the cylinder barrel which experience the highest operational stresses from the power stroke of the piston. These areas are the 12 o'clock area of the first six fins below the head on one side of the engine, and the 6 o'clock area on the other side as described in Figure 1. In addition, inspect for any signs of leakage of oil, fuel, soot or any condition that could indicate that the integrity of the cylinder or the head-tobarrel junction has been breached. See Table I, item 5 "NOTE" for exception. IF ANY OF THE CONDITIONS DESCRIBED ABOVE ARE FOUND, SEE TABLE I FOR REPAIR OR REPLACEMENT INSTRUCTIONS. b. Cylinder Head.Inspect the external surfaces of the cylinder head including the cylinder head fins, intake and exhaust ports, top and bottom spark plug bosses and fuel nozzle boss. Inspect for cracks, exhaust flange leakage or any signs of leakage of oil, fuel, soot or any conditions that could indicate that structural integrity of the cylinder or the head-to-barrel junction has been breached. IF ANY OF THE CONDITIONS DESCRIBED ABOVE ARE FOUND, SEE TABLE I FOR REPAIR OR REPLACEMENT INSTRUCTIONS. c. Inter-cylinder and peripheral baffling. Carefully inspect all inter-cylinder and peripheral baffling for correct installation, proper positioning, deterioration, chafing and missing or broken sections. CORRECT OR REPLACE ANY DISCREPANT BAFFLING. d. Liquid cooled cylinders. In addition to a, b and c above, as applicable, inspect cylinder head cooling jacket for leaks. 2. Thoroughly wash the entire engine with an approved cleaning solution and repeat the visual inspection outlined above. WARNING USE EXTREME CAUTION IN THE PROPELLER AREA WHILE PERFORMING THE FOLLOWING INSPECTION. VERIFY THAT THE MAGNETOS ARE GROUNDED TO PREVENT IGNITION. REMOVE ALL SPARK PLUG LEADS. B. COMPRESSION CHECK 1. Perform a compression check in accordance with the latest instructions in the TCM Service Bulletin concerning cylinder compression leakage check. This procedure and appropriate follow-up, will help make an early identification of internal conditions which may affect the airworthiness of each cylinder. C. LEAK CHECK Many repair stations have already made this simple test part of their routine cylinder compression check. This check serves as an identifier for conditions which may not be detectable by visual inspection and also serves as a back-up for conditions which maybe difficult to detect because of visual limitations. It can be accomplished in a relatively short amount of time and can identify conditions affecting airworthiness.

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1. With the compression tester connected, apply 5 PSI to the cylinder. 2. Position the piston as close to bottom dead center on the compression stroke as possible, ensuring that the intake valve remains closed to allow the cylinder to hold pressure. WARNING IT WILL BE NECESSARY TO HOLD THE PROPELLER STATIONARY WHILE PRESSURE IS APPLIED TO THE CYLINDER. USE EXTREME CAUTION TO PREVENT INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. 3. Increase the pressure slowly to a maximum value of 80 PSI. Saturate the entire cylinder assembly with a soap and water solution. 4. Inspect the complete cylinder for leakage. Leakage will be indicated by an accumulation of bubbles. 5. After complete cylinder inspection, relieve cylinder pressure and remove compression tester. 6. Perform this inspection on each cylinder. ANY CYLINDER THAT EXHIBITS EXTERNAL LEAKAGE FROM THE HEAD OR BARREL STRUCTURE MUST BE REPLACED PRIOR TO FURTHER ENGINE OPERATION. PART II - INSPECTION REQUIREMENTS FOR CYLINDERS REMOVED FROM THE ENGINE FOR OVERHAUL. In addition to the instructions set forth in the applicable TCM Overhaul Manual, and those set forth in PART I,A and PART I,C of this Service Bulletin, perform the following inspections as set forth below. The leak check (PART I,C) may be performed prior to removal of the cylinder(s) if desired. A. MAGNETIC PARTICLE AND FLUORESCENT PENETRANT INSPECTION 1. Clean the cylinder assembly thoroughly in accordance with the applicable TCM Overhaul Manual. WARNING BLASTING TECHNIQUES CAN BE EMPLOYED TO REMOVE HARD CARBON DEPOSITS IF SUITABLE EQUIPMENT IS AVAILABLE. SUITABLE TYPES OF GRIT FOR DRY BLASTING ARE PLASTIC PELLETS AND PROCESSED NATURAL MATERIALS, SUCH AS WHEAT GRAINS AND CRUSHED FRUIT PITS OR SHELLS. AIR PRESSURE SHOULD BE THE LOWEST THAT WILL PRODUCE THE DESIRED CLEANING ACTION. SMALL HOLES AND FINISHED SURFACES, WHICH DO NOT REQUIRE CLEANING, SHOULD BE PROTECTED FROM THE BLAST BY SEALS AND COVERS, PARTICULARLY IF THE GRIT IS SHARP. SAND, GLASS, SHOT AND METAL GRIT ARE TOO ABRASIVE AND TOO HEAVY FOR USE ON SOFT METALS LIKE ALUMINUM, AND MUST NOT BE USED. AFTER ANY BLASTING PROCESS, BLOW OFF ALL DUST WITH DRY COMPRESSED AIR AND MAKE SURE THAT NO GRIT HAS LODGED IN CREVICES, RECESSES AND HOLES. PARTS MAY ALSO BE CLEANED WITH HOT SOAPY WATER, THEN AIR DRIED WITH DRY COMPRESSED AIR. FAILURE TO CLEAN THE CYLINDER IN THIS MANNER COULD RESULT IN CYLINDER BORE DAMAGE DUE TO CONTAMINATION. MO 09

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2. Perform a magnetic particle inspection of the inner and outer surfaces of the cylinder barrel using circular and longitudinal magnetization. This inspection must be performed in accordance with ASTM Standards pertaining to non-destructive testing by a certified technician. 3. Perform a fluorescent penetrant inspection of the cylinder head in accordance with ASTM Standards pertaining to non-destructive testing by a certified technician. NOTE: Applicable ASTM Standards may be obtained from: American Society for Testing and Materials (ASTM) 1916 Race Street Philadelphia, PA 19103-1187 Telephone: (215) 299-5400 Fax: (215) 977-9679 4. Repair or replace any cylinder that exhibits damage in accordance with the instructions set forth in TABLE I. TABLE I - REPAIR AND REPLACEMENT INSTRUCTIONS After performing the inspection requirements set forth in PART I or PART II (as applicable), any cylinder found to exhibit the following conditions must be repaired or replaced in accordance with the following instructions: LOCATION

TYPE OF DAMAGE AND CORRECTIVE ACTION

1. Power Stroke Stress Area of the Cylinder Barrel - See Figure 1.

(a) Cracks, broken or bent fins, (including bent fins that have been straightened) pitting, sharp indentations and chafing damage that alter the original barrel surface contour or reduce the thickness of the barrel fins - CYLINDER REPLACEMENT IS REQUIRED, unless damage can be repaired as described in Item 2 (a) below.

2. Remaining Cylinder Barrel Fin Areas.

(a) Fin tips - Pitting, sharp indentations or chafing damage in the fin tip LESS than .050 inch deep - Remove only enough material to eliminate the damage with a small hand-held grinder and fine grit disk or stone, or by turning the cylinder on a lathe. PRECAUTIONS MUST BE TAKEN TO PREVENT DAMAGE TO ADJACENT FINS AND LOCALIZED FIN HEATING DURING THE MATERIAL REMOVAL PROCESS. Blend the area smooth so that no sharp edges remain and ensure that original fin contours remain. Inspect the area for cracks and if none are present, clean the surface and apply a protective coating of specified TCM enamel paint or equivalent. WARNING

DAMAGE OR REMOVAL OF EXTERNAL BARREL MATERIAL THAT RESULTS IN A REDUCTION OF THE BARREL WALL THICKNESS IS STRICTLY PROHIBITED REGARDLESS OF LOCATION AND REQUIRES CYLINDER REPLACEMENT.

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LOCATION

TYPE OF DAMAGE AND CORRECTIVE ACTION

(b) Bent fins - Cylinder may continue in use, provided that the fin is not bent more than one-half of the distance to the next fin and that no attempt is, or has been made to straighten the bent fin. If the bending is more than the distance indicated, or if an attempt has been made to straighten the bent fin, or it is not possible to determine that neither of these conditions has occurred, the cylinder must be removed for magnetic particle inspection. 3. All External Sur- (a) ELECTRICAL ARC PITTING OR WELD REPAIRS OF ANY SURFACE ON THE CYLINDER BARREL (INCLUDING THE FIN faces of the TIPS) IS STRICTLY PROHIBITED. If such conditions are present Cylinder Barrel. - CYLINDER REPLACEMENT IS REQUIRED. Remaining Cylinder Barrel Fin Areas. (continued)

(b) Discolored or burnt paint - Will require removal of the cylinder for inspection. This could indicate piston and piston pin scoring of the cylinder bore produced by an overheating condition and will require cylinder repair or replacement. (c) Surface corrosion and missing paint - Surface corrosion can in some cases lead to conditions which may be detrimental to cylinder service life. Exterior cylinder surfaces should be maintained in a condition free of surface corrosion. If surface corrosion is present it should be removed by polishing the affected surfaces to a smooth finish and a coating of the specified TCM paint (or equivalent) must be applied. WARNING DO NOT PAINT THE CYLINDER FLANGE NUT SEATS, SKIRT OR FLANGE TO CRANKCASE MATING SURFACE. (a) Except as noted in paragraph (c) below, any crack, other than minor cooling fin cracks that do not extend into the cylinder head structure, or heat checks in the exhaust port less than 1/8" in length - CYLINDER REPLACEMENT REQUIRED.

4. Cylinder Head

(b) Exhaust flange leakage - Replace exhaust flange gasket. If damage to the exhaust system or cylinder flange is found, repair or replace the damaged component prior to further engine operation. (c) Weld repair - Only minor non-structural weld repairs are permitted. TCM allows welding repairs of the intake and exhaust port flanges, rocker cover flange and threaded holes (other than spark plug) and requires that these repairs be performed under carefully controlled conditions. NO STRUCTURAL WELD REPAIRS ARE ALLOWED. TCM does not allow weld repairs to the combustion chamber, head structure and rocker shaft bosses - ANY CYLINDER HEAD THAT IS CRACKED OR DAMAGED in a structural area must be replaced.

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LOCATION

TYPE OF DAMAGE AND CORRECTIVE ACTION (d) Damaged studs - Replace studs in accordance with the applicable TCM Overhaul Manual.

Cylinder Head (continued)

(e) Damage to threaded bores - Repair threaded bores in accordance with the applicable TCM Overhaul Manual. (f)

5.

Cracked cooling jacket (liquid cooled cylinder) - CYLINDER REPLACEMENT IS REQUIRED.

(a) Air, fuel or oil leakage - CYLINDER REPLACEMENT IS REQUIRED. See Section C, LEAK CHECK.

Head to Barrel Junction

NOTE: During assembly of the cylinder head to barrel, a thread lubricant is used. This lubricant will normally leave a dark stain of dry/hard material and is not cause for cylinder replacement. However, if this stain is noted, the cylinder must be leak checked in accordance with section C to verify that the head to barrel junction has not been breached. RELATED SERVICE BULLETINS The latest revision of the following TCM Service Bulletins contain information concerning cylinder inspection and must be referenced to determine compliance requirements: M92-11

LIQUID COOLED CYLINDER ASSEMBLY SPARK PLUG AND SPARK PLUG HELICOIL.

M92-8

APPLICATION OF 4-1/16 INCH DIAMETER CYLINDER ASSEMBLIES.

M92-6

ROCKER SHAFT RETENTION IMPROVEMENT FOR INCLINED VALVE CYLINDER.

M92-4R1

IO & L/TSIO-360 ROCKER SHAFT STUD INSPECTION.

M91-7

CYLINDER BARREL ULTRASONIC INSPECTION.

M91-6

CYLINDER BARREL INSPECTION.

M90-5R1

CYLINDER BORE DIMENSIONS FOR 5 INCH AND 5-1/4 INCH CYLINDERS.

M84-15

CYLINDER COMPRESSION LEAKAGE CHECK.

M73-13

ROCKER SHAFT BOSSES.

M73-2

CYLINDER, NON-H FAA AD #72-20-02.

Also reference all TCM Service Bulletins issued after the original publication date of this bulletin for additional information concerning cylinder inspection. AFFECTED PUBLICATIONS:

MO 09

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96

Insert a copy of this Service Bulletin into the appropriate section of all TCM engine model Overhaul and Maintenance Manuals.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

CATEGORY 3

SB96-3B

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

CRANKSHAFT GEAR BOLT INSPECTION.

PURPOSE:

TCM has identified a discrepancy in the packaging of the P/N 536379 crankshaft gear bolt, in which incorrect part number bolts were supplied. This bulletin provides inspection and replacement instructions for the crankshaft gear bolts. WARNING

OPERATION OF AN ENGINE WITH INCORRECT CRANKSHAFT BOLTS MAY CAUSE LOSS OF CRANKSHAFT GEAR RETENTION AND SUBSEQUENT ENGINE FAILURE. COMPLIANCE: MODELS AFFECTED:

Within the next 25 hours of operation. All IO-346, E-165, E-185, E-225, O-470, IO-470, TSIO-470, IO-520, TSIO-520, LTSIO-520, GTSIO-520, IO-550, GIO-550, TSIO-550 and TSIOL-550 model engines. NOTE: This Service Bulletin does not affect any TCM factory new or rebuilt engines unless field replacement of crankshaft gear bolts has been accomplished using affected bolts as indicated in the following. A. Affected engine models that have had crankshaft bolts installed that were purchased through a TCM Distributor during the period of January 20, 1996 through March 20, 1996. B. All GTSIO-520 engine models that have had P/N EQ6642 starter adapter kits installed that were purchased through a TCM Distributor during the period of January 20, 1996 through March 20, 1996. Crankshaft bolts (6 each) are supplied in the kit. C. Inspect inventory of P/N 536379 bolts and P/N EQ6642 starter adapter kits if purchased during the respective dates and return any bolts that do not conform to the illustration in Figure 1 to your TCM Distributor.

INSPECTION INSTRUCTIONS Reference the appropriate Aircraft Maintenance Manual and Engine Overhaul Manual for component removal and replacement instructions. 1.

For IO-346-A, IO-520-B, BA, BB, C, CB, M, MB, TSIO-520-B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB, IO-550-A, B, C, G, TSIO-550-A, B, C, E and TSIOL-550-A model engines, remove the engine driven fuel pump to facilitate the inspection of the crankshaft gear bolts. Proceed to paragraph number 4.

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2.

For all O-470, IO-470, TSIO-470, IO-520-A, D, E, F, J, K, L, TSIO-520-AE, AF, CE, C, G, H, M, P, R, T, LTSIO-520-AE, all GTSIO-520, IO-550-D, E, F, L and GIO-550-A model engines, remove the starter adapter to facilitate the inspection of the crankshaft gear bolts. Proceed to paragraph number 4.

3.

For all E-165, E-185 and E-225 model engines, remove the starter to facilitate the inspection of the crankshaft gear bolts. Proceed to paragraph number 4.

4.

Inspect the crankshaft gear bolts and verify that the P/N 536379 is installed. The distinguishing feature of the P/N 536379 bolt is that the head is drilled in three places (hole in each flat) as illustrated in Figure 1. Incorrect part number bolts have only one hole drilled through the head. If installation of the P/N 536379 bolt is verified, reinstall components that were removed in accordance with the applicable Aircraft Maintenance Manual and Engine Overhaul Manual. Make a log book entry as to compliance with this Service Bulletin.

5.

If an incorrect bolt or bolts are installed, cut and remove the safety wire.

6.

Note: E-Series engines will require removal of the accessory case to replace the crankshaft gear bolts.

7.

Remove incorrect bolts and replace with new P/N 536379 bolts, one bolt at a time. Lubricate the threads of the replacement bolt with clean 50 weight engine oil. Torque bolt to 380 - 420 inch pounds. Repeat this process to replace all incorrect bolts. Return all incorrect bolts to your TCM Distributor.

8.

Using .032" safety wire, safety all crankshaft gear bolts in accordance with TCM Service Bulletin SIL93-15 or current revision as applicable.

9.

Reinstall components that were removed in accordance with the applicable Aircraft Maintenance Manual and Engine Overhaul Manual. Make a engine log book entry as to compliance with this Service Bulletin.

AFFECTED PUBLICATIONS: None. WARRANTY: Warranty action required to comply with this service bulletin is covered by the TCM Aircraft Engine Part, Component and Accessory Warranty, subject to its terms and conditions.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SERVICE BULLETIN

SB96-4

Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

IMPROVED OIL PUMP GEARS AND SUCTION SCREENS

PURPOSE:

To inform customers of the availability of improved oil pump gears and oil suction screens. The oil pump gear and oil pump drive gear have been improved to provide structural redundancy. The oil suction screens have been improved to enhance oil filtration.

COMPLIANCE:

Installation of these parts is required at engine overhaul or anytime the subject parts require replacement.

MODELS AFFECTED:

All O-300, IO-360, TSIO-360 and LTSIO-360 model engines. See "NOTE" for exceptions.

OIL PUMP GEARS - Reference Figure 1. The following list provides new oil pump drive gear and oil pump gear part numbers and applicable engine models. The installation of these oil pump drive gears will satisfy the compliance requirement of TCM Service Bulletin CSB96-5 and utilize the same identification groove. The new oil pump drive gear and oil pump gear must go into service together and must not be used with earlier production gears.

ENGINE MODEL

DESCRIPTION

PART NUMBER

All O-300's, IO-360's and TSIO-360's. All LTSIO-360's All O-300's, IO-360's, TSIO-360's and LTSIO-360's

Gear, Oil Pump Drive

654210

Gear, Oil Pump Drive

654210-1

Gear, Oil Pump

653814* 653814-1**

* - Must be used in oil pump chambers that have a measured depth of .747 - .745. ** - Must be used in oil pump chambers that have a measured depth of .660 - .658. NOTE:

MO 04

THESE GEARS CANNOT BE USED IN THE EARLY STYLE O-300 AND IO-360-A CRANKCASE COVER ASSEMBLIES THAT UTILIZED THE SQUARE DRIVE OIL PUMP GEAR.

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FIGURE 1. OIL PUMP DRIVE GEAR AND OIL PUMP GEAR OIL SUCTION SCREEN - Reference Figure 2. The following list provides new oil suction screen part numbers and applicable engine models. These oil suction screens utilize wire mesh rather than a perforated tube to provide improved filtration. Identification of these screens is accomplished as indicated in Figure 2. ENGINE MODEL

DESCRIPTION

PART NUMBER

All O-300's ...................................................... Screen, Oil Suction .......... 653986 All IO-360's, TSIO-360's and LTSIO-360's ............................................ Screen, Oil Suction .......... 653658 Contact your TCM Distributor to order these improved gears and screens. AFFECTED PUBLICATIONS: Insert a copy of this service bulletin into the appropriate section of the following TCM manuals: Form # X30014, C-125, C-145 & O-300 Service Parts Catalog. Form # X30595A, IO-360 Series Parts Catalog. Form # X30597A, TSIO-360 & LTSIO-360 Series Parts Catalog.

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FIGURE 2. OIL SUCTION SCREENS

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CATEGORY 3

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

SB96-7C

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

Technical Portions FAA APPROVED

SUBJECT: TORQUE LIMITS PURPOSE: This bulletin provides torque values for fasteners utilized on all TCM engines. COMPLIANCE: During all maintenance, repair or overhaul events. WARNING Proper torqueing practices cannot be over emphasized. Torque values are provided as a convenient method of achieving correct pre-loading of highly stressed fasteners. If the fasteners are not properly plated, the fastener threads are not clean and free of deformation or are not properly lubricated, the correct fastener pre-load will not be achieved even though the given torque value is reached. For this reason, it is critical that all fasteners be inspected for proper plating, thread form and correctly lubricated prior to torquing. Failure to verify a fastener's serviceability or to correctly lubricate the fastener prior to assembly and torquing will result in the fastener not being properly pre-loaded and subsequent failure of the fastener may occur. MODELS AFFECTED: All GENERAL INFORMATION The torque values provided must be used for the specific application. If an application is not listed, then the general torque value must be used. TORQUE VALUES LISTED ARE FOR USE WITH CLEAN 50 WEIGHT AVIATION ENGINE OIL APPLIED TO THE THREADS, UNLESS OTHERWISE SPECIFIED. Refer to appropriate manufacturer’s accessory overhaul manuals for specified torque on accessories. If cotter pin holes must be aligned, set torque wrench at low limit and tighten nut to first hole beyond this torque, but do not exceed the maximum torque limit specified. This torquing procedure must be followed for all applications requiring cotter pin hole alignment, except for ISSUED

connecting rod nuts. Special instructions are provided in Notes at rear of bulletin. NOTE: When you see the text notation (AR) it refers to “As Required.” WARNING THE USE OF SEALANTS OR LUBRICANTS OTHER THAN THOSE SPECIFIED BY TCM ON MATING THREADS AND BETWEEN MATING SURFACES CAN CAUSE INCORRECT TORQUE APPLICATION AND SUBSEQUENT ENGINE DAMAGE OR FAILURE.

REVISED

PAGE NO REVISION TM

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Teledyne Continental Motors, Inc.

1 of 13

02

08

2005

PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

SB96-7

© 2005 Teledyne Continental Motors, Inc.

A Teledyne Tec hnologies Company

C

CYLINDER TORQUE PROCEDURES: Proper cylinder installation requires a multiple step torquing process. Cylinder base stud threads, through bolt threads and nuts must be lubricated with clean 50 weight aviation oil. Through bolt nuts at cadmium plated washers require a lower torque value to achieve the same pre-load on the through bolt since the lubricity of the cadmium plating reduces the friction in the fastener joint. 1. Torque cylinder base nuts to 1/2 of the specified torque value for the fastener. 2. Torque the cylinder through bolt nuts and cylinder base stud nuts to the specified torque value for the cylinder base stud nuts. Through bolt nuts must be torqued on both sides of the engine, even if only one cylinder is being installed. WARNING

3. Torque through bolt nuts, on both sides of the engine, to the specified value for the fastener 4. Engines which incorporate the 7 th cylinder deck stud, install the 7 th stud cylinder bracket and conical stud nut. Torque the stud nut to the value specified for the fastener. NOTE: Through bolt nuts P/N’s 634505 and 649496 have been superseded by nut P/N 652541. Nut P/N 634505 is a flanged 6 point (hex) nut requiring a torque value of 690-710 inch pounds. Nut P/N 649496 is a flanged 6 point (hex) nut requiring a torque value of 790-810. Nut P/N 652541 is a flanged 12-point nut requiring a torque value of 790-810 inch lbs. At engine overhaul all P/N 634505 and 649496 flanged through bolt nuts must be replaced with P/N 652541 flanged 12 point nuts. If replacing P/N 634505 or 649496 nuts in less that a complete set prior to engine overhaul torque nut P/N 652541 to the required valve of the original fastener (P/N 634505 or 649496).

Failure to torque through bolt nuts on both sides of the engine can result in a loss of main bearing crush with main bearing shift and subsequent engine failure.

ISSUED

REVISED

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CRANKCASE CAUTION: The correct torque sequence from the latest version of the appropriate Overhaul Manual must be followed for correct crankcase and cylinder assembly. SIZE

FASTENER

TORQUE VALUE IN/LB. FT/LB.

MODELS AFFECTED

.25 - 28

Nut-Crankcase Flange

100-125

8.3-10.4

.25 - 28 .25 - 28

Nut-Tie bolt prop shaft cages Nut-Engine leg bushing

90-110 90-100

7.5-9.2 7.5-8.3

.31 - 18

Bolt- Oil sump flange

155-175

12.9-14.6

.31 - 24

Nut- Crankcase Flange

180-220

15.0-18.3

.31 - 24

Nut-Crankcase flange (Stainless Steel Only) Nut-Crankcase through bolts Nut-Magneto Flange Nut-Shaft, magneto gear support to case Bolt-Engine mount to crankcase. Nut-Cylinder to crankcase stud Nut-Cylinder to Crankcase studs

240-280

20.0-23.3

180-220 100-120 190-210

15.0-18.3 8.3-10.0 15.8-17.5

A, C, & E Series, O-200, O-300, O-470(AR) IO-240, IOF-240 GO-300 C-125, C-145-, O-300 IO-346, O-470, IO-470, GIO-470, TSIO-470, IO-520, L&TSIO-520, GTSIO-520, IOF-550, IO-550, TSIO-550, TSIOL-550, TSIOF-550 IO-346, O-470(AR), IO-470, GIO-470, TSIO-470, IO-520, L&TSIO-520, GTSIO-520, IO550, IOF-550, TSIO-550, TSIOF-550, TSIOL-550 (AR) Stainless Steel Hardware Only O-470 (AR), E-Series All Engine Models IO-360, L&TSIO-360

220-260

18.3-21.7

IO-550-G, IO-550-N

410-430

34.2-35.8

440-460

36.7-38.3

A, C, & E Series, O-200, O-300 GO-300, O-470 IO-240, IOF-240, IO-360, L&TSIO-360,

.38 - 24

Nut-Crankcase tie bolts

370-390

30.8-32.5

.38 - 24 .38 - 24

Nut-Crankcase tie bolts Nut-Crankcase through bolts-front. Nut-Crankcase though studs.

275-325 370-390

22.9-27.1 30.8-32.5

275-325

22.9-27.1

Nut-Mounting brackets to crankcase Bolt-Crankcase thru front main only. Nut-Through bolt, upper rear Nut-Cyl. to crankcase studs.(includes 7th stud) Nut-Cyl. to crankcase studs. Nut-Through bolts at cadmium plated washer

275-325

22.9-27.1

A-Series, C-75, C-85, C-90 and O-200. All models(AR)

275-325.

22.9-27.1

GO-300

275-325 490-510

22.9-27.1 40.8-42.5

All 470's, All 520's, All 550's All models (except TSIOL-550)

590-610 440-460

49.2-50.8 36.6-38.3

TSIOL-550 All models (AR)

.31 - 24 .31 - 24 .31 - 24 .38 - 16 .38 - 24 .38 - 24

.38 - 24 .38-24 .38-24 .38-24 .44-20 .44-20 .44-20

ISSUED

All models (AR) EXCEPT 360's & IO-240 and IOF240 All 360's, IO-240, IOF240 O-470 (AR) & E-Series

REVISED

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PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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CRANKCASE (continued) SIZE

FASTENER

.44-20

Nut-Crankcase tie bolts-nose & below camshaft Nut-Cyl. to crankcase through studs Nut- Front and Rear Crankcase bearing thru studs Nut-thru stud at Cyl. Flange Nut-Tie bolts at nose and prop shaft cages. Nut-Through bolt at cylinder flange

440-460

36.6-38.3

All models(AR)

400-450

33.3-37.5

A-Series, C-75, C-85 & C-90

490-510

40.8-42.5

O-200

490-510 340-360

40.8-42.5 28.3-30.0

O-200 GO-300.

490-510

40.8-42.5

.44-20

Nut-Through bolt at cylinder flange

590-610

49.2-50.8

All models (AR) EXCEPT 360's, IO-240, IOF-240 All 360's, IO-240, IOF-240

.50-20

Nut-Through bolt at cad plated washer

615-635

51.2-52.9

.50-20

Nut-6 Point-Through bolt at cylinder flange (P/N 634505 .33 in. high) Nut-Through bolt at plated washers Nut-12 Point-Thru bolt at cylinder flange (P/N 652541) Nut-Tall 6 point-thru bolt at cylinder flange. (P/N 649496 .43 inch high) Nut-Crankcase tie bolts-nose Plug-(using crush washer)

690-710

57.5-59.2

690-710

57.5-59.2

TSIOL-550

790-810

65.8-67.5

IO-346, All 470, 520 & 550.

790-810

65.8-67.5

TSIOL-550.

640-660 190-210

53.3-55.0 15.8-17.5

All models(AR) All models(AR)

.44-20 .44-20 .44-20 .44-20 .44-20

.50-20 .50-20 .50-20 .50-20 .62-18

TORQUE VALUE IN/LB. FT/LB.

MODELS AFFECTED

IO-346, O-470, IO-470 TSIO-470, IO-520, L/TSIO-520 GTSIO-520, IO-550, IOF-550, TSIO-550, TSIOF-550, GIO470 IO-346, All 470, 520, 550, (Except TSIOL-550)

GEARS SIZE

FASTENER

TORQUE VALUE IN/LB. FT/LB.

.25-28

Bolt-Gear to camshaft

140-160

11.7-13.3

.25-28

Bolt-Gear to crankshaft (P/N 22532) (SEE NOTE 6) Bolt-Gear to crankshaft. (P/N 534904) (SEE NOTE 6) Bolt-Quill Shaft Retaining Plate (P/N 646920)

140-160

11.7-13.3

170-175

14.2-14.6

90-110

7.5-9.2

.25-28 .25-28

.31-24

Bolt-Gear to camshaft

ISSUED

240-260

20.0-21.7

MODELS AFFECTED A,C, & E-Series, O-200,O-300 O-470, IO-240, IOF-240 A & C-Series, O-200, O-300, GO-300 , IO-240, IOF-240 E-Series, O-470 Numerical O-470-A, E. GTSIO-520 E-Series, IO-360, L/TSIO 360, IO-346, O-470, IO-470, IOF-550 TSIO-470, IO-520, L/TSIO- 520 GTSIO-520, IO-550, TSIO-550, TSIOL-550, TSIOF-550

REVISED

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PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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GEARS (continued) SIZE

FASTENER

TORQUE VALUE IN/LB. FT/LB.

Bolt-Gear to crankshaft (Lower hardness bolts identified with green dykem) (SEE NOTE 6) Bolt-Gear to crankshaft. (Bolt hardness RC 38-42) (SEE NOTE 6).

.31-24

240-260

20.0-21.7

380-420

31.7-35.0

MODELS AFFECTED

E-Series, IO-360 L/TSIO-360, IO-346

.31-24

Bolt-Face gear to crankshaft.

140-150

11.7-12.5

.31-24

Nut-Generator or alternator gear Nut-Generator gear-(531231) With washer-(401507) Bolt-Vac & fuel pump gear to camshaft

175-200

14.6-16.7

175-195

14.6-16.3

O-470, IO-470, TSIO-470, IO-520, L/TSIO 520, IOF-550 GTSIO-520, IO-550, TSIO-550, TSIOL-550, TSIOF-550 IO-346, GIO-470, IO-520(AR) L/TSIO-520(AR), GTSIO-520, IO-550, IOF-550, TSIO-550, TSIOL- 550. A, C & E Series, O-200,O-300 GO-300, IO-360, L&TSIO-360. E-Series

275-325

22.9-27.1

IO-240, IOF-240

.31-24

.31-24 .31-24

CONNECTING RODS SIZE

FASTENER

.38-24

Nut-Connecting rod (Nuts: 24804, 626140 with bolt P/N 530213) (SEE NOTES 1&8)

3/8-24 .38-24

TORQUE VALUE IN/LB. FT/LB.

Nut-Connecting rod (Nuts: P/N 626140 with bolt P/N 35972) (SEE NOTES 1 & 8) Nut -Connecting rod Spiralock (Nut P/N 654487 with bolt P/N 654693) Nut -Connecting rod Spiralock (Nut P/N 654487 with bolt P/N 654811) Nut-Connecting rodSpiralock (Nut hex P/N 643215 with bolt P/N 643112) Nut-Connecting rod Spiralock (12 Point Nut P/N 654490)

3/8-24 .38-24 3/8 -24 .38-24 3/8 -24 .44-20 7/16-20 .44-20

400-475

33.3-39.6

400-475

33.3-39.6

490-510

40.8-42.5

490-510

40.8-42.5

550-600

45.8-50.0

690-710

57.5-59.2

7/16-20

ISSUED

MODELS AFFECTED A & C-Series, O-200, O-240, O-300, GO-300, IO-360, L & TSIO-360, IO-240, IOF240 E-185, E-205, E-225, IO-346, O-470 Numbered and Lettered engines IO-470, TSIO-470 with 628751 Connecting Rod O-200, 240, O-300, GO-300, IO-240, IOF-240, IO-360, L & TSIO-360 E-185, E-205, E-225, IO-346, O-470 Numbered and Lettered engines IO-470, TSIO-470 L & IO-520-P, L & TSIO-520 AE & CE, IO-550, IOF-550, TSIO-550, TSIOF-550, TSIOL-550 FOR SPECIFIC APPLICATION SEE NOTE 9 ON PAGE 13

REVISED

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CONNECTING RODS (continued) SIZE

FASTENER

.44-28

TORQUE VALUE IN/LB. FT/LB.

Nut-Connecting Rod (rod P/N 646474, bolt P/N 631794 nut 631554) (SEE NOTE 1) Nut-Connecting Rod (rod P/N 646476, bolt P/N 629340 nut-P/N 628109 (SEE NOTE 1)

7/16-28 .44-28 7/16-28

MODELS AFFECTED GIO-470, GTSIO-520.

550-575

45.8-47.9

475-525

39.6-43.8

IO-346, O-470, IO-470, TSIO-470, IO-520, TSIO-520 (except L/TSIO-520 AE & CE),

MISCELLANEOUS FUEL INJECTION SIZE

FASTENER

#8-32

Screw-Manifold Cover hold down (AN503-8-12)

#8-32 .125-27 .125-27 .19-24 .25-28 .25-48 .31-24 .31-24 .31-32 .50-24

TORQUE VALUE IN/LB. FT/LB.

MODELS AFFECTED

22-26

1.8-2.2

All fuel injected models, as required

Screw-Aneroid body hold down (AN500-8-14) Fitting-Cover vapor separator fuel pump Nozzle-Fuel injector(with anti-seize compound) Through-bolt, fuel pump

17.5-22.5

1.5-1.9

60-80

5.0-6.7

55-65

4.6-5.4

29-31

2.4 -2.6

Ejector - Fuel Pump Vapor Separator Cover Nut-Aneroid stem jam

90-100

7.5-8.3

All fuel injected models, as required All fuel injected models, as required All fuel injected models, as required All fuel injected models, as required All fuel injected models (AR)

25-30

2.1-2.5

Nozzle-Fuel injector(with anti-seize compound) Nut- Throttle and mixture control levers to shaft Nut-Fuel injection line

55-65

4.6-5.4

100-120

8.3-10.0

40-45

3.3-3.7

Nut; Air reference sleeve “B” nut to air reference line

.38-24

Nut-Fuel injection line

.62-18

Plug & Screen assy. Metering Unit new gasket

ISSUED

Snug nut finger tight to set seal between nut and male connector, then tighten additionl ¾ to 1 turn 55-60 4.5-5.0 120-130

10.0-10.8

All fuel injected models, as required All fuel injected models, as required All fuel injected models, as required All fuel injected models, as required All Turbocharged models All fuel injected models, as required All fuel injected models, as required

REVISED

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MISCELLANEOUS LUBRICATION SIZE

FASTENER

.25-20

Bolt-Oil cooler to adapter

.25-20

Bolt-Oil pump cover crankcase Nut-Collar assembly governor oil transfer.

TORQUE VALUE IN/LB. FT/LB.

MODELS AFFECTED IO-360, L/TSIO-360, O-470, IO-470, TSIO-470, IO-520, TSIO-520(AR), I0-550, IOF-550 TSIO-550 TSIOL-550, TSIOF550 All models as required

100-110

8.3-9.2

75-85

6.3-7.1

75-85

6.3-7.1

280-300

23.3-25.0

280-300

23.3-25.0

LTSIO-360 (Left Hand Thread)

190-210

15.8-17.5

All models, as required.

190-210

15.8-17.5

All models, as required.

.62-18 .62-18 .75-16 .75-16 .88-16

Tach-Shaft to oil pump drive gear. Tach-Shaft to oil pump drive gear. Plug-Oil cooler (using crush washer) Plug-Oil suction tube (using crush washer) Plug-Oil sump drain Oil filter-Cartridge Oil filter-Disposable type. Plug-Oil sump drain. Cap-Oil pressure relief valve

O-470, IO-470, TSIO-470, IO- 520, TSIO-520, IO-550, IOF-550, TSIO-550, TSIOL550, TSIOF-550 IO-360-D, TSIO-360

190-210 180-216 192-216 190-210 190-210

15.8-17.5 15.0-18.0 16.0-18.0 15.8-17.5 15.8-17.5

.88-16

Plug-Oil bypass.

240-260

20.0-21.7

1.00-14

Vernatherm-(Oil temperature control valve) Screen Assy-Scavenge oil

440-460

36.7-38.3

All models as required All models as required All models as required IO-470-M, IO-520-E O-200, IO-240, O-300, TSIO-360, LTSIO-360. O-470, IO-470, TSIO-470, IO-520, TSIO-520, GTSIO-520 IO-550,, IOF-550, TSIO-550, TSIOL-550, TSIOF-550 All models, as required.

200-210

16.7-17.5

Housing-Oil pressure relief valve

240-260

20.0-21.7

Housing tach drive

250-350

20.8-29.2

Plug – Special (Vernatherm) Vernatherm. Oil filter adapter lock nut

310-320 410-420 500-520

25.8-26.7 34.2-35.0 41.6-43.3

Oil filter screen using new crush gasket ( install gasket with parting line up against screen face)

500-520

41.6-43.3

.25-28 .38-24 .38-24 LH Thread .62-18 .62-18

1.00-18 1.12-18

1.375-16 LH Thread 1.25-18 1.25-18 1.75-16 1.75-16

ISSUED

O-300(AR), IO-360(AR), L & TSIO-360(AR) IO-346, O-470, IO-470, TSIO470, IO-520, TSIO-52O,GTSIO520, IO-550, IOF-550, TSIO550 TSIOL–550, TSIOF-550 All models as required All models as required All models as required O-300(AR), IO-360(AR), L & TSIO-360(AR). All models as required

REVISED

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PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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MISCELLANEOUS CYLINDER HARDWARE SIZE

FASTENER

.125-27 .25-20

.25-20 .25-20 .25-20

Connector – Cylinder Drain Set Screw; Rocker shaft locking Screw- rocker box cover (tighten 2 lower screws first) Screw-Rocker box cover.. Screw-Intake flange. Bolt-Rocker shaft hold down

.25-20 .25-28 .25-28

.25-20

.25-28 .31-18 .31-24

TORQUE VALUE IN/LB. FT/LB. 60-80 45-55

5.0-6.7 3.8-4.6

All Models (AR) O-200, O-300

55-65

4.6-5.4

55-65 85-110 85-110

4.6-5.4 7.1-9.2 7.1-9.2

Bolt-Thru bolted rocker shaft

90-100

7.5-8.3

Nut-Rocker shaft hold down. Nut-Exhaust coupling, “V” band clamp (SEE NOTE 2). Nut-Exhaust manifold flange. (Spirotallic gasket) Bolt-Rocker shaft. (SEE NOTE 3). Nut-Induction tube flange.

110-120 42

9.2-10.0

IO-240, IOF-240, IO-360, L & TSIO360 All models, as required All models, as required. O-470-2,4,13, 13A O-470B(AR) O-470, IO-470, TSIO-470, IO-520, IO-550 and IOF-550 (except G, N, P, R), TSIO-520 (except BE), TSIOL550 All 360’s, IO-240, IOF-240 TSIO-520-L, LB, TSIO-520-WB

100-110

8.3-9.2

190-210 50-70

15.8-17.5 4.2-5.8

.31-24

Bolt-Rocker shaft hold down (SEE NOTE 4)

85-110

7.1-9.2

.31-24

Nut-Exhaust manifold flange (Spirotallic gasket) Plug – Cylinder Drain (With O-Ring) Spark plug (SEE NOTE 7)

200-210

16.7-17.5

50-70

4.2-5.8

300-360

25.0-30.0

.44-20 18 MM

MODELS AFFECTED

All models, as required. IO-550 and IOF-550 (G, N, P and R) TSIO-520-BE, TSIO-550, GTSIO-520 All 360’s, IO-240, IOF-240 O-470, IO-470 TSIO-470, IO-520, IO550, IOF-550 (except G, N, P, R), TSIO-520 (except BE), TSIOL-550, TSIOF-550 All models as required TSIOL-550 Series All models

MISCELLANEOUS FASTENERS SIZE

FASTENERS

.25-.62 .25-.62

12-16 10-14

.3-1.3 .8-1.17

.38-16 .31-18 .31-18

Clamp, Hose, Oil Gage Rod Clamp, Hose, Magneto Pressurization Bolt-Turbocharger to bracket Bracket-Turbocharger Bolt-Alternator mounting

310-350 220-250 150-180

25.8-29.2 18.3-20.8 12.5-15.0

.31-24

Nut, Generator Gear

175-200

14.6-16.7

.31-24

Nut, Generator Gear (531231), washer (401507) Nut; Starter Pinion Pivot & Magneto Gear Support

175-195

14.6-16.3

TSIO-520-L1. GTSIO-520-F & K IO-346, GIO-470, All 520's(AR), All 550's(AR). A,C & E-Series, O-200, 0-300 GO-300, IO-360, TSIO-360 E-Series

180-220

15.0-18.3

PE & E-Series

.31-24

ISSUED

TORQUE VALUE IN/LB. FT/LB.

MODELS AFFECTED IO-360, TSIO-360 (AR) As Required

REVISED

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2005

PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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MISCELLANEOUS FASTENERS (continued) SIZE

FASTENERS

TORQUE VALUE IN/LB. FT/LB.

.38-24

Nut-Starter to adapter

200-220

16.7-18.3

.44-20

600-720

50-60

.56-18

Nut-Alt. sheave to starter shaft Nut-Starter shaft gear. (SEE NOTE 5)

450-500

37.5-41.6

.56-18

Nut-Starter jaw, crankshaft.

575-625

47.9-52.1

.56-18

Nut-Generator pulley drive

450-500

37.5-41.7

.62-32

Nut-Alternator hub assembly.

300-450

25.0-37.5

450-500

37.5-41.7

Nut-Alternator or generator pulley

.66-20 .75-16

Nut-Starter shaft gear viscous dampener Adapter-Tach reduction gear

.88-18

120-180

MODELS AFFECTED O-300 (AR), GO-300 (AR), IO-346, All 470’s, All 520’s All 550’s TSIO-520-B as required

180-220

IO-520-BA, BB, TSIO-520-BB, N, NB, L, LB, WB, BE UB, IO-550-B, C, IOF550 B,C TSIO-550-A, B, C, E O-470 Numeral IO-346, All 470’s , IO-520, TSIO-520, IO-550, IOF-550, TSIOL-550 TSIO-550, TSIOF550 IO-346, GIO-470, IO-520(AR) TSIO-520(AR), IO-550, IOF550, GTSIO-520 (AR), TSIOL550, TSIO-550, TSIOF-550 O-470, IO-470, IO-520 (AR), TSIO-520 (AR), TIARA (AR) IO-550, IOF-550, TSIOL-550, TSIO-550. GTSIO-520

10.0-15.0

All 360 series, IO-240, IOF-240

Pipe Plugs Dec. .062 - 27

SIZE In. 1/16-27

TORQUE IN/LB. FT/LB. 30 - 40 2.5 - 3.3

.125 - 27

1/8-27

60 - 80

5.0 - 6.7

.250 - 18

1/4-18

130 - 150

10.8 - 12.5

.375 - 18

3/8-18

185 - 215

15.4 - 18.0

.500 - 14

1/2-14

255 - 285

21.3 - 23.8

.750 - 14

3/4-14

310 - 350

25.8 - 29.2

ISSUED

REVISED

PAGE NO REVISION TM

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PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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General Torque Specifications

Bolts, Nuts and Screws Dec. #2-56

SIZE In. -56

TORQUE IN/LB. FT/LB. 1.4-2.6 N/A

#4-40

-40

2.9-5.5

N/A

#6-32

-32

5.3-10.1

N/A

#8-32

-32

17.5 - 22.5

1.5 - 1.9

#10-32

-32

36 - 50

3.0 - 4.2

#10-24

-24

21 - 25

1.7 - 2.0

.25 - 20

1/4

75 - 85

6.3 - 7.1

.25 - 28

1/4-28

90 - 100

7.5 – 8.3

.3125 - 18

5/16-18

155 - 175

12.9 - 14.6

.3125 - 24

5/16-24

180 - 220

15.0 - 18.3

.375 - 16

3/8-16

220 - 260

18.3 - 21.7

.375 - 24

3/8-24

275 - 325

22.9 - 27.1

.44 - 20

7/16-20

400 - 450

33.3 - 37.5

.50 - 20

1/2-20

550 - 600

45.8 - 50.0

Driving Studs SIZE

TORQUE IN/LB. FT/LB. 50 - 70 4.2 - 5.8

Dec. .25 - 20

In. 1/4

.3125 - 18

5/16-18

100 - 150

8.3 - 12.5

.375 - 16

3/8-16

200 - 275

16.7 - 22.9

.44 - 14

7/16-14

300 - 425

25.0 - 35.4

ISSUED

REVISED

PAGE NO REVISION TM

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PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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HYDRAULIC LINE TORQUE SPECIFICATIONS SIZE .44-20 .56-18 .75-16

HOSE ASSEMBLY Nut-Self locking #4 hose Nut-Self locking #6 hose Nut-Self locking #8 hose

TORQUE IN / LB. 115-165 185-335 360-570

MODELS TSIO-520-L, LB, WB. TSIO-520-L, LB, WB. TSIO-520-L, LB, WB.

ASSEMBLY TORQUE SPECIFICATIONS FOR FITTING SIZE .31-24 .31-24 .38-24 .38-24 .44-20 .44-20 .44-24 .56-18 .56-18 .75-16 .75-16 .88-14 .88-14

FITTING & MATERIAL #2 Brass / Aluminum #2 Steel #3 Brass / Aluminum #3 Steel #4 Brass / Aluminum #4 Steel Steel #6 Brass / Aluminum #6 Steel #8 Brass / Aluminum #8 Steel #10 Brass / Aluminum #10 Steel

TUBE O.D. .125 .125 .188 .188 .250 .250 .190 .375 .375 .500 .500 .625 .625

TORQUE IN / LB. 15-30 15-30 40-65 50-90 60-80 70-120 60-80 75-125 90-150 150-250 135-250 200-350 300-400

MODELS All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR)

TORQUE SPECIFICATIONS FOR HOSE FITTINGS (“B” NUTS) HOSE SIZE #2 (.31-24) #2 (.31-24) #3 (.38-24) #3 (.38-24) #4 (.4375-20) #4 (.4375-20) #5 (.500-20) #5 (.500-20) #6 (.5625-18) #6 (.5625-18) #8 (.750-16) #8 (.750-16) #10 (.875-14) #10 (.875-14) #12 (1.063-12) #12 (1.063-12)

HOSE END FITTING MATERIAL BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING BRASS / ALUMINUM FITTING STEEL FITTING

ISSUED

TORQUE IN / LB. 50-80 75-120 70-105 95-140 100-140 135-190 130-180 170-240 150-195 215-280 270-350 470-550 360-430 620-745 460-550 855-1055

REVISED

MODELS All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR) All Models (AR)

PAGE NO REVISION TM

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2005

PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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TORQUE VALUES FOR FADEC COMPONENTS ALL FADEC ENGINES Hardware ECU 50-Pin Connector Securing Screws SSA 25-Pin Connector Securing Screws Fuel Pressure Sensors Manifold Pressure Sensors Cylinder Head Temp Sensor Manifold Air Temp Adapter (Sensor Nut) Manifold Air Temp Compression Fitting (Ferrule Nut) Exhaust Gas Temperature Sensor Band Clamp Lead To ECU Spark Tower “B” Nut

Torque (inch-lbs) 10-15 10-15 130-150 130-150 55-65 70-120 145-155 30-35 110-120

NOTES NOTE (1) -

Torque to low limit. If cotter pin will not enter, increase torque gradually up to high limit only. If cotter pin will not enter in this range, replace nut and repeat. IN NO CASE SHALL NUTS BE TIGHTENED BELOW THE MINIMUM TORQUE LIMIT OR OVER THE MAXIMUM TORQUE LIMIT. Reference the most current revision of TCM Service Bulletin SIL 93-15 as applicable for special instructions for cotter pinning the 360 model engine connecting rods.

NOTE (2) -

Strike outer periphery of coupling band lightly to distribute load. Then tighten to 50-60 in/lb. for P/N 641284 Clamp and 60-70 in/lb. for P/N 653832 Clamp. Do not realign hex cap screw to suit tab washer.

NOTE (3) NOTE (4) -

Must be reworked to through bolt rocker shaft configuration in accordance with TCM Service Bulletin M92-6 or current revision as applicable.

NOTE (5) -

Align and tension belt in accordance with TCM Service Bulletin M89-6 or current revision as applicable.

NOTE (6) -

Crankgear must be heated to 300° Fahrenheit, then installed on crankshaft. Assure that the gear seats tightly against the end of the crankshaft by tapping lightly with a brass hammer. CAUTION Improper heating of the crankshaft gear will result in damage to the gear and may lead to subsequent engine failure. The instructions contained in the latest revision of the appropriate overhaul manual must be used for crankshaft gear installation. Lubricate threads with Champion thread lubricant P/N 2612 or equivalent only.

NOTE (7) NOTE (8)-

(A) P/N 530184 connecting rod (Identified by forging number 530186), P/N A35159 (identified by forging number 5561) and P/N A35160 (also identified by forging number 5561) must be serviced as follows: P/N 530213 bolt, P/N 24804 or P/N 626140 Nut and P/N 639292 cotter pin.

(B) P/N A36121 connecting rod assemblies utilizing the P/N 632041 forging must be serviced in accordance with the part numbers indicated in the current technical data. P/N A36121 connecting rod assemblies utilizing the P/N 40742 forging ISSUED

REVISED

PAGE NO REVISION TM

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2005

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C

must be serviced as follows: P/N 35972 connecting rod bolt, P/N 24804 nut and P/N MS24665-132 cotter pin. NOTE (9)

Connecting Rod Application:

ROD P/N 655000 Superseded by 655910 (Nut 654490 & Bolt 643112) IO-520-P LIO-520-P TSIO-520-AE LTSIO-520-AE ROD P/N 655004 Superseded By 655910 (Nut 654490 & Bolt 654068) Bolt 654068 Superseded To Bolt 655961 O-470-J, R, S, U IO-470-C, D, E, F, K, L, M, N, S, U, V, IO-520-A, BA, C, D, E, F, J, K, L, M, TSIO-520-A, B, C, D, E, G, H, J, L, M, N, P, R, T GTSIO-520-C, D, F, H, K, L, M, N, R ROD P/N 655910 (Nut 654490 & Bolt 655958) O-470 J,R,S,U IO-470 C,D,E,F,K,L,M, N,S,U,V

IO-550-A, B, C, D, E, F, G, L, N, P, R TSIOL-550-A, B, C TSIO-520-CE TSIO-550A, B, C, E ROD P/N 655005 Superseded By 655911 (Nut 654490 & Bolt 654068) Bolt 654068 Superseded to Bolt 655967 IO-520-BB, CB, MB, TSIO-520-BB, BE, DB, EB, JB, KB, LB, NB, UB, VB, WB

ROD P/N 655911 (Nut 654490 & Bolt 655958) IO-520-BB, CB, MB TSIO520CE TSIO-520-BB, BE, DB, EB, JB, KB, LB, NB,UB, VB,WB

IO-520-A,BA,C,D,E,F,J, K,L,M,P L&TSIO-520-A,AE,B,C,D, E,G,J,M,N,P,R,T GTSIO-520-C,D,F,H,K,L, M,N,R

ISSUED

ROD P/N 655001 Superseded by 655911 (Nut 654490 & Bolt 643112)

IOF-550-ALL TSIO-550-A,B,C,E TSIOL-550-A,B,C TSIOF-550-ALL

ROD P/N 655003 SETOF 6 BALANCED P/N 655004 Con-Rods Superseded by 655913 (Nut 654490 & Bolt 643112 IO-550-B, C Special Edition Only ROD P/N 655007 (SETOF 6 BALANCED P/N 655005 Con-Rods) Superseded By 655913 (Nut 654490 & Bolt 654068) Bolt 654068 Superseded By Bolt 655961 TSIO-520-UB Special Edition

ROD P/N 655913 (SETOF 6 BALANCED P/N 655911 Con-Rods) (Nut 654490 & Bolt 655958) IO-550-B,C,D,F,G,N Special Edition, Platinum TSIO-520-UB Special Edition, Platinum IOF-550-B,C,N Platinum

REVISED

PAGE NO REVISION TM

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06

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PO BOX 90 MOBILE ALABAMA 36601 • 251-438-3411

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A Teledyne Tec hnologies Company

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TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

CATEGORY 3

SB97-11 FAA APPROVED Supersedes M93-7

SUBJECT:

INSTALLATION OF SINGLE PIECE ROCKER ASSEMBLY BUSHINGS PART NUMBERS 652129 AND 652963

PURPOSE:

To insure correct installation of single piece rocker assembly bushings

COMPLIANCE:

At time of cylinder repair or overhaul

MODELS AFFECTED:

O-470, except A, E and J; IO-470, except J & K; all IO-520; IO-550; TSIO-470; and TSIO-520, except AE; all TSIO-550, GTSIO-520, GIO-550-A and all TSIOL-550 engine models.

GENERAL INFORMATION This service bulletin provides specific instruction for installation of single piece rocker arm bushings part numbers 652129 and 652963. Part 1 of this bulletin details the installation of bushing part number 652129. Part 2 of this service bulletin details installation of bushing part number 652963.

INSTALLATION OF SINGLE PIECE BUSHINGS, P/N 652129 AND P/N 652963, IN ROCKER ARMS OTHER THAN SPECIFIED IN THIS SERVICE BULLETIN WILL RESTRICT OR BLOCK OIL FLOW TO THE ROCKER ARM SHAFT AND VALVE GUIDES RESULTING IN POSSIBLE ENGINE FAILURE.

BUSHING INSTALLATION Part 1: Bushing P/N 652129 Bushing P/N 652129 may only be installed in rocker arms P/N 652130 and 652131. 1. Prior to installing a new bushing, perform both a visual and magnetic particle inspection of the rocker arm as detailed in the applicable engine overhaul manual.

MO

DAY

08

15

REVISED YEAR

MO

DAY

3. Measure the new bushing O.D. and insure that it conforms to the dimensions specified in Figure 1. 4. Insure that the bushing oil passages are positioned as illustrated in Figure 1. WARNING

WARNING

ISSUED

2. Measure rocker arm bushing bore I.D. and insure that it conforms to the dimensions specified in Figure 1.

YEAR

97

 1997 TELEDYNE INDUSTRIES INC.

INCORRECTLY POSITIONED BUSHING OIL PASSAGES WILL RESULT IN A LOSS OF LUBRICATION TO THE ROCKER ARM SHAFT, SEVERE ROCKER ARM BUSHING, SHAFT AND VALVE GUIDE WEAR AND POSSIBLE ENGINE FAILURE.

5. Thoroughly oil the bushing with clean 50 weight engine oil. 6. Using Borroughs Tools P/N 8118 (Rocker Arm Bushing Remover/Installer Set) or equivalent and an arbor press carefully press the bushing into the rocker arm bushing bore. Bushing must be installed flush to .020 below surface. Refer to Figure 3. 7. Prior to reaming bushing to size, fill the two bushing oil holes with beeswax to prevent debris from entering the oil passages.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO

1 of 4 SB97-11

REVISION

Ream bushing I.D. to .7505 - .7515 with a surface finish of 32 RMS. Refer to Figure 3. 8. After reaming clean and flush the oil passages with clean solvent removing beeswax and making certain that all passages are clear of any debris. 9. Perform a visually and magnetic particle inspection of rocker arm assemble as detailed in the applicable engine overhaul manual. PART 2: BUSHING P/N 652963 Bushing P/N 652963 may only be installed in rocker arm P/N 652966. 1. Prior to installing a new bushing, perform both a visual and magnetic particle inspection of the rocker as detailed in the applicable engine overhaul manual. 2. Measure rocker arm bushing bore I.D. and insure that it conforms to the dimensions specified in Figure 2. 3. Measure the new bushing O.D. and insure that it conforms to the dimensions specified in Figure 2. 4. Before pressing the bushing in place, insure that the oil passages are positioned as illustrated in Figure 2.

ISSUED MO

DAY

08

15

REVISED YEAR 97

MO

DAY

YEAR

WARNING INCORRECTLY POSITIONED BUSHING OIL PASSAGES WILL RESULT IN A LOSS OF LUBRICATION TO THE ROCKER ARM SHAFT, SEVERE ROCKER ARM BUSHING, SHAFT AND VALVE GUIDE WEAR AND POSSIBLE ENGINE FAILURE.

5. Thoroughly oil the bushing with clean 50 weight engine oil. 6. Using Borroughs Tools P/N 8118 (Rocker Arm Bushing Remover/Installer Set) or equivalent and an arbor press carefully press the bushing into the rocker arm bushing bore. Bushing must be installed flush to .020 below surface. Reference Figure 3. 7. Prior to reaming bushing to size, fill the two bushing oil holes with beeswax to prevent debris from entering the oil passages. Ream bushing I.D. to .7505 - .7515 with a surface finish of 32 RMS. Reference Figure 3. 8. After reaming clean and flush the oil passages with clean solvent removing beeswax and making certain that all passages are clear of any debris. 9. Visually and magnetic particle inspection rocker arm assemble as detailed in the applicable engine overhaul manual.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

2 of 4 SB97-11

.0020 .0065 PRESS * FIT

.54 REF

.54 REF 1.029 1.009

INSTALL BUSHING ORIENTED AS SHOWN

1.029 1.009

.54 REF

INNER DIAMETER .8755 .8725

.0020 .0065 PRESS FIT *

INSTALL BUSHING ORIENTED AS SHOWN

.54 REF

ROCKER ARM OIL GROOVE

INNER DIAMETER .8755 .8725

INTAKE P/N 652131

EXHAUST P/N 652130

X

X

70o

70o

50o

50o HOLES IN BUSHING MUST BE LOCATED IN THESE POSITIONS

HOLES IN BUSHING MUST BE LOCATED IN THESE POSITIONS

FIGURE 1 ∗

Bushing O. D. must maintain a .0020 - .0065 Press Fit in a .8755 - .8725 Rocker Arm Bushing Bore.

ISSUED MO

DAY

08

15

REVISED YEAR 97

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

3 of 4 SB97-11

.937 .917

.463 ± .010

.8755 .8725

INTAKE & EXHAUST P/N 652966

70o

50o

FIGURE 2

∗

HOLES IN BUSHING MUST BE LOCATED IN THESE POSITIONS

Bushing O. D. must maintain a .0020 - .0065 Press Fit in a .8755 - .8725 Rocker Arm Bushing Bore. .03 X 45o CHAMFER BOTH ENDS

.002 Inch

REAM .7515 .7505

IN. DIA.

INSTALL BUSHING FLUSH TO .020 BELOW SURFACE

FIGURE 3 TYPICAL Bushing must have a surface finish of 32 rms after reaming. ⊥ These surfaces must be square within the center line of the bushing bore within .002 inch full indicator reading. ISSUED MO

DAY

08

15

REVISED YEAR 97

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

4 of 4 SB97-11

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

CATEGORY 3

SB97-13 TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

REPLACEMENT FUEL PUMP FOR TSIO-520-BE ENGINE

PURPOSE:

Notify owners, operators, maintenance facilities and accessory overhaul shop of new engine driven fuel pump for the TSIO-520-BE engine.

COMPLIANCE: MODELS AFFECTED:

Next engine driven fuel pump replacement or next engine overhaul, which ever occurs first. TSIO-520-BE

The P/N 653010-1 fuel pump has been replaced by the P/N 649368-20A2 fuel pump on all TCM manufactured TSIO-520-BE engines effective with the following engine serial numbers. New

528523 and after

Rebuilt

273807-R and after

Service spare parts orders for the P/N 653010-1 fuel pump will be filled with the P/N 649368-20A2 fuel pump.

Installation of the P/N 649368-20A2 fuel pump in place of the P/N 653010-1 fuel pump will require replacement of the P/N 646513 fuel pump drive coupling with the 653359 fuel pump drive coupling. See Figure 1 for fuel pump drive coupling identification. The engine fuel injection system must be checked and adjusted as required after replacement of any fuel injection system component. Refer to TCM Service Bulletin SID 97-3A or latest revision for adjustment of the fuel injection system.

FIGURE 1 ISSUED MO

DAY

10

30

REVISED YEAR

MO

DAY

YEAR

97

 1997 TELEDYNE INDUSTRIES, INC.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

1 of 1 SB97-13

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB 97-15

SERVICE BULLETIN Compliance Will Enhance Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

TCM IGNITION SYSTEM SERVICE BULLETIN SB660

PURPOSE:

To inform customers of the subject TCM Ignition Systems Service Bulletin.

COMPLIANCE:

As indicated on the subject service bulletin.

MODELS AFFECTED:

All TCM engine models that us the Push-To-Start Ignition/Starter switches.

Teledyne Continental Motors requires that the subject service bulletin be complied with on all TCM engine models using the Push-To-Start Ignition/Starter switches.

MO 12

ISSUED DAY YEAR 05

97

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 1 SB97-15

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

SERVICE BULLETIN

CATEGORY 3

SB660

Compliance Will Enhance Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

POSSIBLE MALFUNCTION IN CERTAIN PUST-TO-START IGNITION / STARTER SWITCHES

PURPOSE:

To advise of the potential for uncommanded starter engagement and consequent propeller rotation as a result of malfunction in some Push-To-Start Ignition/Starter Switches, and to provide corrective action.

COMPLIANCE:

At the next and each subsequent 100 hour, annual, or progressive inspection, (whichever occurs most often) inspect affected switches for proper function. If improper function is found, replace the switch prior to further flight. NOTE: All TCM Ignition switches, regardless of the part number, date code or manufacturing number are to be functionally tested in accordance with the latest revision of TCM Ignition Systems Service Bulletin SB653 to insure the integrity of the magneto grounding circuit.

EQUIPMENT AFFECTED:

Push-To-Start Ignition/Starter switches, part numbers 10-357210-1 (with key), and 10357240-1 (with lever) with the following date codes or manufacturing numbers ONLY: 1. Units built by Bendix: date codes 8049 (1980, 49th week) and later. 2. 2. Units built by TCM: all manufacturing numbers up to but not including H0192-H (August 1, 1992). Refer to SIL642 to interpret manufacturing numbers. NOTE... 10-357210-1 switches are supplied individually or as part of a kit, such as but not limited to 10-357210-9 (Switch supplied with three keys) and 10-357210-10 (Switch with matching door lock set). All such kits have base part number 10-357210 followed by a suffix number. NOTE... Switch part number and date code or manufacturing number appear on the side of the aluminum switch housing. Switches built prior to 1976, outside the affected date code range, are not marked with any date code. Similar switches with functions other than Push-to-Start carry different part numbers and are not affected by this bulletin.

GENERAL INFORMATION: Field reports and examination of a returned switch indicate that affected switches, under certain circumstances, may allow a "short circuit" condition between the "BAT" terminal (Battery/Bus Power) and the "S" terminal (Starter Solenoid) when the switch is in the OFF position. If this occurs, uncommanded propeller rotation may result any time the Aircraft Battery Master Switch is in the ON

MO 12

ISSUED DAY YEAR 05

97

MO

REVISED DAY YEAR

position and the Ignition/Starter Switch is in the OFF position.

WARNING DO NOT PLACE OBJECTS OR PERSONS IN THE PATH OF PROPELLER ROTATION. DAMAGE, INJURY, OR DEATH MAY RESULT.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 3 SB660

This condition is the result of internal damage to the Ignition/Starter Switch which may be caused by incorrect operation. In some affected switches, this action makes and then breaks continuity to the starter solenoid, resulting in overheating and insulation breakdown. Damage to the switch, however, is not evident until the switch is rotated to the OFF position. Correct operation of the Push-to-Start Switch requires rotating the key or lever FULLY clockwise to the START position, THEN pushing in on the key or lever to engage the starter. If the starter cannot be engaged in the normal manner, discontinue the start procedure and investigate the cause of the difficulty. DO NOT rock the key or lever to hunt for a position to engage the starter, as repeated make-and-break of the inductive DC circuit will cause overheating and consequent damage. Because only some units of affected equipment will make continuity when the key or lever is pushed in and rotated clockwise the first few degrees from the BOTH position, only those switches that display this condition must be replaced. A continuity lamp/buzzer or similar device is used for this test because the condition may occur too quickly to actuate the starter solenoid and starter motor. Because wear may be a factor for all affected equipment, recurrent inspections are required. DETAILED INSTRUCTIONS 1. With the Aircraft Battery Master Switch OFF, and the Ignition/Starter Switch OFF, attach a continuity lamp/buzzer, timing light, or similar device across the BAT and S terminal as shown in Figure 1.

MO 12

ISSUED DAY YEAR 05

97

MO

REVISED DAY YEAR

2. If continuity is indicated with the Ignition/Starter Switch in the OFF position, remove and replace the switch. 3. If continuity is not indicated with the Ignition/Starter Switch in the OFF position, rotate the Ignition/Starter Switch key or lever clockwise to the BOTH position. Push in firmly on the key or lever and slowly rotate it toward the START position. 3.1 Normal function occurs if continuity is indicated ONLY as the key or lever approaches the full clockwise START position. 3.2 The Switch must be removed and replaced prior to further flight if continuity is indicated, however briefly, as the key or lever is rotated the first few degrees away from the BOTH position. If this happens, it is expected that continuity will be broken as the key or lever continues clockwise rotation, and continuity will be indicated again as the key or lever approaches the full clockwise START position.

WARNING WHENEVER A MAGNETO P-LEAD WIRE OR GROUND WIRE IS DISCONNECTED FROM THE SWITCH, THE MAGNETOS ARE IN A "HOT" CONDITION. THE ENGINE MAY INADVERTENTLY EXPERIENCE IGNITION OR START-UP ANY TIME THE PROPELLER IS MOVED. DEATH, INJURY, OR DAMAGE TO PROPERTY MAY RESULT. 4. Make a logbook entry for each action in compliance with this Service Bulletin.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 3 SB660

MO 12

ISSUED DAY YEAR 05

97

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

3 of 3 SB660

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB97-5

SERVICE BULLETIN Compliance Will Enhance Safety.

FAA APPROVED

SUBJECT:

INSTALLATION OF FLANGED TYPE FRONT MAIN BEARINGS

PURPOSE:

Supplement Overhaul Manual Instructions

COMPLIANCE: MODELS AFFECTED:

Engine overhaul or whenever the crankcase is separated. O-470 and IO-470 engines utilizing 537401, 646807 or 538879 standard or oversize one piece flanged front main bearings

Correct installation of flanged type front main bearings requires that the bearing saddle tang slot be properly located so that the flanged portion of the bearing is supported by the machined thrust face of the front main bearing saddle. Prior to installing flanged type front main bearing insure that the bearing saddle tang slot meets the dimensional specifications provided in Figure 1. Front main bearing saddles not meeting these specifications will require repair by an appropriately approved repair agency. When installing any bearing insure that the bearing saddle and bearing back are clean, free of any oil and that no debris will be trapped between the bearing back and bearing saddle. Flanged front main bearings must be positioned in the bearing saddle so that the thrust flange is firmly seated

against the machined thrust surface of the bearing saddle.

NOTE... The thrust surface is the surface that absorbs the load of the crankshaft during engine operation. See Figure 2.

WARNING UNSUPPORTED FRONT MAIN BEARING FLANGES MAY NOT WITHSTAND CRANKSHAFT THRUST FORCES DURING ENGINE OPERATION. THIS CONDITION CAN RESULT IN FATIGUE CRACKING TO THE BEARING FLANGE RADIUS AND POSSIBLE FAILURE.

AFFECTED PUBLICATIONS: Insert a copy of this Service Bulletin into the appropriate section of all TCM O-470 and IO-470 Engine model OVERHAUL and MAINTENANCE Manuals.

ISSUED MO

DAY

03

31

REVISED YEAR

MO

DAY

YEAR

97

 TELEDYNE INDUSTRIES, INC. 1997

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

1 of 2 SB97-5

ISSUED MO

DAY

03

31

REVISED YEAR 97

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601

PAGE NO REVISION

2 of 2 SB97-5

TELEDYNE CONTINENTAL

®

CATEGORY 3

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

SB97-6A FAA APPROVED Supersedes M87-11 REV. 2

SUBJECT:

MANDATORY REPLACEMENT PARTS

PURPOSE:

TO IDENTIFY ITEMS TO BE REPLACED DURING MAINTENANCE, PREVENTATIVE MAINTENANCE AND OVERHAUL

COMPLIANCE:

MODELS AFFECTED:

DURING MAINTENANCE, PREVENTIVE MAINTENANCE AND OVERHAUL

ALL MODELS

During any maintenance or preventive maintenance of engine or components, replace all removed gaskets, seals, packings, hoses, “O” rings, cotter pins, retaining rings (snap rings), safety wire, self locking fasteners (including exhaust and connecting rod nuts) and lock washers with new parts. Engine mounted accessories must be maintained in accordance with the manufacturer’s instructions. All accessories must be overhauled at engine overhaul, or more frequently, in accordance with the manufacturer’s instructions. Items such as spark plugs, alternator drive belts and air-conditioning drive belts must be replaced on condition. Do not re-use any fasteners that are worn, damaged or deformed. Do not replate any cadmium plated fasteners or washers. If the cadmium plating has been removed discard the item and replace it with a new part. At engine overhaul the starter, starter adapter, alternator, magnetos and engine fuel system must be overhauled. On turbocharged engines, the turbocharger, wastegate, controller and exhaust system must be overhauled. All engine baffles must be repaired or replaced and all flexible baffle seal replaced. NOTE....Service bulletins published or revised subsequent to the issuance of this service bulletin may mandate the replacement of components and parts not included in this service bulletin. As such, ISSUED

at engine overhaul the technician must review all service bulletins to insure compliance with the manufacturer’s requirements for continued airworthiness. In addition to the previously listed items, at engine overhaul the following parts must be discarded and replaced with new parts. 1. Hydraulic valve lifters (tappets) 2. Bearings: connecting rod, crankshaft main and thrust, needle, ball, and roller 3. Bushings: rocker arm, connecting rod, counter weight and crankshaft counterweight blade 4. Counterweight pins, retaining plates and snap rings 5. All connecting rod bolts and nuts 6. Connecting rod forging number 626119, TCM P/N’s 646320 and 646321 with beam width less than .625 inches. Reference TCM CSB96-13. 7. Camshaft gear bolts 8. Crankshaft gear bolts 9. Crankshaft alternator face gear bolts and lock plates 10. Woodruff keys 11. Magneto drive rubber bushings 12. Exhaust valves 13. Exhaust valve rotocoils 14. Replace all intake valve rotocoils 15. Replace intake valve rotocoils with solid valve spring retainers on all E-series, O-470, IO-470, IO-520 / 550, TSIO-520 / 550 TSIOL-550 and GTSIO-520 engines.

REVISED

PAGE NO REVISION TM

MO 04

DAY 07

YEAR 1997

MO 09

DAY 09

YEAR 2008

T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC

1 of 2 SB97-6

A

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Intake and exhaust valve keepers Inner and outer valve springs Piston pins Piston rings Pistons Rocker shafts Rockers shaft thrust washers Crankcase Through Bolts Cylinder deck stud nuts and through bolt nuts Exhaust clamps (Turbocharged engines) Cold Start primer diverter valves Fuel pump drive coupling P/N 631263 with P/N 653359 in accordance with TCM Mandatory Service Bulletin MSB 95-6 or latest revision 28. Starter Adapter Torsional Damper: GTSIO-520 model engines only 29. Starter Adapter shaft gear- GTSIO-520 model engines only 30. Replace all GTSIO-520 crankshaft gears.

AFFECTED PUBLICATIONS:

ISSUED

31. Crankshaft gear 536421 or 653631 must be replaced with 657175 or later part number crankshaft gear in all SANDCAST applications; O470, IO470,TSIO470, IO520,LIO520, L/TSIO520, IO550and IOF550 engines. 32. Turbocharger oil supply and return check valves 33. Replace 360 series engine oil suction screens part numbers 649470, 649471, 652669, 652670 with current part number. Reference TCM Service Bulletin SB96-4. 34. Replace C-125, C-145 and O-300 series engine oil suction screen part number 633272 with current part number. Reference TCM Service Bulletin SB96-4. 35. O-300, IO-360, TSIO-360 and LTSIO-360 oil pump gears in accordance with TCM Service Bulletin SB 96-4 and CSB 96-5 or latest revision 36. Ignition system harness

Make the appropriate annotations to applicable manuals to call attention to this service bulletin.

REVISED

PAGE NO REVISION TM

MO 04

DAY 07

YEAR 1997

MO 09

DAY 09

YEAR 2008

T e le d y n e C o n t in e n t a l M o t o rs, In c . A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

© 2008 TELEDYNE CONTINENTAL MOTORS, INC

2 of 2 SB97-6

A

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

CATEGORY 3

SB 98-2 TECHNICAL PORTIONS FAA APPROVED SUPERSEDES M 85-18

SUBJECT: PRE-FINISHED VALVE GUIDE DIMENSIONS PURPOSE: PROVIDE DIMENSIONAL FITS AND LIMITS FOR VALVES AND PRE-FINISHED VALVE GUIDES COMPLIANCE: AT ENGINE MAJOR OVERHAUL, CYLINDER OVERHAUL OR CYLINDER REPAIR MODELS AFFECTED: C-75, C-85, C-90, O-200, O-240 Rolls-Royce, O-300, G0-300, IO-240 IO360, TSIO-360, LTSIO-360 E-SERIES, O-470, IO-470, TSIO-470, IO-520, TSIO-520, LTSIO-520, GTSIO-520, IO-550, TSIO-550 AND TSIOL-550 SERIES ENGINES. GENERAL INFORMATION

IN SERVICE VALVE AND VALVE GUIDE MEASUREMENTS

Teledyne Continental Motors utilizes prefinished intake and exhaust valve guides in all current production cylinders and as service replacement parts. This service bulletin provides dimensional specifications for valves and pre-finished valve guides installed in current production cylinders. See Models Affected section of this bulletin for specific engine applications. Tables 1, 2 and 3 provide dimensional specifications for valves and pre-finished valve guides. NOTE: Refer to the applicable engine overhaul manual for valve guide removal and installation instructions and specifications. All measurements must be made using properly calibrated and certified precision measuring devices.

REVISED

11ISSUED MO

DAY

06

12

YEAR 98

MO

DAY

YEAR

1. Refer to the applicable engine Maintenance or Overhaul Manual for specific inspection criteria for intake and exhaust valves. Valve stems must conform to the new parts dimensions specified in Tables 1, 2 or 3 for the applicable engine. 2. When measuring valve guide inside diameter during cylinder repair or top overhaul; prior to engine major overhaul, take valve guide measurements at locations in the upper 1/3 and center 1/3 of the valve guide length. Reference Figure 1. Measurements taken at the bottom of the intake and exhaust valve guide are not indicative of the overall serviceability of the valve guide.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION 1 of 6 SB98-2

Valve guide inside diameter must not exceed the “Service Limit” dimensions specified for the specific engine and cylinder combination. Valve guides exceeding the “Service Limit” dimensions specified in Table 1, 2, or 3 as applicable will require replacement. NEW VALVE AND VALVE GUIDE MEASUREMENTS 1. New valves and valve guides must be measured before installation to insure they conform with the new parts dimensions specified in Tables 1, 2 or 3. 2. Measure valve guide inside diameter at three equally spaced locations along the length of the valve guide. Reference Figure 1. 3. Measure the outside diameter of the valve guide below the flange, reference Figure 2. Record these readings on the repair work order. 4. Measure valve stem diameter between the valve keeper annulus and the face of the valve. Record this reading on the repair work order.

ISSUED MO

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VALVE GUIDE INSTALLATION: 1. Refer to the applicable engine overhaul manual for specific installation instructions and specialized equipment and tooling required. 2. Before installing a replacement valve guide, the valve guide bore in the cylinder head must be reamed to the proper oversize dimension. The difference between the valve guide outside diameter and the valve guide bore inside diameter must be within the dimensional specification provided in Table 1, 2, or 3 for the applicable engine and cylinder combination. 3. After installing new valve guides allow the cylinder to cool and stabilize at room temperature before taking any dimensional measurements. Measure valve guide inside diameter at three equally spaced locations along the length of the valve guide. Reference Figure 1. If inside diameter is not within the specific new minimum and maximum dimensional limits, the guide will require finish reaming to size or replacement.

TELEDYNE CONTINENTAL M OTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION 2 of 6 SB98-2

MEASURE IN SERVICE VALVE GUIDE I. D. AT THESE LOCATIONS

FIGURE 1 IN SERVICE VALVE GUIDE DIMENSIONAL MEASUREMENTS

VALVE GUIDE

MEASURE NEW VALVE GUIDES AT ALL 3 LOCATION BEFORE AND AFTER INSTALLATION

MEASURE VALVE GUIDE O.D. AT THIS LOCATION

VALVE GUIDE BORE IN CYLINDER HEAD MEASURE BORE AFTER REAMING PRIOR TO INSTALLING GUIDE IN CYLINDER HEAD

FIGURE 2 INSTALLATION CRITICAL MEASUREMENT LOCATIONS

ISSUED MO

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12

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YEAR

TELEDYNE CONTINENTAL M OTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION 3 of 6 SB98-2

TABLE 1 Engine Model

Description Intake Valve Guide In Cyl. Head Intake Valve In Guide

O-240 RollsRoyce

IO-240A&B

IO-360 Series

L / TSIO360 Series

O / IO 470 Series

Intake Guide Bore (New) Intake Guide Bore (installed in cylinder) Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Exhaust Guide Bore (New) Exhaust Guide Bore (installed in cylinder) Exhaust Valve Stem Diameter Intake Valve Guide In Cyl. Head Intake Valve In Guide

O-4704, 11 & 13

Intake Guide Bore (New) Intake Guide Bore (installed in cylinder) Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Exhaust Guide Bore (New) Exhaust Guide Bore (installed in cylinder) Exhaust Valve Stem Diameter

IO / TSIO & LTSIO520 Series IO / GIO & TSIO 550 Series GTSIO520 Series TSIOL550

ISSUED MO

DAY

06

12

REVISED YEAR 98

MO

DAY

YEAR

New Parts Minimum Maximum .0010 T .0025 T .0010 L

.0040 L

.3760

.3770

.3745

.3770

.3730

.3735

.0010 T

.0025 T

.0025 L

.0057 L

.3760

.3770

.3745

.3770

.3713

.3720

.0010 T

.0025 T

.0010 L

.0042 L

.4367

.4377

.4350

.4377

.4335

.4340

.0010 T

.0025 T

.0035 L

.0062 L

.4385

.4395

.4375

.4395

.4333

.4340

Service Limits

.006 L

.008 L

.0065 L

.0085 L

TELEDYNE CONTINENTAL M OTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION 4 of 6 SB98-2

TABLE 2 Engines Model C-75 C-85 C-90 O-200’s O-300’s GO300’s with P/N 653816 Cylinder

C-75’s C-85’s C-90’s O-200’s O-300’s GO300’s with P/N 653426 Cylinder

Description Intake Valve Guide In Cyl. Head Intake Valve In Guide Intake Guide Bore (New) Intake Guide Bore (installed in cylinder) Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Exhaust Guide Bore (New) Exhaust Guide Bore (installed in cylinder) Exhaust Valve Stem Diameter Intake Valve Guide In Cyl. Head Intake Valve In Guide Intake Guide Bore (New) Intake Guide Bore (installed in cylinder) Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide Exhaust Guide Bore (New) Exhaust Guide Bore (installed in cylinder) Exhaust Valve Stem Diameter

ISSUED MO

DAY

06

12

REVISED YEAR 98

MO

DAY

YEAR

New Parts Minimum Maximum .0010 T .0025 T .0010 L

.0040 L

.3760

.3770

.3745

.3770

.3730

.3735

.0010 T

.0025 T

.0025 L

.0057 L

.3760

.3770

.3745

.3770

.3713

.3720

.0010 T

.0025 T

.0010 L .3447

.0045 L .3457

.3432

.3457

.3412

.3422

.0010 T

.0025 T

.0035 L

.0057 L

.4367

.4377

.4360

.4377

.4320

.4325

Service Limit

.006 L

.008 L

.006 L

.008 L

TELEDYNE CONTINENTAL M OTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION 5 of 6 SB98-2

TABLE 3 Engines Model

Description Intake Valve Guide In Cyl. Head Intake Valve In Guide

O-470-4 11 & 13

Intake Guide Bore (New) Intake Guide Bore (installed in cylinder) Intake Valve Stem Diameter Exhaust Valve Guide In Cylinder Head Exhaust Valve in Guide

E-Series with P/N 654761 and P/N 654947 Cylinders

New Parts Minimum Maximum .0010 T .0025 T .0010 L

.0042 L

.4367

.4377

.4350

.4377

.4335

.4340

.0010 T

.0025 T

.0026 L

.0053 L

.4376

.4386

.4366

.4386

.4333

.4340

Exhaust Guide Bore (New) Exhaust Guide Bore (installed in cylinder) Exhaust Valve Stem Diameter

Valve Guide Material by Guide Part Number 643766 Aluminum - Bronze643767 Ni-Resist 646681 Aluminum - Bronze 649177 Aluminum - Bronze 653214 Ni-Resist 653726 Ni-Resist 653802 Aluminum - Bronze

ISSUED MO

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12

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MO

DAY

YEAR

Service Limit

.0065 L

.0076 L

Pre-finished Pre-finished Pre-finished Pre-finished Pre-finished Pre-finished Pre-finished

TELEDYNE CONTINENTAL M OTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION 6 of 6 SB98-2

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

CATEGORY 3

SB 98-4 TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

EXHAUST SYSTEM INSPECTION

PURPOSE:

Notification to Owners, Operators and Maintenance facilities of necessity to inspect exhaust systems manufactured by Wall Colmonoy for Teledyne Continental Motors.

COMPLIANCE: MODELS AFFECTED:

Within the next 100 hours time in service but not later than the next scheduled maintenance event or inspection. TSIO-360 - MB and TSIO-360-SB Engines

Inspection of a returned TSIO-360-MB / SB engine exhaust system has revealed a condition that if not corrected could result in disengagement of the exhaust slip joint at the number 5 cylinder riser crossover assembly, P/N 654890. GENERAL INSPECTION: Remove engine cowling as necessary to gain access to the engines exhaust system. Visually inspect the entire exhaust system for broken, missing or incorrectly assembled components. It is not unusual for exhaust system expansion slip joints to exhibit some evidence of minor leakage. However; exhaust stains and / or discoloration of adjacent areas such as push rod housings, cylinder cooling fins, inter-cylinder baffles, engine mount structure and the nacelle are indicative of unacceptable expansion slip joint leakage. DETAILED INSPECTION: Inspect number 5 cylinder exhaust riser flange for evidence of leakage.

ISSUED MO

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06

12

REVISED YEAR 98

MO

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YEAR

Visually inspect the number 5 cylinder exhaust riser crossover assembly, P/N 654890, slip joint link and brackets for cracks or broken welds. Refer to Figure 1. Insure the number 5 cylinder exhaust riser cross over assembly, P/N 654890, slip joint link rod is centered between the “L” brackets welded on the crossover elbow and that the spacer, P/N 654309, is installed in the link rod slot. When assembled the link rod must move freely the full limit of its travel. Refer to Figure 2. Inspect the exhaust system crossover slip joint located at the centerline of the engine for evidence of leakage. Refer to Figure 3. Insure that the slip joint heat shield is installed in accordance with the instructions provided in the Mooney Aircraft Service Manual. Failure to correctly install the heat shield will negate the function of the slip joint and cause thermal expansion stress loading to the system and possible exhaust system failure.

TELEDYNE CO NTINENTAL M O TO RS An Allegheny Teledyne Company

P.O. Box 90 M obile Alabam a 36601 Ph. 334-438-3411

PAGE NO REVISION 1 of 4 SB98-4

CORRECTIVE ACTION:

CAUTION

Replace any broken or cracked exhaust system component with a new part or a part that has been repaired and certified by a certificated repair agency. Refer to Figure 4 for part information.

Do not operate any engine with broken, missing, damaged or incorrectly assembled exhaust systems or exhaust system components. Failure to correct exhaust leaks may result in a loss of engine power, elevated cylinder head and / or oil temperature.

Exhaust leaks at cylinder riser flanges must be repaired. Do not arbitrarily replace any exhaust system gaskets. Thoroughly inspect the component (s) for cracks, warped flanges, distortion and damaged sealing surfaces. Replace or repair component (s) with these conditions.

Current Production Wall Colmonoy

Original Production Elano

INSPECT THIS AREA FOR CRACKS

FIGURE 1

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TELEDYNE CO NTINENTAL M O TO RS An Allegheny Teledyne Company

P.O. Box 90 M obile Alabam a 36601 Ph. 334-438-3411

PAGE NO REVISION 2 of 4 SB98-4

NUMBER 5 CYLINDER RISER ASSY. SLIP JOINT LINK ATTACHMENT: INSURE PROPER ASSEMBLY AND FREEDOM OF MOVEMENT THRU THE FULL RANGE OF TRAVEL

FIGURE 2

SLIP JOINT FRONT CENTER LINE OF ENGINE BETWEEN NUMBER 5 AND 6 CYLINDER

FIGURE 3

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TELEDYNE CO NTINENTAL M O TO RS An Allegheny Teledyne Company

P.O. Box 90 M obile Alabam a 36601 Ph. 334-438-3411

PAGE NO REVISION 3 of 4 SB98-4

FIGURE 4

INDEX 4-8 Attaching Parts

PART NUMBER DESCRIPTION QUANTITY 654890 * #5 Cylinder Riser & Crossover Assy. 1 AN3-4A Bolt 1 MS21043-3 Nut, Self locking 1 654309 Spacer 1 * Part Number 654890 Riser and Crossover Assy. consist of 1 each 654881 crossover (body), 1 each 654882 number 5 exhaust rise and the attaching parts as listed above.

ISSUED MO

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12

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TELEDYNE CO NTINENTAL M O TO RS An Allegheny Teledyne Company

P.O. Box 90 M obile Alabam a 36601 Ph. 334-438-3411

PAGE NO REVISION 4 of 4 SB98-4

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB 98-8

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy of Operation

TECHNICAL PORTIONS FAA APPROVED

SUBJECT: NUMBER ONE AND THREE CYLINDER INTAKE TUBE MODIFICATION PURPOSE:

Provide Installation Flexibility To Avoid Loading Tube Flange

COMPLIANCE: Next Scheduled Maintenance MODELS AFFECTED: I0-360-ES, TSI0-360-MB, SB, RB AND LTSI0-360-RB REMOVAL 1. Remove engine cowling and any components that obstruct access to the number one and number three cylinder induction tubes in accordance with the airframe manufacturer’s instructions. 2. Remove four nuts, four lock washers and four plain washers from the number one and three cylinder induction tube flanges. 3. Loosen four hose clamps and separate the number one and number three cylinder induction tubes from the intake manifold. Remove and discard lock washers and gaskets. 4. Remove the number one and number three cylinder intake tubes from the engine. 5. Remove the mounting flanges from the intake tubes and clean using stoddard solvent. Store flanges in a clean protected area until intake tube is to be assembled to engine. 6. Fluorescent penetrant inspect the tube flange radius for cracks. Fluorescent penetrant inspection must be performed in accordance with ASTM E 1417. Specific process procedures are referenced in ASTM E 1208, E 1209, or E 1219. The penetrant method used must be Type I (fluorescent), Method A, B, C or D.

ISSUED MO

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10

22

REVISED YEAR 98

MO

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YEAR

Kit P/N EQ6977 which contains: a. 1ea. new hose P/N 642917-16 b. 2 ea. clamps P/NAN737TW74 c. 1 ea. Gasket P/N 654227 may be ordered from TCM for reassembly of the number one and number three cylinder induction tubes. NOTE…Order two kits to modify both number one and number three cylinder induction tubes.

MODIFICATION The number one and number three cylinder induction tubes may be modified using the following instructions. 1. Cut and remove material from the number one and number three cylinder intake tubes in accordance with Figure 1. After material has been removed debur the tube ends. Using 180 grit paper, roughen 1/2 inch from the edge of the new cuts inward on each tube piece to improve hose seating. Clean the tubes using stoddard solvent. The tubes must be free of any debris.

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

1 of 4

P.O. Box 90 Mobile AL 36601

SB98-8

334-438-3411

2. The reworked tube assemblies now have new part numbers. Part numbers 655230-1 for the tube portion with the flange and 655230-2 for the inboard tube portion for cylinder number one intake tube. Part numbers 655224-1 for the tube portion with the flange and 655224-2 for the inboard tube portion for cylinder number three intake tube. See Figure 1. REASSEMBLY 1. Place flange on tube assemblies 655230-1 and 655224-1. Using new gaskets P/N 654227 install tube assemblies on number one and number three cylinders. Adjust intake tubes so they are seated squarely on cylinder flanges and aligned with remaining section of tube and casting. Secure using two nuts P/N AN315-5R, two washers P/N AN960-516L and two new lock washers P/N MS35338-45.

WARNING During engine inspection run, do not stand or allow anyone else to stand in the propeller arc area. 5. Start and operate the engine in accordance with the airframe manufacturer’s airplane flight manual (AFM) and inspect for any leaks. 6. The engine must be operating properly and free of any leaks prior to returning it to service. 7. Install engine cowling in accordance with the airframe manufacturer’s instructions.

WARNING Do not pre-load the tube flange. 2. Install a new hose P/N 642917-16 and two new clamps AN737TW74 on tubes 655230-1 and 655224-2. Adjust hose and clamps so that tube ends can be aligned and attached. Install tube end into manifold hose and clamp. Attach tube 655230-2 end to tube 655230-1 and 655224-2 end to tube 655224-1. 3. Torque the tube to cylinder flange nuts to 50-70 inch pounds. Torque all clamps (19) to 40-50 inch pounds. 4. Install any components that that were removed to gain access to the number one and three cylinder induction tubes in accordance with the airframe manufacturer’s instructions.

ISSUED MO

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22

REVISED YEAR 98

MO

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TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

2 of 4

P.O. Box 90 Mobile AL 36601

SB98-8

334-438-3411

6.38 ± .03 3.06 ± .03 1.31 ± .03

3.06 ± .03 1.68 ± .03 5.31 ± .03

4.93 ± .03

7.50 ± .03

10.51° 7.50 ± .03

.50 ± .03 2.90 ± .03 2.92 ± .03

NEW P/N 655230-2

3.40 ± .03

NEW P/N 655224-2

.50 ± .03 2.75 ± .03

NEW P/N 655224-1

2.60 ± .09

NEW P/N 655230-1

INDUCTION TUBE CYLINDER #3

INDUCTION TUBE CYLINDER #1

FIGURE 1.

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TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

3 of 4

P.O. Box 90 Mobile AL 36601

SB98-8

334-438-3411

INTENTIONALLY LEFT BLANK

ISSUED MO

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REVISED YEAR 98

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TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

4 of 4

P.O. Box 90 Mobile AL 36601

SB98-8

334-438-3411

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB99-8

SERVICE BULLETIN Compliance Will Enhance Safety

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

ENGINE FUEL INJECTION SYSTEM PRESERVATION

PURPOSE:

To provide instructions for deinhibiting the fuel injection systems on Factory New and Rebuilt engines.

COMPLIANCE: MODELS AFFECTED:

During engine installation, prior to first engine start. All TCM Factory New and Rebuilt Fuel Injected Engines.

Teledyne Continental Motors is now purging / preserving the fuel injection system on all fuel injected engines prior to shipment from Teledyne Continental Motors. The purging / preservation fluid being used is MIL-PRF-6081D Grade 1010. This Service Bulletin provides information on deinhibiting the engine fuel injection system during engine installation and prior to the first engine start. In addition to the “Preparation for Service Instructions” provided in the applicable engine Maintenance Manual perform the following. 1. Remove the shipping plugs installed in the lower spark plug holes of all cylinders and, by hand, turn the crankshaft through at least two complete revolutions in order to purge the preservative oil from the cylinders. 2. Remove the shipping cap installed on the inlet fitting of the engine driven fuel pump. Allow any preservation oil present to drain into an approved container. Reinstall the shipping cap to prevent debris from entering the fuel pump during engine installation.

ISSUED MO

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18

REVISED YEAR

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99

 1999 Teledyne Technologies Incorporated

After completing the engine installation and before the first engine start perform the following. 1. Disconnect the fuel supply line at the inlet to the fuel manifold valve. 2. Connect a length of the appropriate size hose to the disconnected fuel manifold supply hose using an AN union fitting and place the end of the hose in an approved Type 1 flammable fluid container that is properly grounded. CAUTION: Ensure that the magneto switch is in the off position and stand clear of the propeller arch prior to proceeding. 3. While holding the hose connected in the preceding step “2” above in the approved contained have an assistant turn the aircraft master switch on. 4. Place the mixture control to full rich and the throttle to full open. 5. Turn the aircraft boost pump to the on position.

TELEDYNE CONTINENTAL MOTORS A Teledyne Technologies Company P.O. Box 90 Mobile Alabama 36601 334-438-3411

PAGE NO REVISION

1 of 2

6. Continue to operate the aircraft boost pump until the preservation fluid has been purged from the fuel system, approximately one (1) minute. 7. Turn the aircraft boost pump and master switch to the off position. 8. Close the mixture and throttle. 9. Remove the extra length of hose and AN union installed in the preceding step 2 from the fuel manifold valve supply hose. 10. Connect the fuel manifold valve fuel supply hose to the inlet fitting on the manifold valve and torque the fuel hose “B” nut to the valve specified in latest revision of TCM SB 96-7 Rev. B. CAUTION: Ensure that the magneto switch is in the off position and stand clear of the plane of the propeller arch prior to proceeding. NOTE: Place approved containers at the induction system drain locations to collect fuel as it is drained overboard during the following procedure.

12. With the mixture control in FULL RICH and the Throttle ¼ OPEN, turn the aircraft boost pump to the ON position. 12. Visually inspect all fuel injection system lines, hoses and fitting for evidence of fuel leakage. 13. Place the mixture control to IDLE CUT-OFF and CLOSE the THROTTLE. 14. Turn the aircraft fuel boost pump OFF. 15. Turn the aircraft master switch OFF. 16. Correct any discrepancies noted. 17. Properly dispose of the fuel / oil mixture in accordance with Federal and State Regulations. Perform a normal engine start in accordance with the aircraft manufacturers POH / AFM. NOTE: There may be a small amount of preservation oil remaining in the cylinders, induction system and fuel nozzles lines resulting in some minor visible smoke being emitted from the exhaust immediately after engine start.

11. Have an assistant turn the aircraft master switch to the ON position.

ISSUED MO

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TELEDYNE CONTINENTAL MOTORS A Teledyne Technologies Company P.O. Box 90 Mobile Alabama 36601 334-438-3411

PAGE NO REVISION

2 of 2

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 4

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy of Operation

SID 05-1 Technical Portions FAA Approved

SUBJECT:

THIS SERVICE INFORMATION DIRECTIVE (SID) SUMMARIZES INFORMATION PERTINENT TO THE DESIGN, OPERATION, MAINTENANCE AND WARRANTY FOR TCM CAMSHAFTS AND HYDRAULIC LIFTERS

PURPOSE:

1) To provide information on the operation and material of the cam and lifters. 2) To provide information to determine if inspection is required. 3) To assist with inspection criteria if any inspection is indicated. 4) To update TCM’s warranty policy if cam and lifter component issues are determined

COMPLIANCE: MODELS AFFECTED:

TCM recommends inspection described only if the indications defined are found. In the absence of such indications, no action is needed or recommended. All TCM engine models

INTRODUCTION DESIGN The camshaft in TCM engines is located below the crankshaft and is driven by a gear set from the crankshaft at one-half the speed of the crankshaft. The lobes on the cam control valve lift and duration. The links between the cam and the valves are the hydraulic lifters, the push rods and the rocker arms. VALVE CAMSHFT LOBE

ROCKER ARM

LIFTER PUSHROD

FIGURE 1:

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama • 251-438-3411

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The hydraulic lifter performs two functions. First, it provides an interface between the camshaft lobe and the remaining valve train. This allows conversion of the cam lobe profile into a linear movement for actuation of the intake and exhaust valves. Secondly, the hydraulic mechanism inside the lifter maintains zero clearance between the valve and it’s actuating components The loads on the lifter are a result of the force of the cam lift against the valve springs and the inertia of the components. This load transfers between the cam face and the lifter face over a small area with some sliding occurring between the two surfaces. High contact stresses are generated and are countered by use of very hard materials with splash oil present to reduce friction. The face of the lifter has a small curvature or crown, and the cam lobe has a slight taper. This results in the contact point being off-center of the lifter and causes the lifter to rotate during operation, avoiding single point contact between the lifter and the camshaft lobe.

8 7 11 9 10 6 1 12 5 2 14 4

Steel Body (1) Expanding Spring (2) Check Valve Assembly (3, 4 and 5) Plunger (6) Pushrod End Socket (7) Retaining Ring (8) Outside Groove (9) Interior Body Groove (11) Hole (10) Reservoir (12) Reservoir (14) Check Valve Ball (5) Spring (4) Housing (3)

3

FIGURE 2 HYDRAULIC LIFTER CROSS SECTION

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FIGURE 3

CAM AND LIFTER INTERFACE MATERIALS

The material of the cam is aircraft quality steel with the cam lobes carburized for additional hardness and wear resistance. During manufacture, the lobes are also coated with a manganese phosphate coating to resist rust and lower friction during the initial hours of engine operation.

MJ

#6 EXH

# 5 IN T # 6 IN T

CL

CL

#5 EXH

MJ

CL

#4 EXH

# 3 IN T # 4 IN T

#3 EXH

CL

CL

CL

#2 EXH

MJ

CL

# 2 IN T # 1 IN T

CL

#1 EXH

CL

MJ

T y p ic a l C a m s h a f t

M J = M A IN J O U R N A L CL = CAM LO BE

CAMSHAFT DRIVE GEAR

FIGURE 4 TYPICAL CAMSHAFT

The lifter body is made of cast iron with the face being “chilled” during casting. The chilled cast iron face has areas of extremely hard wear resistant material, iron carbides, surrounded by a softer matrix of iron. This combination provides excellent wear characteristics under high contact stress situations such as the camlifter interface. The face of the lifter is also manganese phosphate coated for the same reasons as the cam lobes. ISSUED

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This combination of materials has been used by TCM for many years on all of our engines. Other aircraft engine producers use very similar materials. WEAR MECHANISMS The interface between a cam lobe and lifter is intended to wear to some degree as the engine operates. This is similar to the piston ring / cylinder wall interface that must seat together for proper operation and wear over time. The manganese phosphate will quickly wear off in loaded areas of the cam lobe and the lifter face. Normal wear may take the form of a bright shiny uniform wear surface, with a circular pattern visible on the lifter face. Damage to the lifters is often referred to as “galling” or “spalling”. Localized areas may show signs of spalling or galling in service due to various operating conditions. Some level of such conditions will frequently be found at overhaul. Note that this wear material as with all other normal wear material will be collected by the oil and trapped in the oil filter element or screen

FIGURE 5 TYPICAL LIFTER FACES FROM SERVICE Galling results from a breakdown in lubrication allowing bare metal to metal contact. Bonding of one of the materials to the other can result, transferring a small amount of material. The transferred material may cause a high stress region and can lead to spalling. In spalling, high contact stresses induce cracks in the softer matrix around the iron carbides in the lifter face. This type of damage appears as a small area of the lifter face that has separated leaving a small hole. This type of distress occurs due to the chilled iron face having regions of high hardness in a matrix of softer material. Under high loads and with stress concentrations, small sections of the softer material may fatigue and separate from the harder material. Since the camshaft is steel and the lifter body is iron, rust or corrosion is by far the most common reason for lifters to spall. The pits caused by corrosion are stress concentrations that result in spalling. ISSUED

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Foreign material between the cam lobe and lifter can result in very high local loads on the surfaces and break down a local area of the lifter. Foreign material may also stop a lifter from rotating in the bore. This results in one area being loaded constantly and can also lead to spalling. Manufacturing issues such as not having the correct dimensions have the potential to result in spalling. Material issues with the lifter body can effect the chilled area adversely leading to spalling as well. WEAR EFFECTS The cam lobe / lifter interface is designed to wear to some extent during service life and the lifter and cam lobe “break in” together similar to piston rings in a cylinder bore. Such wear is normal as are circular wear patterns on the face of the lifter and polishing of the cam lobes. Circular scratches may also result from hard particle passage and will not effect operation. Minor spalling due to corrosion or other factors will not affect operation as the loads are redistributed to the surrounding material. The appearance will be some number of separated spalled areas with polished contact patterns on the remainder of the face. (Reference Figure 6)

FIGURE 6 MINOR SPALLING Major spalling that involves much of the face will also usually have no effect on operation and will also frequently “heal over” and re-establish a stable surface for the cam interface. The effect on the cam is minimal. Note that the hydraulic feature of the lifter continuously adjusts for any wear and keeps valve operation normal. The material from such spalling is small and drops into the oil sump when generated and is captured in the oil filter element or screen

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In very rare cases, the lifter deterioration will cause significant wear to the cam lobe. In such cases, the lift of the valve may be reduced. Initially, the effect on performance would be negligible, but may eventually lead to reduction of power of the cylinder effected. Valve lift is in the order of one-half inch so the wear would have to be extreme to noticeably effect cylinder performance. Note that the hydraulic lifter has a limited range of hydraulic adjustment and would run out of travel before extreme wear occurred. This could result in an audible tapping noise from the engine.

CORROSION ETCHING ON BODY

FULL FACE SPALLING

FIGURE 7 LIFTER CORROSION AND SIGNIFICANT SPALLING In some cases, significant spalling may result in some damage to the cam lobe apex. This level of damage is rare, but will manifest itself as surface cracks on the nose with some depth. Note that appearance of the cam lobe apex may vary normally, and only if such cracks are present should the camshaft be considered a candidate for replacement. Corrosion (rust) will also cause cam lobe distress. See the INSPECTION SECTION for specifics.

CAM-LIFTER DISTRESS DETECTION As with other wearing parts in the engine, the normal means of detecting excessive wear are by oil analysis, examination of the oil filter element or screen at each oil change, and for engines with oil suction screens and/or magnetic drain plugs, examination of those screens and/or plugs for iron or steel. Extreme wear may be detected by audible noise from the valve train. Such noise may also indicate a lifter that is not pumping up properly to take up system lash rather than wear. IN THE ABSENCE OF SUCH INDICATIONS, NO ACTION IS NEEDED.

If an abnormal amount of iron material is observed in the filter and believed to be from the lifters, an inspection may be carried out as detailed in lifter and cam lobe inspection section.

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CAM-LIFTER DISTRESS PREVENTION Issues related to corrosion such as the majority of the cam-lifter reports can be reduced by frequent flight operation with the oil up to normal temperatures. A minimum of 30 minutes cruise flight after oil temperatures are stable (in the 170°f to 200°F range) is needed. Such use keeps lubrication on the parts and helps to remove moisture and acids from the oil. Any initial corrosion on cylinder bores or the cam lobe-lifter interference is eliminated before etching pits into the surface. As a result of such frequent operation, fleet operators rarely experience such corrosion and subsequent cam lobe / lifter distress issues. Unfortunately, this may not be possible for aircraft that are infrequently flown. It is especially important for infrequently flown aircraft to have frequent oil changes. TCM recommends that aircraft that are not flown on a regular basis have the oil and filter changed at least four times a year. Oil changes are needed not because the oil is “breaking down” but to eliminate wear particles, combustion by-products, moisture and acid buildup in the oil. Clean oil should be installed and the aircraft flown prior to significant periods of inactivity. Also, the instructions in TCM Service Bulletin SIL99-1, Engine Preservation For Active and Stored Aircraft must be followed. Pre-heating using crankcase heaters is an effective means of warming an engine. However, the warming and cooling process can also condense moisture into the oil aggravating corrosion issues. See the latest revision of TCM bulletin SIL03-1 Cold Weather Operation – Engine Pre-Heating for more information on this subject. Various types of oils are approved for use in the engines. All provide good lubrication under normal operation. There are differences in the tendency to retain moisture and to scavenge lead and other combustion products between straight oil and multi-viscosity oil and between mineral oil and semi-synthetics. No conclusive evidence is known correlating these characteristics to the incident rate of cam-lifter reports.

LIFTER AND CAM LOBE INSPECTION If abnormal amounts of iron/steel are detected by oil analysis, oil filter element or screen examination, oil suction screen examination, or drain plug examination, the lifters and cam lobes may be examined as described below. No examination is needed in the absence of such indicators or audible noise from the valve gear. INSPECTION (1) Using the airframe manufacturers maintenance instructions remove engine cowlings and cooling baffles as necessary to gain access to the cylinders for valve cover removal. Using the appropriate engine overhaul or maintenance manual, remove the lifters as follows: WARNING VERIFY MASTER SWITCH IS IN THE "OFF" POSITION AND MAGNETO SWITCHES ARE CONNECTED TO THE MAGNETOS, THAT THEY ARE IN THE "OFF" POSITION AND "P" LEADS ARE GROUNDED WHILE WORKING IN CLOSE PROXIMITY TO THE PROPELLER.

(2) Remove valve covers from the cylinders. (3) Position the crankshaft so that the valves of the cylinder being worked are fully closed.

(4) Remove rocker shaft retaining hardware, rocker shafts, rocker arms and thrust washers (as required). Discard tab lock washers (Where used) Mark the removed parts for re-installation in the position from which they were removed. (5) Remove the pushrods. Mark the removed pushrods and for reinstallation into the position from which they were removed and mark their installed orientation.

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(6) Compress the pushrod housing against the spring until the outboard end is clear. Drop the cylinder flange end of the pushrod housing until it is clear of the cylinder and then remove the housing from the crankcase. NOTE Some engine configurations allow removal of the pushrod housing through the cylinder head flange. These configurations may be identified by the presence of two pushrod housing washers on either side of the pushrod housing seal installed in the cylinder head. After removal of the pushrod housing seals and washers from the cylinder head, the pushrod tube may then be removed through the cylinder head. On engine models not incorporating this design, removal of induction system components may be required to facilitate pushrod tube removal. (7) Remove the hydraulic lifter assemblies from the lifter bores. Mark the lifters for reinstallation into the position from which they were removed. (8) If the lifter face and body shows normal signatures, coat with Dow-Corning G-N paste and reinstall in the same location as removed. (9) Reinstall items removed in steps 1 through 6 above (using new tab washers as applicable) using the latest revision of the appropriate maintenance or overhaul manual and the latest revision of Service Bulletin SB96-7 Torque Limits. Replace lifters with severe face or lifter body wear signatures or spalling that exceeds 10% of the surface area. Lifters associated with noise indicating excessive valve lash should also be replaced regardless of face condition.

FIGURE 8 ACCEPTABLE LIFTER FACE SIGNATURE ISSUED

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FIGURE 9 REPLACEMENT SIGNATURES, SPALLED LIFTER If a lifter must be replaced following the inspection criteria and Figures 10 - 12, inspect the associated cam lobe as follows: WARNING VERIFY MASTER SWITCH IS IN THE "OFF" POSITION AND MAGNETO SWITCHES ARE CONNECTED TO THE MAGNETOS, THAT THEY ARE IN THE "OFF" POSITION AND "P" LEADS ARE GROUNDED WHILE WORKING IN CLOSE PROXIMITY TO THE PROPELLER. (1) Turn engine so that the apex of the cam lobe is visible through the lifter bore in the crankcase, reference Figure 10.

FIGURE 10 CAM LOBE APEX IN INSPECTION LOCATION (Normal wear signature shown) ISSUED

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(2) Perform visual inspection using an inspection light. If the surface is smooth and shiny with only small areas of rough appearance, no further action is required.

CAM LOBE OPENING FACE

APEX OF CAM LOBE

CAM LOBE CLOSING FACE FIGURE 11 TYPICAL CAM LOBE WEAR SIGNATURES

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(3) If the visual inspection indicates the presence of crack like features in the surface along the cam lobe apex, proceed as follows: Using a sharp pick, move the point over the nose. If a crack like feature has any depth, the pick will catch in the groove or pits. If no positive indication of a crack is felt, no further action is required. If an indention is present, the cam must be examined by a TCM service representative to determine the next steps.

SPALLED CAM LOBE

CORROSION PITTED CAM LOBE FIGURE 12 SUSPECT CAM LOBE APEX SIGNATURES

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NOTE CONTACT TCM SERVICE DEPARTMENT TO ARRANGE EXAMINATION OF THE SUSPECTED AREA BY A TCM SERVICE REPRESENTATIVE. For minor distress, the camshaft may be continued in service and re-examined upon the accumulation of 100 hours operation or 12 months, whichever occurs first. If the TCM representative determines the camshaft should be replaced, the engine should be removed for repair. Note that cylinder removal to gain better access may be required to make the final determination.

FIGURE 13 CAM LOBE APEX MINOR DISTRESS

SUMMARY This bulletin contains the Instructions for Continued Airworthiness to inspect lifters and their associated camshaft lobes on in-service engines. TCM considers lifters to be a 100% replacement item at overhaul. WARRANTY For warranty information and coverage, refer to the Warranty supplied with your engine or contact TCM. TCM warranty will cover replacement of lifters and cam where distress is found, in accordance with the applicable warranty policy in effect on the engine at the date of occurrence, except as noted below: (1) TCM warranty does not cover lifter or cam replacement required due to distress originating from corrosion or lack of lubrication. (2) TCM warranty will not cover lifter or cam replacement unless authorized by a TCM Service Representative prior to the work being done. (3) TCM may require the inspections or repair be done at facilities selected by TCM. (4) TCM warranty will not cover inspection for such conditions in the absence of the indications described in this bulletin.

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 4

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy Of Operation

SID05-7 Technical Portions FAA Approved

SUBJECT:

Teledyne Continental Motor’s (TCM) Position-Tuned Fuel Injection Nozzles

PURPOSE:

To Provide Installation Instructions and Instructions For Continued Airworthiness for TCM Position-Tuned Fuel Injection Nozzles

COMPLIANCE:

At any time TCM Position-Tuned Fuel Injection Nozzles are initially installed or when removal is required for service procedures or routine cleaning.

MODELS AFFECTED:

All Fuel Injected Engines

GENERAL TCM fuel nozzles have traditionally been matched to provide equal fuel flow to each cylinder. All nozzles are carefully flow calibrated to give precise metering of fuel flow with respect to fuel pressure. Fuel nozzles are now being produced in additional intermediate sizes, which allow smaller changes to be made in fuel flow. Identification of the new intermediate-flow nozzle is made by combining the flow letter designations of the nozzles one size smaller and one size larger than the new nozzle. (For example: 12D, 12DE, 12E, etc.) Within the constraints of engine installations and variations in the design of engine induction systems, small differences in airflow can occur within the cylinders on an engine. The variations are small and the resultant changes in air/fuel ratio do not have a significant effect on the power produced in each individual cylinder. TCM's latest engine models, such as the IO-360-ES, IO550-N, TSIO-520-BE, TSIO-550-B,C and others, feature tuned induction systems which improve the balance of airflow to the cylinders. The capability exists on ALL engine models to further match the air/fuel ratio between cylinders by carefully modifying the fuel flow between each cylinder in small increments while maintaining the correct total fuel flow. For this purpose TCM has developed "position-tuned" fuel nozzle systems, which match injector flow to each individual cylinder's airflow while maintaining the correct total fuel flow. An automated test method was created to measure and evaluate the fuel flow range between the first and the last cylinder EGT peaks as the mixture was leaned from full rich at cruise operating conditions. Based on the actual fuel flow at each cylinder's peak EGT, individual nozzle flows were changed to align the peaks. The process can yield smaller cylinder-to-cylinder air/fuel ratio variations at selected engine settings. This assures that each cylinder is operating at the same air/fuel ratio in cruise conditions while maintaining acceptable air/fuel ratios at other operating points.

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© 2005 Teledyne Continental Motors, Inc.

INSTALLATION INSTRUCTIONS 1) In accordance with the airframe manufacturer's instructions, remove cowling and any airframe accessories that may obstruct access to the fuel nozzles. 2) Turn the aircraft fuel selector to the off position. 3) Loosen and remove the fuel injection lines from the existing fuel nozzles. 4) On turbocharged engine models, loosen fuel nozzle sleeve assembly nuts from the upper deck reference tubes and remove the metal washer, the rubber washer and the sleeve assembly from each nozzle. Retain the metal washer and the sleeve assembly for re-use. Discard the rubber washer. 5) Loosen and remove the fuel nozzles from each cylinder.

CAUTION . . . Never use teflon tape on fluid fittings or fuel nozzles. Figure 1. General Antiseize Lubricant Application Typical Fuel Nozzle Shown 6) Remove the TCM Position-Tuned Fuel Nozzles from their packages. Inspect each nozzle for debris to avoid possible nozzle restriction after installation. Visually inspect each nozzle jet orifice to verify that it is open and contains no restriction. If cleaning is required, the Maintenance Instructions contained in this bulletin must be followed. 7) Apply a thin film of anti-seize compound, TCM P/N 646943 or Loctite 76732, to the large threaded end of each nozzle assembly. Reference Figure 1 for proper installation of the antiseize compound to the nozzle assembly. 8) Each TCM Position Tuned nozzle is identified as to cylinder position and nozzle size, reference Figure 2 for cylinder arrangement on the engine crankcase and Figure 3 for nozzle position marking. ISSUED

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RIGHT SIDE Cyl. #3

Cyl. #1

REAR

FRONT

Cyl. #5

Cyl. #6

Cyl. #4

Cyl. #2

LEFT SIDE

Figure 2. Cylinder arrangement as installed on the engine.

112B

TYPICAL STANDARD TUNED NOZZLE TYPICAL TUNED NOZZLE FOR 550 SERIES TUNED INDUCTION ENGINES

TYPICAL TUNED NOZZLE FOR 360 SERIES ENGINES

TYPICAL TUNED NOZZLE FOR TURBOCHARGED ENGINES

112B CYLINDER POSITION NUMBER

NOZZLE SIZE NUMBER / LETTER

Figure 3. Nozzle Position Marking ISSUED

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METAL WASHER RUBBER WASHER SLEEVE ASSEMBLY

P/N 630979-9 “O” RINGS

FIGURE 4. Typical Turbo-Charged Injector Installation

SHROUD

SHROUD

SCREEN

SCREEN

P/N 630979-9 “O” RING

NO “O” RING

STANDARD NOZZLES IO-550 NOZZLE

IO-360 NOZZLE

Figure 5. Typical Nozzle Assemblies For Normally-Aspirated Engines ISSUED

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9)

Install each nozzle in the fuel nozzle port of the appropriate cylinder finger tight to insure that it does not cross-thread.

10) Torque each nozzle to 55-65 inch pounds using a properly calibrated torque wrench. 11) For turbo-charged engine models, reinstall nozzle sleeve assemblies ensuring new P/N 630979-9 O-rings are used. Tighten the nut to the upper deck reference tube finger tight to set the seal between the nut and the male connector, then tighten an additional 3/4 to 1 turn. Install a new P/N 640612 rubber washer and the previously retained metal washer on each nozzle, reference figure 4. 12) Reinstall each fuel injection line to the appropriate nozzle and tighten to a torque value of 4045 inch pounds using a properly calibrated torque wrench. CAUTION… Do not apply any type of thread lubricant or sealant to the fuel injection line to nozzle junction. 13) Clean each fuel injection line at the location of the identification label application with acetone, reference figure 6. With this area clean and dry, apply an identification label P/N 655303 to each fuel injection line and wrap the label around the fuel injection line to form a flag as indicated in figure 6. An identification label may also be applied to the valve rocker cover in a conspicuous location in addition to the fuel injection line.

Figure 6. Label Application 14) Turn the aircraft fuel selector to the "ON" position. 15) Perform a complete fuel system leak check in accordance with aircraft manufacturer's maintenance instructions prior to engine operation. WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. ISSUED

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16) Perform the engine fuel system verification in accordance with the latest revision of SID97-3. 17) Reinstall all airframe-supplied accessories and cowlings in accordance with the airframe manufacturer's instructions. MAINTENANCE INSTRUCTIONS NOTE . . . This bulletin contains the Manufacturer's Instructions for Continued Airworthiness for Position Tuned Nozzle Assemblies as required by FAR43.13. All fuel nozzles must be removed annually or every 300 hours, whichever occurs first, for inspection and cleaning as follows: 1) In accordance with the airframe manufacturer's instructions, remove cowling and any airframe accessories that may obstruct access to the fuel nozzles. 2) Turn the aircraft fuel selector to the off position. 3) Loosen and remove the fuel injection lines from the fuel nozzles. 4) On turbo-charged engine models, loosen fuel nozzle sleeve assembly nuts from the upper deck reference tubes and remove the metal washer, the rubber washer and the sleeve assembly from each nozzle. Retain the metal washer and the sleeve assembly for re-use. Discard the rubber washer. 5) Loosen and remove the fuel nozzles from each cylinder. 6) Clean each nozzle by soaking in lacquer thinner, MEK or acetone for several hours. Wipe clean the exterior of the nozzle with a lint-free cloth. Dry the nozzle interior with dry compressed air. Visually inspect the nozzle jet orifice to verify that it is open with no obstructions. 7) If the nozzle jet orifice is obstructed and cannot be cleaned by solvent action as noted in step 6 above, the nozzle must be replaced. CAUTION . . . Never attempt to clear or clean a nozzle jet orifice restriction by mechanical means. This can damage the orifice and affect the flow rate of the nozzle. Any nozzle which has been cleaned by mechanical means must be replaced. 8) Once each nozzle has been cleaned and inspected, they should be reinstalled in accordance with the following: 9) Apply a thin film of anti-seize compound, TCM P/N 646943 or Loctite 76732, to the large threaded end of each nozzle assembly. Reference Figure 1 for proper installation of the antiseize compound to the nozzle assembly. 10) Each TCM Position Tuned nozzle is identified as to cylinder position and nozzle size, reference Figure 2 for cylinder arrangement on the engine crankcase and figure 3 for nozzle position marking. ISSUED

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11) Install each nozzle in the fuel nozzle port of the appropriate cylinder finger tight to insure that it does not cross-thread. 12) Torque each nozzle to 55-65 inch pounds using a properly calibrated torque wrench. 13) For turbo-charged engine models, reinstall nozzle sleeve assemblies ensuring new P/N 630979-9 O-rings are used. Tighten the nut to the upper deck reference tube finger tight to set the seal between the nut and the male connector, then tighten an additional 3/4 to 1 turn. Install a new P/N 640612 rubber washer and the previously retained metal washer on each nozzle, reference figure 4. 14) Reinstall each fuel injection line to the appropriate nozzle and tighten to a torque value of 4045 inch pounds using a properly calibrated torque wrench. CAUTION… Do not apply any type of thread lubricant or sealant to the fuel injection line to nozzle junction. 15) Turn the aircraft fuel selector to the "ON" position. 16) Perform a complete fuel system leak check in accordance with aircraft manufacturer's maintenance instructions prior to engine operation. WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. 17) Perform the engine fuel system verification in accordance with the latest revision of SID97-3. 18) Reinstall all airframe-supplied accessories and cowlings in accordance with the airframe manufacturer's instructions.

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TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 4

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy of Operation

SID07-10 Technical Portions FAA Approved

SUBJECT:

IO240B Fuel System Component Installation

PURPOSE:

To provide instructions for the installation of a Factory Flushed fuel system component kit and instructions for reorientation of inline fuel filter. This is in support of Diamond Aircraft Service Bulletin DAC1-73-05 See Diamond Service Bulletin DAC1-73-05 for compliance

COMPLIANCE: MODELS AFFECTED:

IO240B13B, 17B, 20B, 21B engines equipped with Altitude Compensating Fuel Systems and IO240 engines modified per SIL05-4A to incorporate a 656859 inline fuel filter

GENERAL

Teledyne Continental Motors has introduced a Factory Flushed fuel system kit to reduce the potential for contaminants in engine fuel system components. The kit includes the following components; inline fuel filter, throttle body/metering unit, manifold valve, a set of position tuned fuel injection nozzles and all attaching hoses from the fuel pump to the manifold valve. The fuel component kit is furnished preassembled from the fuel pump to the manifold valve. All hoses are installed, capped and plugged to assure cleanliness in shipping and installation. The preassembled components are to be installed as a single unit. Fuel line fittings may be loosened to allow alignment during hose and

component attachment, but are NOT to be disconnected. This section gives removal and installation instructions for the Manifold valve, Throttle body/Metering unit, Fuel injection nozzles and associated hoses and hardware. CAUTION: All fuel system components must be handled with care with any openings sealed with appropriate clean caps and plugs prior to installation or immediately upon removal. The engine, tools and environment must be clean to minimize any potential for fuel system contamination. Fuel system purging instructions must be performed in the sequence provided in this SID. During Installation: (1) Select the proper size open-end wrenches that will fit the fitting body and hose or tubing end fitting. (2) Torque the hose or tubing end fitting to the specified torque using a properly certified calibrated torque wrench while maintaining sufficient force on the component fitting to prevent twisting and shear loads. ISSUED

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SID07-10

(3) Support the last fitting in the assembly on components that contain multiple fittings coupled in one location. (4) DO NOT over torque fittings.

WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. Procedure: Referring to the airframe manufacturer’s maintenance instructions: (a) Remove upper and lower engine cowlings from the aircraft (b) Remove electrical power from the aircraft. (c) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. 1. Disconnect the four fuel injector lines from the manifold valve and cap the fuel injector line ends. Plug the openings in manifold valve. Disconnect the vapor return hose and the vent hose from the manifold valve, plug hose ends and cap manifold valve fittings. Remove and discard the three screws that secure the manifold valve to isolator plate. Remove manifold valve. 2. Disconnect the induction air hose from the throttle body. Install cap plugs or tape on both the throttle body inlet and the induction air hose openings. Disconnect the throttle control cable from the throttle body lever and retain hardware., Disconnect the throttle body assembly from the intake manifold leaving the fuel hoses connected. Retain the four 0.25 diameter nuts and flat washers. Discard the four lock washers and gasket. 3. Disconnect the inline fuel filter and bracket assembly from the forward apron by disengaging the camloc fasteners. Remove the fuel system fuel line cushion clamps and fuel system transducer at the vertical baffle. Cap the fuel transducer and discard the fuel transducer grommet. Plug the transducer tee. Disconnect the fuel pump to fuel filter hose from the fuel pump outlet fitting. Cap the fuel pump fitting and plug the fuel pump to filter hose. 4. Remove fuel filter assembly, throttle body assembly, manifold assembly, along with all attaching hoses as a single unit. This assembly is to be returned to TCM upon completion of installation.

5. Modify the existing opening in the forward baffle assembly as referenced in the figure below. All dimensions in mm’s. See Diamond Service Bulletin DAC1-73-05 NOTE: A rotary tool with a sanding drum is recommended for the baffle modification. Insure that all fuel and air openings are sealed before starting. Carefully clean all surfaces after rework to avoid contamination.

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NOTE: All caution must be exercised during maintenance of the fuel system NOT to allow any contaminants to enter the components, lines and fittings during installation. All surfaces surrounding the area where components are to be installed must be clean and free of all forms of contaminant before and during installation. Components must be flushed and verified to be free of contamination prior to final installation. 6. Remove new fuel system from packaging and lay on top of engine in the approximate installed position. Confirm hose and fitting clocking of the fuel pump to inline fuel filter hose. This hose must be installed prior to filter installation as it is not accessible when the filter is attached to the forward apron. When clocking is verified, torque fitting to 135-190 inch pounds using a calibrated torque wrench. See the figure below for clocking. P/N 646644S4Y5.00 Hose assembly

Hose assemblies supplied with the 45º fittings in plane with the fuel filter assembly as shown

P/N 656859A6 Fuel Filter Assembly. (Mounting Bracket Omitted for Clarity.)

P/N 646644S4Y6.50 Hose assembly

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7. Install the manifold valve to the isolator plate using the included hardware. Remove protective caps and plugs on manifold valve. Remove fuel injection line caps and attach the fuel injector lines (torque to 55-60 inch-lbs), fuel vapor return hose, and vent hose to the manifold valve body. 8. Install the supplied pressure transducer grommet. Place the pressure transducer Tee through the vertical baffle with new MS 35489-20 grommet installed per the drawing below. Remove plug from pressure transducer Tee and install the pressure transducer in accordance with the Diamond Maintenance Manual. Install the fuel system MS21919WCF10 cushion clamps per the drawing below.

9. Route the fuel pump to fuel filter line through the forward apron and attach the fuel filter to the apron by engaging the camloc fasteners on filter mounting bracket. It will be necessary to guide the fuel

line around the back side of the engine driven fuel pump and into the correct position for installation. Assure that the four lockwired screws are on the lower side of the filter installation. Install the throttle body assembly using retained hardware, new supplied lock washers and new gasket. Torque attaching nuts to 90-110 inch-lbs. Assure that the metal cap part number 639494 is installed at the metered fuel pressure tee on the metering housing and torqued to 135-190 inch-lbs. 10. Restore electrical power to the aircraft. Select the fuel to ON. 11. Remove fuel pump outlet protective cap then flush a minimum of 1 quart of fuel through the pump into a coffee filter in a clean dry container using the aircraft boost pump. Check for contamination. If contamination is found, continue to flush until contaminant is no longer found. If no contamination is found, remove the protective plug from the fuel filter hose and connect to the fuel pump outlet fitting. Torque the fuel pump outlet fitting B nut and fuel pump to inline fuel filter hose B nut to 135 – 190 inch lbs with a calibrated torque wrench.

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12. Remove fuel injector lines from fuel injector nozzles. Remove fuel injector nozzles from cylinder heads and set aside removed fuel nozzles. These nozzles should be returned with assembly above to TCM at completion of maintenance. 13. Verify that the fuel injector cylinder position number etched on the fuel injector nozzle wrench flat matches the correct cylinder position. The first digit in the 4 digit etched number is the cylinder position, example 1125 would indicate installation in cylinder number 1, 2120 in cylinder number 2 and so on. Apply a small amount of 646943 anti-seize lubricant to the fuel injector nozzle threads as illustrated in the figure below. Hand tighten the fuel injector nozzle into the cylinder head. Use a modified 6 point deep wall socket to torque the fuel injector to 55 – 65 in-lbs using a calibrated torque wrench.

14. Place a clean, dry cup at the cylinder end of each fuel injector line to capture fuel and inspect for contaminants. Flush the complete fuel system using the aircraft boost pump while observing the fuel coming out of the fuel injector lines. Two to three cups of fuel are recommended to allow full flush of the system and effective inspection for contaminants. If contamination is found, continue to flush until contaminants are removed. If no contamination is found, install each fuel injector line and torque nut to 40-45 in-lbs. 15. Visually inspect all hoses, attachment points and pressure test fuel system for leaks using airframe boost pump. Assure all hose fittings to be torqued and secure at this time. All steel hose B nuts in this system are torqued to 135-190 inch-lbs. If no leaks are found, proceed to fuel system setup. 16. Perform the fuel system setup and operation verification in accordance with the instructions and specifications contained in TCM bulletin SID07-3, revision A or later and the instructions contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. Assure that 639464 caps are installed on the fuel metering tee and the manifold tee pressure checking points. Make an engine logbook entry that SID07-10 has been complied with. WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. ISSUED

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NOTE: Pressure altitude must be used when determining fuel system set-up values. To determine pressure altitude prior to take-off, set your altimeter to 29.92 in hg, and the altimeter will indicate your pressure altitude. 17. Using the airframe manufacturers instructions, return the aircraft to its normal configuration.

WARRANTY Contact Teledyne Continental Motors Customer Service at 1-888-826-5465 for part kit availability and labor claim filing instructions to allow completion of the modification section of this Service Bulletin. Please provide the following information to TCM representative at time of contact; 1. 2. 3. 4. 5. 6.

Model and Serial number of the affected aircraft Registration number Engine Serial Number Total time on engine Owner’s Name, Address and Telephone Contact info FBO Name, Address and Telephone Contact info

PARTS REQUIRED P/N EQ7495 IO240B Fuel System Modifications Kit

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 4

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy Of Operation

SID07-3A Technical Portions FAA APPROVED

SUBJECT:

PROCEDURES AND SPECIFICATIONS FOR ADJUSTMENT OF TELEDYNE CONTINENTAL MOTORS IO-240-B ENGINES EQUIPPED WITH THE ALTITUDE COMPENSATING BYPASS FUEL INJECTION SYSTEM INSTALLED IN THE DIAMOND DA20-C1

PURPOSE:

To provide procedures and specifications for the adjustment of the Teledyne Continental Motors (TCM) continuous flow fuel injection system.

COMPLIANCE:

At Engine Installation, 100 hour/Annual Inspection, after replacement of any fuel system component or as required if engine operation is not within specifications.

MODELS AFFECTED:

IO-240-B Specifications equipped with the Altitude Compensating Bypass Fuel System as installed in the Diamond DA20-C1

GENERAL INFORMATION Teledyne Continental Motors (TCM) has developed new IO-240-B engine specifications for production, utilizing the altitude compensating fuel pump in conjunction with a bypass fuel manifold valve. A conversion kit is available for conversion of earlier IO-240-B engines. The new IO-240-B configurations offer an altitude compensating fuel pump in conjunction with fuel distribution modifications for improved idle stability and fuel vapor evacuation. These improvements enhance engine start procedures and smooth engine idle performance during ground operation. These improvements are especially noticeable at high altitude airports and in extreme weather conditions. FUEL SYSTEM SETUP This Service Information Directive contains the Instructions for Continued Airworthiness for fuel system setup for IO-240-B engines equipped with the Altitude Compensating Bypass Fuel System. These instructions pertain only to the above listed engines. For all other versions of the IO-240-B engine refer to the latest revision of TCM bulletin SID97-3. WARNING

New or updated Instructions for Continued Airworthiness may be contained in TCM Service Documents. Service Documents containing updates to the ICA’s that are applicable to the engine or accessories on which work is being performed must be consulted and applicable procedures complied with while performing any installation, maintenance, or overhaul function. Failure in following all published manufacturers ICA’s may result in engine damage, possible bodily injury, or death.

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TABLE OF CONTENTS

1-1. Operational Checks................................................................................................................................ 3 1-1.1. Maintenance Preflight Inspection.................................................................................................. 4 1-1.2. Engine Operational Check Preparation ......................................................................................... 6 1-1.3. Engine Operational Check........................................................................................................... 11 1-1.4. Engine Shutdown ........................................................................................................................ 18 1-1.5. Operational Checklist .................................................................................................................. 19 1-1.6. Flight Check ................................................................................................................................ 21

LIST OF TABLES Table 1-1. Engine Operation Prerequisites ................................................................................................... 3 Table 1-2. IO-240-B Operational Checklist................................................................................................ 20 Table 1-3. IO-240-B Flight Check Limits .................................................................................................. 21

LIST OF FIGURES Figure 1-1. Porta-Test Connections ................................................................................................ 8 Figure 1-2. Calibrated Gauge Connections..................................................................................... 9 Figure 1-3. Metered Fuel Pressure Connection ............................................................................ 10 Figure 1-4. Altitude Compensating Fuel Pump Fittings and Adjustments................................... 12 Figure 1-5. Throttle Body Fuel Mixture and RPM Adjustments.................................................. 13 Figure 1-6 Unmetered Fuel Pressure Boost Pump On……………………………………………15 Figure 1-7A,B Metered Fuel Pressure Boost Pump On……………………………………….16,17

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1-1. Operational Checks An Engine Operational Check must be performed after any of the following: • Engine Installation •

Fuel System Component Replacement, Maintenance

•

Overhaul

•

Return from Storage

•

After each 100-Hour/Annual, and 500-Hour Inspection

•

Significant Changes in Geography, Climate, or Operating Environment

Some IO-240-B engines use an altitude compensating (aneroid) fuel pump. All IO-240-B engines equipped with the bypass fuel system utilize the altitude compensating fuel pump. As the name implies, the pump compensates for variations in barometric pressure. Prior to performing adjustments, determine the difference from sea level barometric pressure in order to properly adjust the fuel system.

NOTE: Engine driven fuel pump pressure varies with engine RPM. During ground operation, the engine may not reach rated Full Power RPM. This operational check compensates for the lower RPM settings. Perform the “1-1.1 Maintenance Preflight Inspection” in Section 1-1.1 Gather the Required Test Equipment indicated in Section 1-1.2 and connect according to instructions in Sections 1-1.2.1 or11.2.2, depending on the test equipment selected. A newly installed, repaired, or overhauled engine requires the listed tasks in Table 1-1 be performed before the engine can be released for normal flight.

WARNING The tasks listed in Table 1-1 must be completed on a newly installed, routinely inspected, repaired, or overhauled engine before the aircraft is returned to service. DO NOT FLY THE AIRCRAFT UNTIL ALL FLIGHT PREREQUISITES HAVE BEEN MET. TABLE 1-1 Engine Operation Prerequisites Sequence 1

Section References Section 1-1.1, “1-1.1 Maintenance Preflight Inspection” 2 Check Engine Operation Section 1-1.3, “1-1.3 Engine Operational Check” 3 Complete Operational Checklist Section 1-1.5, “1-1.5 Operational Checklist” 5 Perform Test Flight Section 1-1.6, “1-1.6 Flight Check” *Also in accordance with the Airplane Flight Manual/Pilot’s Operating Handbook (AFM/POH).

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1-1.1 Maintenance Preflight Inspection Perform the preflight inspection prior to engine operation following engine installation, inspection, troubleshooting, maintenance, or overhaul work to determine if the aircraft and engine are in an airworthy condition.

WARNING Operation of a malfunctioning engine can result in additional damage to the engine, possible bodily injury, or death. Procedure 1. Verify all switches are OFF. WARNING Ensure the propeller plane of rotation area is clear of personnel and equipment; Verify the work area is free of ignition sources. 2. Remove engine cowling in accordance with airframe manufacturer’s instructions. 3. Purge the aircraft fuel system: a. Disconnect the engine driven fuel pump hose and terminate in a large, clean container suitable for waste fuel.

b. Operate the aircraft fuel boost pump to allow a minimum of one gallon of fuel to flow into the container. Inspect the fuel for contaminants; locate and correct the source of contaminated fuel, if detected.

c. Reconnect the fuel supply line and torque in accordance with the airframe manufacturers instructions.

WARNING Use of inaccurate gauges will result in improper fuel system adjustment and possible engine damage. WARNING The engine is certified for operation with 100-LL Blue or 100 Green aviation fuel. If the minimum grade required is not available, use the next higher grade. Never use a lower grade fuel. Using lower octane rated fuel or jet fuel will result in damage to, or destruction of, an engine the first time high power is applied. If the aircraft is inadvertently serviced with the wrong fuel grade, drain the fuel system completely and the service the tanks according to the aircraft manufacturer’s recommendations. Inspect the engine according to the “Contaminated Fuel” Inspection instructions in the TCM Maintenance Manual (X30621).

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4. Service the aircraft fuel system according to the airframe manufacturer's instructions with either 100LL Blue or 100 Green aviation fuel. If the minimum grade is not available, use the next higher grade; never use a lower grade fuel.

5. Check the engine oil level and service the oil sump according to “Engine Oil Servicing” instructions in the Installation and Operation Manual (X30620).

6. Verify the accuracy of the tachometer, manifold pressure gauge and fuel flow gauges prior to making any adjustments; replace faulty gauges.

7. Verify the fuel system components are properly configured (part number conforms to type design and parts are installed properly).

8. Remove, clean, inspect, and reinstall the aircraft fuel screens according to the airframe manufacturer’s instructions.

9. Inspect the airframe induction air filter and alternate air system for condition, operation and cleanliness according to the airframe manufacturer’s instructions.

10. Inspect the aircraft vapor return system for proper operation according to the airframe manufacturer’s instructions.

11. Ensure the fuel manifold valve vent and fuel pump drain lines are properly installed, open and free of obstructions.

12. Inspect engine control rod ends for wear, freedom of movement, proper installation and security according to the airframe manufacturer’s instructions.

13. Inspect the throttle and control assembly link rods (where used) for correct installation, security and wear at attach points.

14. Ensure engine controls operate freely through their full range of travel and are properly adjusted according to the airframe manufacturer’s instructions.

15. Lubricate control rod ends and fuel system linkage components with Shell #5 (MIL-G-3545-C) lubricant.

16. Locate the IDLE speed stop screw on the throttle body and turn it counter-clockwise two complete turns. During fuel system adjustments, IDLE RPM will be controlled manually using the cockpit throttle control.

17. Inspect lines, hoses, and wire bundles for chafing, loose connections, leaks, and stains. 18. Inspect the exhaust and induction systems for proper installation, security and leaks. 19. Verify the engine crankcase breather is secure, with no breather airflow restrictions. 20. If the engine is newly installed or being returned to service after long-term storage, refer to the “Installation and Operating Manual”. (X30620).

21. Visually inspect the engine, propeller hub area, and nacelle for evidence of fuel and engine oil leaks.

22. Visually inspect the engine and nacelle for debris, loose, missing, or broken lines, hoses, fittings, clamps, or connections. Inspect for restrictions to cooling airflow.

23. Verify baffles and baffle seals are installed, correctly positioned, and serviceable. 24. Correct all discrepancies prior to engine operation. MO 08

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25. If the engine has been exposed to temperatures below 20ºF (-7°C) for more than 2 hours, preheat the engine according to the “Engine Preheating” instructions in the Installation and Operation Manual (X30620). If the engine has been exposed to ambient temperatures between 20 to 40ºF (-7 to 4°C), follow the “Cold Weather Starting without Preheating” instructions in the Installation and Operation Manual (X30620).

1-1.2 Engine Operational Check Preparation Required Test Equipment Procedure 1. TCM recommends the Model 20 ATM-C Porta-Test Unit or equivalent to ensure the fuel injection system meets pressure and flow requirements.

2. Calibrated gauges may be used as an alternative. NOTE: Pressure gauges must be accurate within ± 1%. The gauge calibration period should not exceed one year.

a. One 0-60 psi gauge, graduated in 0.1 psi increments for unmetered pressure. b. One 0-30 psi gauge, graduated in 0.1 psi increments for metered pressure. 3. Two P/N MS51523-B4 swivel tees to install test equipment inline with fuel lines for metered and unmetered pressure references.

4. Hoses of sufficient length to allow personnel and equipment to be located away from the propeller arc and blast area.

5. Tachometer verification instrument to verify aircraft tachometer accuracy during fuel system adjustment. NOTE: Fuel system adjustments are interactive. Follow the procedure in its entirety whenever fuel system adjustment is altered.

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1-1.2.1 Porta-Test Unit Setup Procedure 1. Remove the dust cap from the tee at the fuel metering unit. 2. Connect the Porta-Test unit (Figure 1-1) unmetered fuel pressure test hose to the tee fitting. 3. Remove the fuel supply hose from the fuel manifold valve inlet fitting. 4. Install a MS51523-B4 swivel tee directly to the fuel manifold valve inlet fitting. 5. Reconnect the fuel supply hose to the straight end of the tee connector. 6. Connect the metered fuel pressure test hose from the Porta-Test Unit to the tee fitting. 7. Torque all connections according to the Engine Maintenance torque specifications. 8. Position the throttle control to the FULL OPEN position and the mixture control to FULL RICH. Operate the aircraft boost pump according to the aircraft manufacturer’s instructions. Bleed the air from the Porta-Test unit and test hoses according to the manufacturer’s instructions.

WARNING Ensure all fuel is drained from the induction prior to attempting engine start. Failure to comply with this warning may result in hydraulic lock and subsequent engine failure. 9. Install the engine cowling or cooling shroud during ground operation.

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Figure 1-1 Porta-Test Connections

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1-1.2.2 Calibrated Gauge Test Setup Procedure 1. Remove the cap from the tee connector at the fuel metering unit. 2. Connect the unmetered test hose (Figure 1-2) from the 0-60 psi gauge to the tee with a length of hose to allow proper clearance from the engine cowling and propeller arc.

Figure 1-2 Calibrated Gauge Connections 3. Remove the fuel supply hose from the manifold valve inlet fitting. 4. Install one MS51523-B4 swivel tee directly to the fuel manifold valve inlet fitting. 5. Attach the fuel supply hose to the straight end of the tee connector. 6. Connect the 0-30 psi gauge to the open tee fitting using a length of hose that provides suitable clearance from the engine cowling and propeller arc.

7. Torque connections according to the Maintenance Manual torque specifications. 8. Position the throttle control to the FULL OPEN position and the mixture control to FULL RICH. Operate the aircraft boost pump in accordance with the aircraft manufacturer’s instructions. Loosen the test connections at each gauge to bleed the lines of air. Hold the gauge at or slightly above the fuel system connections to allow the fuel to force the air out of the lines. Operate the

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boost pump only long enough to purge the line of air. Torque all lines loosened during bleeding operation.

Figure 1-3 Metered Fuel Pressure Connection WARNING Ensure all fuel is drained from the induction system prior to attempting engine start. Failure to comply with this warning may result in hydraulic lock and subsequent engine failure. 9. Install the engine cowling or cooling shroud during ground operation.

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1-1.3 Engine Operational Check WARNING Make all adjustments with the engine stopped and the ignition switch in the OFF position! Procedure 1. Inspect the engine according to Section1-1.1. Set up test equipment according to Section 1-1.2 instructions.

2. Start the engine according to the “Engine Start” instructions in the AFM/POH. CAUTION: Operating the engine without oil pressure will result in engine malfunction or stoppage. 3. Check engine oil pressure. If no oil pressure is noted, shut down the engine and investigate the cause.

4. Aircraft Fuel Boost Pump Switch............................... ON 5. Throttle ....................................................................... 1000 ± 25 RPM CAUTION: Do not allow the engine CHT to exceed 420° F or engine oil temperature to exceed 210° F. RESULT: Allow the engine to warm up to minimum oil temperature and oil pressure specifications.

6. Set the aircraft altimeter to 29.92 in. Hg. Record the aircraft altitude in reference to sea level on the altimeter as “field elevation.” Locate the field elevation on the Pressure Altitude scale in Figure 1-6. Trace a line at a right angle from the indicated field elevation on the altitude scale to the charted line. Trace the intersecting point of field elevation on the charted line to the Unmetered Fuel Pressure scale. The intersecting point of the Pressure Altitude and Unmetered Fuel Pressure must fall within the idle setup tolerance shown in the setup chart.

7. Check the fuel pump unmetered pressure versus the value determined by step 6. RESULT: Indicated unmetered fuel pump pressure is within tolerance values depicted in Figure 16. If the setting is correct, proceed to step 8. If the setting is not within tolerance, adjust the unmetered pressure:

a. Shut down the engine. b. Loosen the lock nut on the Low Pressure Relief Valve Assembly located at the rear of the fuel pump (See Figure 1-4) and adjust the screw clockwise to increase unmetered pressure or counterclockwise to decrease unmetered pressure.

c. Snug the jam nut on the Low Pressure Relief Valve.

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Fuel Inlet

Vapor Return

TELEDYNE CONTINENTAL MTR

Aneroid Adjustment

PART NO SER NO

Fuel Inlet

Low Pressure Relief Valve Mixture Control

Drain

Pump Output

Figure 1-4 Altitude Compensating Fuel Pump Fittings and Adjustments d. Start the engine and check the fuel unmetered pressure. Repeat step 7 until the engine meets the Unmetered Pressure specification illustrated in Figure 1-6. NOTE: Operate the engine at 1500-1800 RPM for 15 seconds after each adjustment. Retard the throttle to 1000 ± 25 IDLE RPM to obtain an accurate fuel pump pressure reading after adjustment. e. After final adjustment, shut down the engine and torque the jam nut according to the Maintenance Manual torque specification. Restart the engine and re-verify the unmetered fuel pressure setting was not disturbed by tightening the lock nut.

8. Mixture control........................................................... toward IDLE/CUT-OFF NOTE: Use an accurate tachometer verification instrument when adjusting the idle cutoff mixture rise during the Engine Operational Check. RESULT: The observed IDLE CUT-OFF RPM mixture rise is 75-100 RPM. An RPM rise greater than 100 RPM indicates the mixture is richer than the operational check setup value; less than 75 RPM indicates the mixture is leaner than the operational check setup value. If the IDLE CUT-OFF RPM mixture rise is within the 75-100 RPM setup value, proceed to step 9. If adjustment is required: a. Shut down the engine.

b. Adjust the idle mixture (Figure 1-5) to obtain 75-100 RPM rise. c. Start the engine and check IDLE RPM unmetered pressure with the boost pump ON and adjust, if necessary. NOTE: During normal operations, an idle cutoff mixture rise of 25-100 RPM is acceptable.

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

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IDLE MIXTURE ADJUSTMENT CW = LEAN CCW = ENRICH

FUEL OUTLET

IDLE RPM ADJUSTMENT CW = INCREASE CCW = DECREASE

FUEL INLET (UNMETERED PRESSURE)

Figure 1-5 Throttle Body Fuel Mixture and RPM Adjustments 9. Mixture control........................................................... FULL RICH RESULT: Allow the engine to stabilize for 30 seconds. Record engine RPM and test gauge indications. 10. Throttle ....................................................................... WIDE OPEN (WOT)

11. Note engine RPM. Locate the field elevation (recorded in step 6) on the Pressure Altitude scale in Figure 1-7A or 1-7B (as applicable). Trace a line at a right angle from the field elevation on the Pressure Altitude scale to the corresponding WOT engine RPM line. From the intersecting point on the RPM line, trace a line at a right angle to the pressure scale to determine the full throttle/full rich metered fuel pressure setting. Indicated metered fuel pressure should equal the charted value ±2.0 psi. If metered fuel pressure is within the charted specification, proceed to step 12. If adjustments are required:

a. Shut down the engine. b. Turn the aneroid adjustment (Figure 1-4) clockwise to decrease; counterclockwise to increase metered pressure.

c. Restart the engine, check IDLE RPM unmetered pressure and idle mixture. Check metered pressure at full power. Allow WOT operation for 15-30 seconds to allow stabilization of fuel pressure reading. Return to idle for 10-15 seconds, then return to WOT for 15-30 seconds. Note readings, then repeat. Three full WOT runs at 15-30 seconds each should be utilized to establish WOT metered pressure setting. The three full WOT runs should be accomplished prior to any metered fuel pressure adjustments. NOTE: Two consistent readings taken during the WOT runs are sufficient to establish the metered pressure setting.

d. Adjust as necessary; repeat step 11(c) to verify WOT metered pressure setting.

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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Fuel Inlet

Vapor Return

TELEDYNE CONTINENTAL MTR PART NO SER NO

Aneroid Adjustment

Fuel Inlet

Low Pressure Relief Valve Mixture Control

Drain

Pump Output

Figure 1-4 repeated for reference 12. Reduce the engine speed to 1000 ± 25 RPM. Note the position of the throttle. Shut down the engine according to the AFM/POH.

13. Reposition the throttle to the setting noted in step 12. Adjust the IDLE RPM (Figure 1-5) stop screw to rest against the stop pin.

14. Start the engine and verify the engine speed is 1000 ± 25 RPM with the throttle in the IDLE position. Verify that the idle cutoff mixture rise is 75-100 RPM. If not, reset the idle mixture to 75-100 RPM.

15. TCM strongly recommends an IDLE speed of 1000 RPM ± 25 RPM. Light weight, low inertia propellers require a higher engine IDLE RPM to maintain stable idle speed. Certain flight and ground maneuvers such as spins, stalls, crosswind landings and high speed taxi turns have been known to result in adverse aerodynamic loads being applied to the propeller. These adverse aerodynamic loads may reduce the engine IDLE speed below a stable level. An IDLE speed of 1000 RPM ± 25 RPM must be used when the aircraft is operated under these conditions. If a lower IDLE RPM setting is desired, reduce the IDLE RPM to the desired setting, but not less than 900 RPM. (Assure mixture rise at desired IDLE setting is still 75-100 RPM. Reset if necessary.) The propeller must be capable of sustaining momentum at engine IDLE RPM. If the engine will not IDLE at the lower settings, increase the IDLE RPM setting, not to exceed 1000 ± 25 RPM.

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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ID L E M IX T U R E A D JU S TM E N T CW = LEAN C C W = E N R IC H

ID L E R P M A D JU S TM E N T C W = IN C R E A S E CCW = DECREASE

F U E L IN L E T (U N M E T E R E D P R E S S U R E )

FU EL O U TLET

Figure 1-5 repeated for reference

16. Upon successful completion of the Engine Operational Check, shutdown the engine in accordance with section 1-1.4 and the AFM/POH.

17. Perform flight check in accordance with section 1-1.6 and the airframe AFM/POH to confirm correct engine setup and performance.

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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Pressure Altitude (ft)

13.4 13.2 13.0 12.8 12.6 12.4 12.2 12.0 11.8 11.6 11.4 11.2 11.0 10.8 10.6 10.4 10.2 10.0 9.8 9.6 9.4 9.2 9.0 8.8 8.6 8.4 8.2 8.0

10000 9800 9600 9400 9200 9000 8800 8600 8400 8200 8000 7800 7600 7400 7200 7000 6800 6600 6400 6200 6000 5800 5600 5400 5200 5000 4800 4600 4400 4200 4000 3800 3600 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 -200 -400 -600 -800 -1000 -1200

Unmetered Fuel Pressure (psi)

FIGURE 1-6 UNMETERED FUEL PRESSURE BOOST PUMP ON MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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FIGURE 1-7A METERED FUEL PRESSURE BOOST PUMP ON 3000 2800 2600 2400 2200 2000 1800 1600

1200 1000 800 600

Pressure Altitude (ft)

1400

400 200 0 -200 -400 -600 -800 -1000

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

26.0

27.0

28.0

29.0

30.0

31.0

32.0

33.0

-1200 Metered Fuel Pressure (psig)

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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FIGURE 1-7B METERED FUEL PRESSURE BOOST PUMP ON 10000 9800 9600 9400 9200 9000 8800 8600 8400 8200 8000 7800 7600 7400 7000 6800 6600 6400 6200 6000

Pressure Altitude (ft)

7200

5800 5600 5400 5200 5000 4800 4600 4400 4200 4000 3800 3600 3400 3200 11.0

12.0

13.0

14.0

15.0

16.0

17.0

18.0

19.0

20.0

3000

Metered Fuel Pressure (psig)

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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1-1.4 Engine Shutdown Procedure 1. Shut down the engine and allow it to cool adequately. a. Remove the test equipment, test fittings and test hose from the fuel manifold valve and the fuel metering unit.

b. Reconnect, support, and torque the fuel inlet hose at the fuel manifold valve. c. Fuel Selector Valve.............................................. ON d. Master Power Switch ........................................... ON e. Magneto Switch ................................................... BOTH f. Throttle ................................................................ WIDE OPEN g. Mixture Control ................................................... FULL RICH h. Boost Pump.......................................................... ON i. Check the fuel system connections for leaks. Pay particular attention to the connections disturbed during the engine operational check.

j. Boost Pump.......................................................... OFF k. Throttle ................................................................ IDLE l. Mixture Control ................................................... IDLE/CUTOFF m. Magneto Switch ................................................... OFF n. Master Power Switch ........................................... OFF o. Fuel Selector Valve.............................................. OFF 2. Perform a visual inspection of the engine and engine compartment, look for indications of fuel or oil leaks. If the engine exhibits malfunctions or fails to meet operating specifications, refer to the Troubleshooting Instructions in the Maintenance Manual (X30621) to correct the discrepancy.

3. Install the engine cowling in accordance with the aircraft manufacturer's instructions. 1-1.5 Operational Checklist Make a copy of the Operational Checklist to record operational test results.

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

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IO-240-B17B Operational Checklist Date:

Manifold Valve Serial No.

Aircraft ID:

Throttle Serial No.

Total Time:

Fuel Pump Serial No.

Tech Name:

CHT

Pressure Altitude:

Oil Temp.

Outside Air Temp.:

Oil Pressure:

Section 1-1.3 Fuel System Ground Setup (A/C boost pump =ON) RPM Target

Unmetered Pressure Actual

Target

Actual

Metered Pressure Target

Mixture Rise

Actual

Adjustments (# turns) CW CCW

Section 1-1.6 Flight Check Data EGT Altitude Example:

RISE

Actual Pressure Altitude

FULL RICH TO PEAK EGT TARGET 50° -250°F 50° -250°F 50° -250°F

6000 ft 8000 ft 10,000 ft

ACTUAL

TABLE 1-2

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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1-1.6 Flight Check Perform an Engine Operational Check and a normal preflight ground run-up, in accordance with the Airplane Flight Manual or Pilot’s Operating Handbook (AFM/POH), before the A&P mechanic can approve the airplane for a Flight Check. A Flight Check is required after any adjustment that may affect engine operational characteristics. If FULL POWER RPM was not attained during fuel injection system adjustments, a flight check is required to verify the engine is performing within the specified limits. A flight check is required: a) after initial setup, b) every twelve months, c) whenever fuel system components are replaced, d) whenever auto-leaning operation is suspect.

CAUTION: High power ground operation resulting in cylinder and oil temperatures exceeding normal operating limits can be detrimental to cylinders, pistons, valves, and rings. Start the engine in accordance with the AFM/POH and follow the flight check procedures contained in Table 1-1.6.2

1-1.6.1 Flight Check Limits Observe the following operating limits during the Flight Check and Break-In. Table 1-3 IO-240-B Flight Check Limits ITEM Full Throttle RPM Idle Speed-RPM Rated Manifold Air Pressure Engine Intake Air Temperature Engine Intake Air Pressure Fuel Grade (Octane) Maximum Oil Temperature Limit Oil Pressure (Max. Oil Cold) Minimum Oil Pressure at Idle Oil Sump Capacity (Quarts) Ignition Timing CHT(with bayonet thermocouple) Oil Consumption

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

SPECIFICATION 2800 ±25 RPM 900-1000 ±25 RPM (propeller dependent) 29.5 in. Hg. Ambient Ambient 100-LL or 100 240°F (116°C) 100 psig 10 psig at or below 200°F (93°C) 6 Quarts 26° BTC +/- 1° 460°F (238°C) Max 0.006 x (rated power of engine) x (%power at which measured/100) x (hours duration) = oil consumed (1 quart of oil = 1.875 lbs)

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1-1.6.2 Flight Check Procedures Procedure

IO-240-B Altitude Compensating Fuel Pump Flight Check

Perform a normal takeoff according to AFM/POH. Monitor engine instruments; Observe operating limits in Table 1-3. Ascend to a minimum of 3000 ft above airport elevation. Adjust aircraft to maintain 2450 RPM, full throttle. Retard the mixture control from Full Rich to Peak EGT while monitoring EGT indication. Note EGT rise from Full Rich to Peak EGT on the operational checklist. (Table 1-2)

NOTE:

Adjust the fuel mixture control for Peak EGT in a slow, deliberate movement while monitoring the EGT indicator. Leaning from FULL RICH EGT to PEAK EGT requires no less than 30 seconds. Abruptly chopping the fuel mixture control will yield an inaccurate indication of PEAK EGT.

Select two different additional altitudes at least 2000 ft above the initial test altitude. Repeat and record the leaning authority test.

Exhaust Gas Temperature

Less than 50°F (10°C)

Greater than 250°F (121°C)

Rise?

50°F -2 50°F (10°C -121 °C)?

Full power fuel pump pressure is too low.

Full power fuel pump pressure is too high.

Maintenance Complete.

Recheck Metered Pressure setting vs. Fig. 1-7A,B

Recheck Metered Pressure setting vs. Fig. 1-7A,B Equal to or Greater than Maximum Metered Pressure Limit.

Less than Maximum Limit

Equal to or Less than Minimum Metered Pressure Limit.

Greater than Minimum Limit

Increase Metered Pressure setting in Section 1-1.3. step 11.

Reduce Metered Pressure setting in Section 1-1.3. step 11. Troubleshoot Fuel System according to Maintenance Manual Instructions

MO 08

ISSUED DAY YEAR 28

2007

MO 09

REVISED DAY YEAR 05

2007

PAGE NO REVISION TM

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 4

SERVICE INFORMATION DIRECTIVE SID94-12 Compliance Will Enhance Safety, Maintenance or Economy Of Operation

FAA APPROVED

SUBJECT:

PRECISION AIRMOTIVE CORPORATION SERVICE BULLETIN - MSA-7.

PURPOSE:

To inform customers of accessory manufacturer's service instructions.

COMPLIANCE: MODELS AFFECTED:

As indicated on the subject service bulletin.

All O-200 model engines.

Teledyne Continental Motors requires that the attached Precision Airmotive Corporation Service Bulletin MSA-7 be complied with.

MO 11

ISSUED DAY YEAR 14

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS PAGE NO REVISION P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

1 of 1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN Compliance Will Enhance Safety, Maintenance or Economy Of Operation SUBJECT: PURPOSE: Bulletin. COMPLIANCE: MODELS AFFECTED:

CATEGORY 4

SID96-6 FAA APPROVED

TCM IGNITION SYSTEMS SERVICE BULLETIN SB653. To inform customers of the subject TCM Ignition Systems Service As indicated on the subject service bulletin.

All TCM engine models.

Teledyne Continental Motors requires that the subject service bulletin be complied with on all TCM model engines, regardless of the type of ignition system (TCM, Bendix, Slick, Eiseman, etc.) installed.

MO 05

ISSUED DAY YEAR 03

96

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 3

SB653

SERVICE BULLETIN Compliance Will Enhance Safety

FAA APPROVED

SUBJECT:

HOT MAGNETO TEST

PURPOSE:

To provide test procedure to ensure the integrity of the magneto grounding circuit.

EQUIPMENT AFFECTED:

All ignition systems utilizing TCM or Bendix magnetos and/or ignition switches on all aircraft types.

GENERAL INFORMATION: Magneto ignition systems must be tested in the following manner to ensure magnetos are grounded after engine shutdown in order to avoid engine ignition from movement of the propeller. DETAILED INSTRUCTIONS: 1. Prior to engine shut-down, and prior to performing any maintenance on the engine, perform the Magneto RPM drop-off Test as detailed in the Pilot’s Operating Handbook (Normally found under Preflight Engine Run-Up Procedures). 2. If no RPM drop is noted when a magneto is individually selected, either the magneto selected is timed far in advance of the magneto, or a discontinuity exists between the other magneto primary circuit and airframe ground. Either condition must be remedied before further flight and before moving the propeller by hand. 3. Stop the engine using normal procedures as detailed in the Pilot’s Operating Handbook.

WARNING THE ENGINE MAY INADVERTENTLY EXPERIENCE IGNITION OR START-UP ANY TIME THE PROPELLER IS MOVED. INJURY, DEATH OR DAMAGE TO PROPERTY MAY RESULT. 4. If there is evidence of discontinuity in the magneto grounding circuit, inspect circuit connections for cleanliness and tightness, inspect wire and fed-through capacitors (whether mounted inside or outside the magneto) for continuity, and inspect switch (es) for correct electrical operation. Repair or replace malfunctioning parts as necessary as specified in the appropriate service manual. NOTE . . . Do not use an ohmmeter or continuity tester to troubleshoot the magneto grounding circuit with the magneto connected, as false continuity to ground will be read through the points or coil primary windings. Instead, position the magneto shaft so that the points are open, and use a magneto timing light to troubleshoot the magneto grounding circuit with the magneto connected.

ISSUED MO

DAY

05

23

REVISED YEAR 95

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 Mobile AL 36601

334-438-3411

PAGE NO REVISION

1 of 1 SB653

®

TELEDYNE CONTINENTAL

AIRCRAFT ENGINE

CATEGORY 4

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy Of Operation

SID97-2B FAA APPROVED

SUBJECT:

THIS SERVICE INFORMATION DIRECTIVE (SID) SUMMARIZES INFORMATION PERTINENT TO THE DESIGN, OPERATION, MAINTENANCE AND WARRANTY FOR TCM CYLINDERS.

PURPOSE:

1. To provide information to assist in obtaining maximum cylinder assembly service life. 2. To assist in inspecting for and identifying certain cylinder problems. 3. To provide information related to product improvement in TCM cylinders. 4. To introduce TCM's TopCare Program and TopCare Cylinder Warranty. TCM recommends that the TopCare Health Check Inspection be performed at time of engine or cylinder installation and annually thereafter in conjunction with a regularly scheduled inspection.

COMPLIANCE:

MODELS AFFECTED:

All TCM engine models. The information is especially critical to the higher output and larger displacement engines such as the IO-520, TSIO-520, GTSIO-520, IO-550, TSIO-550 and TSIOL-550 series.

INTRODUCTION: The information presented is pertinent to obtaining maximum service life for all cylinder assemblies, the larger and higher output 520 and 550 series engine cylinders are more susceptible to premature service life issues identified in this SID. These TCM engine series have been used in a large number of engine installations that have been in service for many years. They are also frequently employed as power upgrades to older aircraft. These installations require careful control of cooling as margins can be quickly eroded by deviations from nominal baffling performance, improper fuel system setup and inadequate maintenance. Improperly maintained and low-usage aircraft are the most susceptible to premature cylinder service issues. Many of the factors which lead to these problems are within the control of operator and maintenance personnel and are detectable during routine inspections, if the proper preventive checks are performed. Even with cylinder design and manufacturing process improvements, decreased cylinder life can occur if proper attention is not given to the various factors identified in this SID.

When operated regularly in a properly designed and maintained installation, current TCM cylinders provide excellent reliability and durability. In specific fleet applications, TBO extensions based on condition inspections have been regularly obtained. TCM has invested heavily in the development of improved cylinder designs and manufacturing processes. So that we can continue to deliver increased value to our engine and cylinder customers.

MO 02

ISSUED DAY YEAR 17

97

MO 04

REVISED DAY YEAR 19

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

1 of 26 SID97-2

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TCM TopCare Program Improved Cylinder Head Castings “Beefier” in critical stress areas

Improved Insert Installation For Enhanced Valve Seating Manganese Phosphate Coating Resists Corrosion During Break-in Barrels are made from High-Grade 4140 Thru Hardened Steel Alloy then Nitride Coated for additional hardness

Revised Hone Pattern for Improved Ring/Wall Lubrication

Figure 1. TopCare Cylinder Improvements TCM TopCare Program TCM TopCare Product Improvements: Beginning in February 1997, TCM introduced 520 and 550 cubic inch cylinders which include a revised hone pattern for improved piston ring and wall lubrication, reduced oil ring tension for increased oil flow to cylinder walls, coated pistons for increased scuffing protection and manganese phosphate coated cylinder barrels to provide corrosion protection for the first hours of cylinder operation. TCM has also improved valve seat installation and implemented cylinder head casting improvements in areas where cracking has been observed. These improvements have been incorporated into the complete line of TCM cylinders effective March 1997. The product improvements are intended to provide additional durability to address a complex combination of operational, maintenance and fleet aging factors. All cylinders released from the TCM Factory since March 1997 are brand new and have incorporated the TopCare improvements and are eligible for the new TopCare warranty, which became effective August 1999.

MO 02

ISSUED DAY YEAR 17

97

MO 04

REVISED DAY YEAR 19

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

2 of 26 SID97-2

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TCM TopCare Health Check Inspection - Two of the purposes of this SID are to assist in identifying problems with cylinders in service and to provide a preventive maintenance checklist to utilize in identifying and correcting factors which, if not addressed, can lead to reduced cylinder service life. The TCM TopCare Health Check Inspection is intended to supplement the checks normally prescribed by TCM and the airframe manufacturer relating to factors affecting cylinder life and should be conducted at least once per year in conjunction with a regularly scheduled inspection. TCM TopCare Cylinder Warranties - Aircraft owners who participate in the TopCare Program can be eligible for special warranty coverage, provided certain eligibility requirements are met. The TopCare Cylinder Warranty applies to cylinder assemblies manufactured or supplied by TCM which incorporate the applicable TopCare cylinder improvement package. Additionally, any engine presently covered by the Gold Medallion Standard Aircraft Engine Warranty or the Gold Medallion Plus II Aircraft Engine Warranty but without the TopCare cylinder improvement package may qualify for additional warranty coverage. A summary of TCM TopCare Warranties is presented on page 23 of this SID. Any engine that does not qualify for coverage under the TopCare warranties will continue to be covered under the terms of the Gold Medallion Standard Aircraft Engine Warranty, the Gold Medallion Plus II Aircraft Engine Warranty or the Aircraft Engine Part, Component & Accessory Warranty, as applicable. It should be noted, however, that the issues addressed in this SlD relate to the proper installation, operation and maintenance of TCM engines. The discrepancies discussed in this SID may adversely affect the engine and any resulting damage will not be eligible for coverage under any TCM warranty.

TCM TopCare Health Check Inspection TCM recommends that each operator of a TCM powered aircraft have the TopCare Health Check Inspection performed annually in conjunction with a regularly scheduled inspection to identify cylinder condition and installation items which can result in reduced cylinder life. The points of the TopCare Health Check are: • • • • • • • • • • •

MO 02

Cylinder Differential Compression Check And Trend Monitoring Cylinder Borescope Inspection, As Required Oil Consumption Trend Monitoring Oil Analysis Trend Monitoring Baffle Condition Inspection Induction System Examination Cowling Inspection And Cowl Flap Operational Check Ignition System Inspection Fuel System Setup Verification Of Accuracy Of Engine Gages Flight Test

ISSUED DAY YEAR 17

97

MO 04

REVISED DAY YEAR 19

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

3 of 26 SID97-2

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Minimum Tool Requirements For Performing TCM TopCare Health Check Inspection: • • • • • • • • • •

Basic Mechanic's Hand Tools Calibrated Torque Wrench Inspection Light and Mirror Calibrated Differential Compression Tester Master Orifice Tool, P/N 646953 Borescope Magneto Timing Light, Protractor and TDC Plug Calibrated Fuel System Adjustment Gages Tachometer Tester CHT / EGT Tester

1. CYLINDER DIFFERENTIAL COMPRESSION CHECK Wearing of cylinder walls, ring surfaces, and valve seats occur throughout the life of an engine. At regular maintenance or when condition inspections are indicated, differential compression checks should be made and recorded for trend monitoring. The latest version of the TCM Service Bulletin SB03-3 concerning cylinder compression checks describes the necessary equipment, procedures, and recommended actions. It is important to note that differential compression checks are used to identify cylinder leakage rates and the source of the leakage. This check cannot be directly related to engine horsepower. ENGINE TESTING HAS SHOWN THAT CERTIFICATION HORSEPOWER RATINGS WILL CONTINUE TO BE DELIVERED EVEN WHEN ALL CYLINDERS ARE AT OR BELOW THE MINIMUM ALLOWABLE CALIBRATED COMPRESSION READING AS ESTABLISHED BY THE MASTER ORIFICE TOOL. Specifically, differential compression checks are designed to identify cylinder leaks that are occurring by the piston rings or in the valve/seat areas. The use of a calibrated differential gage as described in the latest version of the TCM Service Bulletin SB03-3 concerning differential compression checks is mandatory for accurate readings. If the leakage value is greater than the minimum allowable calibrated compression reading established by the Master Orifice Tool, no further action is indicated unless leakage is by either valve. If the leakage value is less than the minimum allowable calibrated compression reading, further investigation in accordance with the latest version of TCM Service Bulletin SB03-3 should be followed prior to cylinder removal. 2. CYLINDER BORESCOPE INSPECTION: Cylinder borescope inspections are recommended when reported oil consumption is high, or as routine inspections to monitor cylinder condition. Conducting meaningful borescope inspections requires practice and experience to properly interpret the limited view available. When conducting the TopCare Health Check borescope inspection, the maintenance technician should examine the cylinder for the presence of rust and overall condition of the cylinder bore and valve area. Refer also to the latest version of TCM Service Bulletin SB03-3 for procedures and recommended test equipment necessary to borescope the cylinder barrel and valve area condition.

MO 02

ISSUED DAY YEAR 17

97

MO 04

REVISED DAY YEAR 19

2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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A. RUST EXAMINATION: To achieve long cylinder life, TCM cylinder barrels are constructed of through-hardened steel with a nitrided surface. Regular use of the aircraft in normal operation is usually sufficient to provide an oil coating which prevents excessive rust formation in the cylinders. However, new cylinders are particularly sensitive to rust formation if not used frequently or preserved during periods of inactivity. To provide improved rust formation protection in new cylinders, TCM cylinders produced beginning in February and March 1997 (depending on the model) have a manganese phosphate coating. Cylinders produced after these dates also have an advanced multi-step hone pattern to aid in oil retention. Note that the phosphated cylinder bore will have a dark gray to brownish color that will wear away as hours in service are accumulated. Infrequent or irregular use of the aircraft can easily lead to rust formation which may result in reduced cylinder life if the engine is not properly preserved in accordance with the latest revision of the TCM Service Information Letter SIL99-1 concerning engine preservation. Caution: The practice of ground operation of the engine as a substitute for regular use of the aircraft is unacceptable. Ground running does not provide adequate cooling for the cylinders. In addition, ground running introduces water and acids into the lubrication system which can cause substantial damage over time to cylinders and other engine components such as camshafts. Turning the propeller by hand is not recommended as this wipes off the residual oil.

Light Rust Formation, Hone Not Affected FIGURE 2 Light rust signatures which have not pitted the cylinder wall, or rust indications above the top ring travel area, are not usually cause for concern. See Figure 1. Severe rust will pit the barrel wall and can damage rings. See Figure 2. Such damage will usually be evident by low differential compression checks and high oil consumption. TCM'S WARRANTY DOES NOT COVER DAMAGE FROM RUST. Rust damage must be prevented by the operator and/or maintenance facility.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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Heavy Rust Formation, Surface Pitting Has Altered Honed Pattern FIGURE 3 B. CYLINDER WALL EXAMINATION Borescope inspections of the cylinder wall are performed to assess the condition of the hone pattern and identify abnormal wear patterns which can contribute to low differential compression readings or increased oil consumption. The cylinder wall hone pattern consists of a carefully applied pattern of surface "scratches" introduced at the time of manufacture. These scratches aid in ring seating by allowing the ring and wall surface to wear into conformity to each other and provide a reservoir of oil for lubrication during ring travel. The cylinder walls and rings are designed to wear over the life of the engine, particularly in the high pressure and temperature combustion area. The visible hone pattern in the upper portion of the bore may disappear during normal operation. SUCH NORMAL PATTERNS ARE NOT CAUSE FOR CYLINDER REMOVAL. The following figures show hone patterns in a new cylinder and at TBO for typical TCM cylinders. As can be seen from the photograph at TBO (Figure 4), cylinders which have a very light or no hone pattern in the upper portion of the bore can function normally, have normal oil consumption and have acceptable differential compression checks. For this reason, the borescope inspection should be used in conjunction with differential compression checks and oil consumption trends to assess engine condition.

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

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New Steel Cylinder Bore FIGURE 4

Typical Cylinder Bore At TBO FIGURE 5 Scratches or grooves that extend in the direction of piston travel can result from contamination and may lead to low differential compression checks and high oil consumption. Heavy bore wear with a complete loss of visible hone pattern over the full ring travel can result from overtemperature operation or abrasive wear. See Figure 5. These signatures, in conjunction with low differential compression checks or high oil consumption, generally indicate cylinder repair or replacement or, at minimum, call for more frequent condition inspections.

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

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Heavily Worn Cylinder Bore FIGURE 6 Over time, the cylinder wall may develop a glazed coating which is generally beneficial to cylinder life as a rust inhibitor. The glaze is a residue of hydrocarbon constituents and lead deposits which serve as both a rust inhibitor and lubricant. Changes and variations in fuel constituents and types of oil used in recent years may impact this beneficial coating. TCM's revised hone pattern, reduced oil control ring tension and manganese phosphate coating are intended to offset this impact. 3. OIL CONSUMPTION TREND MONITORING Aircraft piston engines continuously wear over their service life. One indication of the rate of wear, or indication of the need for inspection or service, is found in oil consumption trends. Every owner/operator and maintenance facility should maintain formal records on oil consumption in the aircraft log book. Oil consumption can be expected to vary with each engine depending on the load, operating temperature, type of oil used and condition of the engine. A differential compression check and borescope inspection should be conducted if oil consumption exceeds one quart every three hours or if any sudden change in oil consumption is experienced and appropriate action taken. It is important to note that the current technology of general aviation aircraft reciprocating engines requires a certain level of oil consumption to assure proper lubrication of the cylinder walls and rings. Aircraft engines operate under much greater loads and at higher temperatures than automotive engines and require correspondingly greater oil use. In addition to lubrication, oil serves as a coolant and as a means to transport contaminants, wear particles, acids and moisture from the engine at oil changes. Frequent oil changes based on operating hours or calendar time are critical to engine life. Approved oils are listed in the latest version of the TCM service bulletin concerning approved fuel and oil grades.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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TCM cylinder assemblies produced after February 1997, for 520 and 550 engines have revised oil ring tensions to produce improved cylinder bore lubrication characteristics. The TopCare Health Checklist Form at the end of this SID contains a means to record oil consumption that should be completed and maintained with the engine logbook. OIL CONSUMPTION TRENDS ARE EXCELLENT INDICATORS OF CYLINDER BORE AND RING CONDITION. 4. OIL ANALYSIS TREND MONITORING Oil analysis is a tool to monitor wear material and contaminants in the engine. To be effective, a baseline of at least three analyses must be established from a single source to provide trend characteristics. For those engines with an established oil analysis profile, changes in iron, copper and other tracked elements can indicate unusual wear. In such cases, other diagnostic tools such as differential compression checks, borescope inspections, oil filter/screen examination and oil consumption trends can be useful in identifying the problem. Oil analysis can also detect air filtration or induction system leaks indicated by high silicon content. Note that oil analysis does not provide any indication of cracks, leaks or similar situations that could result in engine problems. NOTE:

To establish a meaningful data base for comparison, the oil samples must be taken on a regular schedule using the same sampling technique and laboratory. The engine must have operated long enough to obtain normal operational temperatures and the oil sample taken within 30 minutes after engine shut down. The tube or funnels used to drain the oil from the oil sump must be clean and free of any foreign material or residue. If the oil sample is taken from the oil as it drains from the sump, allow approximately 1/3 of the oil to drain prior to taking the sample. If the sample is taken via the oil filler or other location using a sampling tube it is critical that the sample not be taken from the bottom of the sump, but at a location 2 to 3 inches above the bottom of the sump. Under no circumstances should an oil sample be taken from the oil filter canister.

The TCM LINK Aviator Services program provides a mechanism for recording and tracking oil analysis through the software supplied to Aviator Services members. For additional information on Aviator Services, contact TCM LINK Aviator Services Desk at 1-888-826-5465. 5. BAFFLE CONDITION INSPECTION Investigations into cylinder service life issues found that maintenance of cylinder and oil cooling systems (incorrect and improperly fitting baffles) were factors in premature cylinder removals. To understand the importance of this cooling control, note that approximately one third of the energy of the fuel used is transferred as heat to the structure (cylinder head, barrel, crankcase, etc.) and oil. THE AMOUNT OF HEAT ENERGY THAT MUST BE REMOVED BY THE COOLING AIR IS APPROXIMATELY EQUAL TO THE HORSEPOWER THAT IS DRIVING THE PROPELLER. This is why failure of the cooling baffles to perform efficiently can lead to rapid and significant deterioration of the cylinders and other engine components. To remove this heat, cooling airflow is directed by a series of baffles and ducts so that the airflow passes over cooling fins or directly to components requiring cooling. IT IS IMPORTANT TO UNDERSTAND THAT THE PRESSURE DIFFERENTIAL IN THE COWLING IS SMALL AND SLIGHT IRREGULARITIES IN THE BAFFLES CAN EASILY HAVE AN ADVERSE AFFECT ON ENGINE COOLING.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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Field inspections indicate that critical baffles are often poorly maintained or deteriorate with age. In some cases, multiple engine removals have been made over the aircraft life without the replacement or repair of baffles and seals. In such cases, operators may have experienced excellent durability on early engines but have experienced less favorable results on later engine installations due to loss of cooling control. In addition to the age of the aircraft, many engines have been installed as power upgrades through the Supplemental Type Certificate (STC) process. All of these installations should be thoroughly examined to ensure completeness of baffling and the replacement of old and potentially dysfunctional baffles. THE QUALITY OF DOCUMENTATION FOR STC INSTALLATIONS CAN VARY WIDELY, AND IF THE INSPECTION REVEALS INSTALLATION PROBLEMS THAT COULD AFFECT ENGINE COOLING OR OPERATION, THE STC HOLDER MUST BE CONTACTED FOR RESOLUTION. FOR THESE REASONS, IT IS IMPORTANT THAT ALL AIRCRAFT BAFFLES BE INSPECTED ANNUALLY. Some manufacturers, conversion shops, and maintenance facilities have developed baffle kits with improved, more flexible material that can provide excellent engine cooling airflow. Such kits may be particularly beneficial for older aircraft. Groups such as the American Bonanza Society and the Cessna Pilots Association can be useful sources for information about kits for specific aircraft. Baffles in the conditions shown in the following photographs indicate problems found in the field that will shorten cylinder life by causing inadequate cooling airflow. The TopCare Health Check list indicates areas to be checked such as intercylinder baffles, perimeter baffles, cowl seals, cooling ducts, and any other seals or areas that direct or control airflow. Ensure that all holes and cracks that may waste cooling air are sealed.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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Peripheral Baffle Seals Improperly Positioned

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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Aft and Side Peripheral Baffle Seals Not Sealing Properly

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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Cooling Air Loss Due to Gaps in Baffle Seal

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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6. INDUCTION SYSTEM EXAMINATION Improper or inadequate maintenance of the air induction components of the aircraft engine installation can and often does result in the engine breathing unfiltered air. Unfiltered air contains particulates, which are abrasive to the engine, especially to the cylinder walls and ring faces. Induction system maintenance that emphasizes properly sealed filters, alternate air doors, and air ducts can prevent much of that damage. Induction system deficiencies can often be detected through oil analysis which identifies the contamination. In addition to using the engine manuals, also consult the aircraft maintenance manual for information. The TopCare Health Check Inspection contains the basic elements that should be considered as a minimum to inspect induction system integrity. 7. COWLING INSPECTION AND COWL FLAP OPERATIONAL CHECK In addition to baffle conditions, other components that affect airflow though the cowling must be reviewed. Supplemental equipment or modifications must not restrict cowl openings and exit areas. Abnormal temperatures can result from airflow blockage or restrictions, which can lead to cylinder damage. Cowl flap operation is also an integral part of engine cooling control. The TopCare Health Check Inspection recommends verification of the correct opening, rigging, and operation of the cowl flaps. 8. IGNITION SYSTEM INSPECTION Advanced magneto to engine timing can cause elevated cylinder head temperatures. Maintain and adjust magnetos in accordance with the engine or magneto service instructions. Inspect the magneto harness and spark plugs and replace if needed. 9. FUEL SYSTEM SET-UP Improper maintenance and adjustment of the fuel system can be a significant factor in premature cylinder removal. Engine operation and cooling are directly related to the correct setup of the fuel system. In addition, improper fuel system settings can affect engine performance in terms of both power and response to throttle movement. For most installations, the available airflow is insufficient to cool the engine during high-power operation and additional fuel is required to provide supplemental cooling. Mixture control can also be used in cruise to maintain correct cylinder head temperatures. Full rich fuel flows must be set properly in order to provide designed cooling margins. Refer to the latest version of TCM Service Bulletin SID97-3 concerning fuel system set-up instructions. Use the aircraft manuals and, if the installation is an STC, use the instructions provided with the STC. Caution:

When performing fuel system set-up or adjustment, it is essential that the applicable manufacturer's and/or STC holder's published instructions be followed. It is also essential that proper tools, equipment and calibrated test gages be utilized. Do not rely on aircraft fuel flow pressure gages for fuel system set-up or adjustment. Aircraft tachometer and manifold pressure gages must be verified for accuracy.

To assist in this critical system adjustment, TCM has produced a video about the setup and maintenance of TCM fuel injection systems as a supplement to existing information. The video (P/N X30650) may be ordered by contacting the TCM Customer Service Department.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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10. AIRCRAFT ENGINE GAGE VERIFICATION To ensure that the engine is operating within recommended limits for normal operation, the aircraft engine gages must be verified for correct indications and any discrepancies rectified. Engine gages include the tachometer, manifold pressure, fuel flow, oil pressure, oil temperature, cylinder head temperature (CHT) and exhaust gas temperature (EGT). Caution:

Inaccurate aircraft engine related gages can cause operation outside of engine certification and specification limits and can lead to decreased cylinder life. Aircraft gage calibration errors can be particularly harmful for high horsepower engines. Gages must be re-marked for modified (STC) engines. WARNING

SIGNIFICANT AIRCRAFT ENGINE GAGE INACCURACIES CAN LEAD TO CYLINDER DETONATION WHICH CAN RESULT IN ENGINE STOPPAGE. 11. FLIGHT TEST At the conclusion of the inspections, repairs and adjustments, conduct a test flight to verify normal operation of the engine and related systems. The instructions in TCM Service Bulletin M89-7R1 provide ground runup and test flight procedures. Caution:

Ground running during adjustments must be carefully monitored to avoid high and potentially harmful cylinder head temperatures. Extended and full power ground operations must be held to a minimum, especially on newly installed cylinders.

PILOT OPERATIONAL AWARENESS The aircraft operator can significantly influence the service life of the cylinders and other components by an increased awareness of engine requirements. Example: Rust prevention by frequent operation or by following recommended preservation procedures if the aircraft is inactive. Using the correct type and grade engine oil and requiring frequent oil changes are important areas where an informed owner/operator can extend engine life. In general, becoming knowledgeable about all of your aircraft's maintenance requirements will help you make informed decisions. Membership in TCM LINK Aviator Services provides an outstanding means of obtaining information and recommendations for operation and maintenance of your engine. The life of cylinders and cylinder components is highly dependent on correct operating temperatures. Control of operating temperatures is a function of installation design and maintenance, and operator control of fuel flow and cowl flaps. During high power and slow speed aircraft operations, the fuel/air mixture must be rich to supplement air cooling. Enriched fuel flow is a powerful way of controlling combustion temperatures and, therefore, cylinder, piston, and ring temperatures.

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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The highest combustion temperatures occur near the ideal fuel/air ratio of about one pound of fuel for 15 pounds of air. Combustion temperatures drop on both the lean side and rich side of this point. However, on the lean side of peak, the reduction in power with leaning is rapid and lean misfire occurs on many engines about 100 degrees F lean of peak. On the rich side, power is very stable with changes in fuel flow. This characteristic allows the engine to obtain rated power with rich mixtures where the combustion temperatures are substantially reduced. This additional fuel at takeoff is required to maintain control of cylinder structure and oil cooling. In cruise, operating rich reduces combustion temperatures and should be used to control engine temperatures. For maximum range, operation on the lean side of peak or at peak is permitted at low cruise power on some engine models. For normal operation, it is good practice that mixtures be controlled so that the hot cylinder is 50 to 100 degrees F rich of peak at cruise settings. In addition, rapid temperature changes should be avoided. Warm-up and cool down periods at the start and end of flights are also recommended. Leaning recommendations and fuel flow limits are found in the Airplane Flight Manual, or supplemental Airplane Flight Manual if you have an STC installation. These recommendations should be followed with pilot control of fuel flows and cowl flaps used to maintain temperature control. COMMENT ON ENGINE TOP OVERHAUL PROCEDURES If the results of the TopCare Health Check Inspection indicate that one or more cylinders should be removed from the engine, it is extremely important the cylinder removal, repair or replacement, and installation be conducted according to the instructions contained in the appropriate aircraft manufacturer's instructions, TCM Overhaul Manuals and other related TCM service documents for the aircraft and engine under service. Evaluations of engine service issues and incidents in the field indicate that a number of engines that experience reduced service life can be attributed to improper field top overhaul procedures. Improper torque sequencing or procedures employed during reassembly can result in loss of engine crankcase through-bolt torque. WARNING THE USE OF IMPROPER PROCEDURES FOR CYLINDER REMOVAL AND REPLACEMENT CAN LEAD TO LOSS OF MAIN BEARING CRUSH AND ENGINE FAILURE. To assist with the understanding of the proper procedures for engine top overhaul, TCM has produced a video that highlights the critical elements of a field top overhaul. The top overhaul video (P/N X30562) may be ordered by contacting the TCM Customer Service Department. Anyone can contact TCM Customer Service and order the video for a nominal charge.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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TCM TopCare Health Checklist NOTE:

In order to perform the TopCare Health Check Inspection, all applicable aircraft, engine, and STC holder's manuals, instructions and service information must be available and utilized. Use the TopCare Health Checklist Form to document the results of the following inspections and required repairs and adjustments. The latest version of TCM Service Bulletin SB96-12 provides additional cylinder inspection criteria that should be performed in addition to the inspections called for in this SID.

1. DIFFERENTIAL COMPRESSION CHECK a. Perform Differential Compression Check in accordance with the latest revision of TCM Service Bulletin SB03-3 and record the master orifice tool reading. 1. For cylinders with differential pressures greater than the minimum allowable calibrated compression reading, and borescope inspection reveals no abnormalities, then continue in service. 2. For cylinders with differential pressures less than the minimum allowable calibrated compression reading, a borescope examination must be performed and the aircraft flown at power with a re-check of the suspect cylinder. If the cylinder leakage rate is still below the minimum allowable calibrated reading, the leakage source must be determined and corrected. 3. For cylinders where leakage by the valves is identified, perform a borescope inspection of the affected cylinder(s). If the leakage rate is above the minimum allowable calibrated compression reading, and borescope examinations reveal no abnormalities, continue in service. If the leakage rate is below the minimum allowable calibrated compression reading, and borescope examinations reveal no abnormalities, operate the engine to normal temperatures and recheck cylinder differential leakage. 4. For cylinders where leakage by the rings or valves is less than the minimum allowable calibrated compression reading, further investigation in accordance with the latest version of TCM Service Bulletin SB03-3 should be followed prior to cylinder removal. b. Record differential compression values for each cylinder and reference pressure value. 2. CYLINDER BORE INSPECTION CHECK LIST a. In addition to the procedures listed here, refer also to the latest revision of TCM Service Bulletin SB03-3 for cylinder barrel and valve area borescope examination procedures. Inspect each cylinder for signatures of normal wear. See Figure 4. Cylinder walls which appear to have minimum or no hone pattern are acceptable if the cylinder has acceptable differential compression readings and the engine has acceptable oil consumption. b. Inspect each cylinder for signatures of light rust. See Figure 1. Light rust which has not resulted in excessive pitting of the cylinder wall is acceptable. Several small, localized areas less than 1/16 inch in diameter are acceptable as long as the total affected areas in any one cylinder does not exceed 1 inch in diameter. The affected areas must be separated by at least 1/2 inch. Rust above the top ring travel is inconsequential and not cause for cylinder removal. Surface discoloration or staining is acceptable and will not result in any damage to the cylinder barrel or to the piston rings. MO 02

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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c. Inspect each cylinder for signatures of heavy rust. See Figure 2. Cylinder walls which show heavy rust as characterized by pitting of the cylinder wall surface should be removed for repair or replacement if the cylinder has low differential compression or the engine oil consumption is high. Areas of corrosion where the honed surfaces have been altered are of primary concern. These areas are normally very dark in contrast to the surrounding areas. Small localized areas less than 1/2 inch in diameter are acceptable as long as there are no signatures of scoring or material pick up. d. Inspect each cylinder for signatures of heavy wear. See Figure 5. Heavy bore wear is identified as a complete loss of visible hone pattern over the full ring travel and will normally have associated low cylinder differential compression and/or high oil consumption. This generally will indicate a need for cylinder repair or replacement or, at minimum, call for more frequent condition inspections. e. Inspect each cylinder for signatures of scoring. A predominant amount of cylinder bore scratches or grooves that extend in the direction of piston travel will normally lead to low differential compression checks and high oil consumption. This may also be identified by burnt or blistered paint on the exterior of the cylinder barrel. This will indicate a need for cylinder repair or replacement. 3. OIL CONSUMPTION TREND MONITORING a. A formal oil consumption record should be generated for the engine installation. If oil consumption is more than one quart every three hours of operation or if the oil consumption trend has changed substantially, conduct the differential compression and borescope examinations defined by sections 1 and 2 of the TopCare Health Checklist. If the oil consumption trend is stable and the oil consumption is less than one quart every three hours, continue with the TopCare Health Checklist. b. Record type of oil used. c. Record the number of quarts of oil added. d. Record oil change interval. e. At every oil change, strain the oil and examine for debris. Also, cut open the oil filter and examine it for unusual material content. Record examination results of the strained oil, oil filter or screen. The presence of a heavy amount of material will require investigation to determine the source prior to further engine operation. 4. OIL ANALYSIS TREND MONITORING a. If an oil analysis profile has been established, review the results for indications of wear or contamination. b. Based on the latest oil analysis, record the results of the profile trend. If the trend indicates an abnormal increase in material amounts, reference the recommended actions provided by the oil analysis laboratory. c. If no prior oil analysis exists, initiate sampling according to the instructions you receive with the oil analysis kit.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

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5. BAFFLE CONDITION INSPECTION a. Check baffles for condition, correct position, and proper contact with cowl. b. Repair or replace worn or distorted baffles. c. Check and adjust inter-cylinder baffles to ensure a tight fit. d. Seal holes and cracks that would allow cooling airflow to be wasted. This may be accomplished by applying a non-corrosive silicone adhesive/sealant. Consult the aircraft manufacturer for application instructions. e. Check the integrity of all cooling ducts, heater ducts, etc. and repair as necessary. 6. INDUCTION SYSTEM EXAMINATION a. Check the air filter for cleanliness, normal operation and the absence of gaps or leaks in the filtering element. Check the air filter seal for potential bypass circuits from the filter. Correct or replace as necessary. b. Verify the integrity of the airbox by examining for alternate air circuits which can bypass the filtering system. Any holes or bypass circuits found behind the filtering element should be repaired as required. c. Verify the operation of the alternate air door and the integrity of the seal when in the closed position. Verify the door operating mechanism for security when in the closed location. Replace or repair as necessary. d. If the operator conducts regular oil analyses, use the silicon content of the most recent analysis and the overall silicon trend to further assess the possibility of induction system leaks or pilot operational issues such as extensive use of carburetor heat or alternate air during ground operation. e. Identify induction system inspection requirements for the specific aircraft in service and comply with all requirements for inspection and maintenance of the induction system. 7. COWLING INSPECTION & COWL FLAP OPERATION CHECK a. Verify that equipment such as add-on accessories and their associated hardware does not restrict cowl inlet, cowl outlet, and air flow through the cooling fins. b. Verify cowl flap rigging and operation in accordance with the appropriate aircraft maintenance manual as applicable. 8. IGNITION SYSTEM INSPECTION a. Check magneto timing and adjust to specification. Refer to the latest revision of TCM Service Bulletin MSB94-8A concerning magneto to engine timing. b. Clean, gap and test spark plugs; replace as needed. CAUTION: Always use new spark plug gasket. Failure to install a new spark plug gasket each time the spark plug (s) are installed may result in incomplete sealing of the combustion chamber, loss of spark plug heat transfer, spark plug over heating, possible pre-ignition / detonation and internal engine damage. c. Inspect ignition harness leads for damage; replace as needed.

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9. FUEL SYSTEM SETUP a. Adjust fuel system in accordance with the latest version of TCM Service Bulletin SID97-3 concerning fuel system adjustment and STC instructions, if applicable. b. Calibrated test gages, not aircraft gages, must be used and the published recommendations shall be followed. 10. AIRCRAFT ENGINE GAGE VERIFICATION a. In addition to the verification of accuracy of the tachometer and manifold pressure gage required for fuel system setup, verify that the fuel flow, cylinder head temperature (CHT) and exhaust gas temperature (EGT) gages are providing accurate indications. 11. FLIGHT TEST a. Refer to TCM Service Bulletin M89-7R1 for guidelines for initial operation and flight test after maintenance. b. Conduct flight test as called for in TCM Service Bulletin M89-7R1. c. Make adjustments as indicated by the flight test. d. Follow the limitations and operating instructions provided in the Airplane Flight Manual or supplemental Airplane Flight Manual. e. Under standard atmospheric conditions, typical full rich climb cylinder head temperatures should be 380 to 420 degrees F and oil temperatures should be 180 to 220 degrees F. f.

Under standard atmospheric conditions, typical lean cruise cylinder head temperatures should be 340 to 380 degrees F and oil temperatures should be 170 to 190 degrees F.

PILOT OPERATIONAL AWARENESS In addition to the items contained in the TopCare Health Checklist, the maintenance facility should also provide the owner information concerning the following: a. Rust - Refer to latest revision of TCM Service Information Letter SIL99-1 for engine preservation instructions. Frequent use for periods that ensure at least 30 minutes of flight operation after oil temperatures have stabilized is the best routine. DO NOT SUBSTITUTE GROUND RUNNING FOR FLIGHT OPERATION. b. Lubrication - Use only oils approved for aircraft engines. Refer to the latest revision of TCM Service Information Letter SIL99-2 concerning recommended fuel and oil grades. Oil changes at intervals not to exceed 50 hours of operation (25 hours for engines with oil screens) or 6 months, whichever occurs first, is considered good practice. c. Cooling Control - Follow the leaning recommendations and fuel flow limits in the Airplane Flight Manual or supplemental Airplane Flight Manual if an STC installation. Pilot control of fuel flow and cowl flap position to maintain temperature within the guidelines is recommended practice.

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P.O. Box 90 Mobile AL 36601 • 251-436-8134

2004 TELEDYNE TECHNOLOGIES INCORPORATED

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TCM LINK Aviator Services - This free owner information service provides direct exchange of information with TCM and provides reference information such as TCM service bulletins and FAA Airworthiness Directives related to specific TCM engines and ignition systems. Register for Aviator Services on-line in a matter of minutes; you may call the TCM Link Aviator Services Desk at 1 -888-TCM-LlNK (826-5465) to register or you can register on-line, just go to http://www.tcmlink.com/registration/aviatorservices.cfm and receive the following programs available to you 24 hours a day: Aviator Member & Engine Profile TCM Engine & Ignition Service Bulletins Scheduled Maintenance Checklists Oil Analysis Tracking Program

Electronic Illustrated Parts Catalog FAA Airworthiness Directives Troubleshooting Guide & Technical Briefs SB/AD Compliance Matrix

Summary of TCM TopCare Warranties 1. TopCare CYLINDER WARRANTY For complete TopCare cylinder warranty information and coverage see the latest revision of TCM TopCare™ Cylinder Warranty Form, X30684. You can also obtain a free copy of this warranty at our web site address http://www.tcmlink.com/warranty.html . 2. ENROLLMENT INTO THE TOPCARE WARRANTY PROGRAM Each new aircraft powered by an engine which incorporates the TopCare cylinder improvement package is covered and no enrollment is required. For other than new aircraft, enrollment into the TopCare Warranty Program must be accomplished by performing the initial TopCare Health Check at time of engine (or cylinder) installation and correcting any discrepancies. The initial TopCare Health Check Form must be completed, signed by the inspecting mechanic and returned along with the attached TCM TopCare Warranty Enrollment Form to: Teledyne Continental Motors Attn. Warranty Services P.O. Box 90 Mobile, AL 36601 Fax Number 251-432-7352. To maintain coverage, the TopCare Health Check Inspection must be performed annually and any discrepancies corrected at that time. The TopCare Health Check Form must be completed for each inspection, signed by the inspecting mechanic and retained by the owner for submittal to TCM with any warranty claim under the TopCare warranty. Any FBO facility having all of the minimum tools required for performing the TopCare Health Check Inspection as identified on page 4 of this SID and the capability to properly perform the TopCare Health Check Inspection may contact TCM Service Department at 1-888-826-5465 and request that they be included on a list to be maintained by TCM to assist customers in identifying facilities capable of properly performing the TopCare Health Check Inspection. TCM reserves the right to audit both the equipment and capability of any FBO facility requesting to be included on the list and may require demonstration of capability and/or training for continuation on the list.

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

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The aircraft owner/operator must select an FBO facility that has the equipment and capability to properly perform the TopCare Health Check Inspection. Any owner/operator desiring the name of an FBO facility in a particular geographic region having the equipment and capability required to perform the TopCare Health Check Inspection may contact TCM Service Department at phone number (251) 438-3411 or (888) 826-5465. Any FBO identified by TCM will be based upon information and representations provided by the FBO. The FBO’s capability to properly perform the TopCare Health Check Inspection must be confirmed by the owner/operator prior to having the inspection performed. The expanded TopCare Cylinder warranty requires that the inspection be properly performed for warranty coverage to apply. Table 2 – TopCare Cylinder Warranty Reference Guide FuII Coverage Period

Type Warranty

Type Coverage

Additional Coverage Period

Pro-rata Calculation

TopCare Cylinders. (Shipped prior to 8/1/99).!

12 Months or 480 hours, whichever occurs first.

Parts & Labor

Pro-Rated to TBO of engine or 48 months, whichever occurs first.

Actual hours or 25 hours per month, which ever is greater.

TopCare Cylinders. (Shipped on or after 8/1/99).!

12 Months or 1000 hours, whichever occurs first.

Parts & Labor

Parts only for 24 months or 1000 hours, whichever occurs first, after the initial 12 month period.

Not Applicable.

Existing Cylinders on Engines Covered Under Gold Medallion Warranty With Required TopCare Health Check Inspection.!

Per Gold Medallion.

Parts & Labor

ENGINES

Existing Cylinders on Engines Covered Under Gold Medallion Plus II Warranty With Required TopCare Health Check Inspection.!

Per Gold Medallion Plus ll.

Parts & Labor

New Engines

One (1) year or

Parts and

(shipped after 8/1/99)!

1000 hours

Labor

Rebuilt Engine

One (1) year or 500 hours

Parts and Labor

(shipped after 8/1/99)!

To TBO based on Actual hours or 40 hours per month whichever occurs first. ENGINES

TopCare Cylinders Actual hours or 25 hours per month, whichever is greater. TopCare Cylinders

To TBO based on Actual hours or 30 hours per month whichever occurs first.

Actual hours or 25 hours per month, which ever is greater.

Full Parts years 2 and 3, no labor, no prorated or 1000 hours

Not applicable

Remainder of TopCare Cylinder Warranty!

Not Applicable

! For a full explanation of the TCM TopCare™ Cylinder Warranty Policy see page 22 of this bulletin “Summary of TCM TopCare Warranties” and our web site at www.tcmlink.com. NOTE On all engines other than those installed in new aircraft, the TopCare™ Warranty Enrollment Form must be received by TCM to validate the TopCare™ cylinder warranty.

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

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TCM TopCare Warranty Enrollment Form Owner Name:

Aviator Services Membership #:

Date:

City:

State/Country:

Zip Code:

Aircraft Registration #:

Make/Model:

S/N:

Engine Model:

Serial Number:

Position: L – R – S

Date Installed:

Time Since Major O/H:

Engine Model:

Serial Number:

Date Installed:

Time Since Major O/H:

Address:

Time Since Top O/H: Position: L – R – S Time Since Top O/H:

I wish to enroll in the TCM TopCare Warranty. I understand that TCM requires me to complete and maintain custody of periodic TopCare Health Checklist Forms for the purpose of proof of accomplishment for warranty and that TCM has no responsibility to review any of the forms submitted nor make any comment, recommendation or otherwise contact the owner regarding the contents thereof. The continued airworthiness of the aircraft remains the responsibility of the aircraft owner. I understand that if I make a claim under the TCM TopCare Warranty, I will be required to supply a copy of each of the TopCare Health Checklist Forms to TCM at the time the warranty claim is made. NOTE: Complete a copy of this form for each aircraft for initial TopCare enrollment. Return a completed copy of this TopCare Warranty Enrollment Form and the TopCare Health Checklist Form to:

Teledyne Continental Motors Attn: Warranty Services PO Box 90 Mobile, Alabama 36601 Fax Number 251-432-7352

Owner’s Signature: Date:

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

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TCM TopCare Health Checklist Form Inspecting Agency: _________________________________

Date:

Inspecting Mechanic: _______________________________

Aviator Services Member #: (As Applicable)

Aircraft Owner: ____________________________________ Aircraft Make/Model: _______________________________

Aircraft Serial #:

Aircraft Year:______________________________________

Registration #:

Engine Model:_____________________________________

Engine Serial #:

Engine Hours: Time since major O/H __________________

Time Since Top O/H:

1. Differential Compression Check

Record Readings

1a. Master Orifice Reading ............................................................................................................................. 1b. Record Differential Compression Values for Each Cylinder ..................................................................#1 #2 #3 #4 #5 #6 2. Cylinder Bore Inspection

Check

! Inspection Results for Each Cylinder

2a - Normal Wear 2b - Light Rust 2C - Heavy Rust 2d - Heavy Wear

2e- Scoring

Cylinder #1.............................................. Cylinder #2.............................................. Cylinder #3.............................................. Cylinder #4.............................................. Cylinder # ............................................... Cylinder #6.............................................. 3. Oil Consumption Trend Monitoring

Record Information

3a. Record Oil Consumption - One (1) Quart Every ............................................................................................. 3b. Type of Oil Used .............................................................................................................................................. 3c. Record the Number of Quarts Added............................................................................................................... 3d. Record Oil Change Interval ............................................................................................................................. 3e. Sump Oil Strained and Filter Contents Examined and Found to be:

4. Oil Analysis Trend Monitoring

Check

4a. Oil Analysis Profile Established ....................................................................................................................... 4b. Latest Oil Analysis Indicates ........................................................................................................................... ..................................................................................................................................................................... 4c. Oil Analysis Sampling Initiated......................................................................................................................... Oil Analysis Lab Used

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Hours Hours Clean Light Material Heavy Material

! as Applicable Yes No Normal Trend Abnormal Trend Yes No

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5. Baffle Condition Inspection Check ! as Applicable 5a. Baffles in Good Condition, Correct Position and Proper Contact .............................................................................................. 5b. Replaced or Repaired Baffles..................................................................................................................................................... 5c Inter-Cylinder Baffles Installed Properly ...................................................................................................................................... 5d. Holes and Cracks Sealed .......................................................................................................................................................... 5e. Cooling / Heating Duct Condition Correct or Repaired ............................................................................................................... 6. Induction System Examination

Check

! as Applicable

6a. Air Filter Clean and Properly Installed ........................................................................................................................................ 6b. Air Box Inspected and Repaired as Required............................................................................................................................. 6c. Alternate Air Door Sealing and Functioning Properly.................................................................................................................. 7. Cowling Inspection and Cowl Flap Operation

Check

! as Applicable

7a. No Restrictions in Cowling Inlet, Outlet or Cooling Fins ............................................................................................................. 7b. Proper Cowl Flap Rigging and Operation Verified...................................................................................................................... 8. Ignition System Inspection

Check

! as Applicable

8a. Magneto to Engine Timing Set at...................................................... Left and Right Degrees BTDC 8b. Spark Plugs Cleaned, Gapped, Tested and Replaced as Necessary ........................................................................................ 8c. Ignition Harness Inspected for Damage and Leads Replaced as Necessary ............................................................................. 9. Fuel System Setup

Check

! as Applicable

9a. Idle Unmetered Fuel Pump Pressure Set at ........................................................................... PSI at RPM Idle Fuel Mixture RPM Rise at Idle Cutoff = 25/50 RPM............................................................................................................. Full Throttle Metered Fuel Set at ...................................................................... GPH/LBS-HR at RPM 10. Aircraft Engine Gage Verification 10a. Verified accuracy of Tach, MP, Fuel Flow, CHT and EGT Gages............................................................................................ 11. Flight Test Flight Test Performed and All Parameters Within Specification If Cylinder Repair or Replacement was Required Due to Results of the Preceding Inspections, Indicate Below. Low Compression

Rust

Scored

Oil Consumption

Other

Cylinder #1 ............................................... Cylinder #2 ............................................... Cylinder #3 ............................................... Cylinder #4 ............................................... Cylinder #5 ............................................... Cylinder #6 ...............................................

Comments:

I hereby certify that I have performed the TopCare Health Check and any of the items identified above that required repair, replacement or verification have been repaired, replaced or verified. I also understand that TCM requires submission of this form for purposes of proof of accomplishment for warranty and that TCM bears no responsibility for the review or action on the actual details of this checklist form.

Date:

Mechanic's Signature:

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile AL 36601 • 251-436-8134

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy Of Operation SUBJECT: PROCEDURES AND SPECIFICATIONS FOR ADJUSTMENT OF TELEDYNE CONTINENTAL MOTORS (TCM) CONTINUOUS FLOW FUEL INJECTION SYSTEMS.

CATEGORY 4

SID97-3E Technical Portions FAA APPROVED SUPERSEDES M73-22, M89-10, M92-17, SID98-10A, SID97-3, SID97-3A, SID97-3B, SID97-3C and SID97-3D,

PURPOSE:

Provide procedures and specifications for the adjustment of Teledyne Continental Motors (TCM) fuel injection systems.

COMPLIANCE:

At Engine Installation, 100 hour/Annual Inspection, fuel system component replacement or as required if operation is not within specifications.

MODELS AFFECTED:

All TCM continuous flow fuel injected engine models except IO-240-B w/ Bypass Fuel System; L/TSIO-360-RB; TSIO-520-L, LB, WB; GTSIO-520-F, K, N and GIO-550-A Engine Models.

WARNING THE PROCEDURES AND VALUES PROVIDED IN THIS SERVICE BULLETIN APPLY TO TCM FUEL INJECTED ENGINES THAT HAVE NOT BEEN MODIFIED FROM THEIR ORIGINAL TYPE DESIGN. REFER TO SUPPLEMENTAL TYPE CERTIFICATE (STC) HOLDER INFORMATION AND INSTRUCTIONS FOR AIRCRAFT AND ENGINES THAT HAVE BEEN MODIFIED FROM THEIR ORIGINAL TYPE DESIGN.

GENERAL INFORMATION Fuel injection system components manufactured by TCM are adjusted and calibrated to meet engineering specifications. This insures operation within those specifications throughout the full range of operation. Fuel injection system components installed on factory new and rebuilt engines are further adjusted to meet design specifications during operation in the production engine test facility. These tests and adjustments are carried out in an environment of controlled fuel supply pressures and calibrated test equipment. When engines are installed in aircraft, they are subjected to a different induction system, fuel supply system and operating environment. These MO 03

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differences require checking and adjusting the fuel injection system to meet operational specifications before flight. Aircraft and engines that have been modified from their original type design must have the fuel injection system maintained in accordance with the Supplemental Type Certificate Holder’s FAA approved instructions. Operational verification of the engine fuel system is required any time one of the following circumstances occurs: (1) at engine installation, (2) during 100 hour and annual inspections, (3) whenever a fuel system component is replaced or adjusted, (4) when changes occur in the operating environment.

CAUTION: Engine performance, service life and reliability will be compromised if the engine's fuel injection system is neglected. The following adjustment procedures are presented in a sequential format that must be followed to insure proper fuel system adjustment. Reference the applicable Aircraft Maintenance Manual for detailed fuel system adjustment and maintenance procedures.

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© 2008 TELEDYNE CONTINENTAL MOTORS, INC.

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Any fuel system that cannot be adjusted to meet the specified values will require repair or replacement of the affected components prior to further engine operation.

(maximum) increments. This gauge will be used for metered pressure measurements and verification of aircraft fuel flow gauge on turbocharged engines only.

The adjustment procedures provided in this SID also apply to engine fuel systems equipped with TCM Position Tuned Fuel Nozzles. Refer to Form X306474, Position Tuned Fuel Nozzle Installation and Maintenance Manual for more detailed information and installation instructions.

NOTE: Pressure gauges must be accurate within ±1 %. Pressure gauges must be checked for accuracy and, if necessary, calibrated at least once each calendar year. Calibrated pressure gauges may be purchased from various suppliers such as: Davis Instruments 4701 Mount Hope Drive Baltimore, MD 21215 Phone: 410-358-3900 or 1-800-368-2516

CAUTION: Refer to the torque specifications, Table 1, page 10 for specified values when torquing hose end fittings. A. ADJUSTMENT TOOLS AND EQUIPMENT REQUIRED A complete set of tools and test equipment is essential for correct setup of TCM fuel injection systems. Various combinations of these tools and equipment will be used, depending on the engine model. A proper inventory of tools and equipment for fuel system adjustment will include the following: 1. TCM recommends the Model 20 ATM-C Porta Test Unit P/N 630045-20 ATM-C or equivalent to insure the fuel injection system meets all pressure and flow specifications. You may acquire a Model 20 ATM-C Porta Test Unit by contacting the following company: AERO TEST, Inc. 29300 Goddard Road Romulus, Michigan 48174 (734) 946-7777

4. Two (2) P/N MS51523-B4 swivel tee. These fittings will be used to tee into fuel lines for unmetered and metered pressure reference. 5. Hoses of appropriate diameters and sufficient lengths to allow personnel and equipment to be located away from propeller arc and blast area. 6. Common hand tools including: 7/8”, 11/16”, 9/16”, 1/2”, 3/8”, 7/16”, 11/32”, and 5/16” wrenches. A 1/4” drive ratchet and sockets, universal swivel, extension, and a 5/32” allen wrench common screw driver, a calibrated torque wrench, an oil can, mirror and flashlight. Safety equipment including hearing and eye protection must be used. 7. Tachometer verification instrument - various types are available. Verify aircraft tachometer accuracy prior to fuel system adjustment. B.

An alternative procedure would be to use calibrated gauges. 1. One (1) calibrated 0-60 PSI gauge, graduated in 1 PSI increments. This gauge will be used for unmetered pressure measurement. 2. One (1) calibrated 0-30 PSI gauge, graduated in .2 PSI (maximum) increments. This gauge will be used for metered pressure measurements and verification of aircraft fuel flow gauge indications on normally aspirated engines only.

PRE-SETUP PROCEDURES

1. During engine installation, or if any fuel system component has been replaced, flush the aircraft fuel system by first removing the engine-driven fuel pump inlet hose and terminating the end into a large, clean container. Operate the aircraft boost pump and allow a minimum of one gallon of fuel to flow through the system. Take necessary precautions to prevent a fire hazard. If contamination is present, locate and correct the source, and repeat this step before proceeding.

3. One (1) calibrated differential gauge, 0-30 PSID maximum, graduated in .2 PSI

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2. For all IO-240-B engines the following procedure must be used for fuel system flush whenever any fuel system component has been replaced: (a) Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the fuel pump inlet hose into a clean, dry container. Inspect the flushed fuel. If free from contamination connect to the engine driven fuel pump using the appropriate maintenance instructions. If contamination issue before proceeding further. (b) Using the airframe boost pump, flush a minimum of 1 quart of fuel through the engine driven fuel pump into a clean, dry container while working the mixture control through it’s full range of operation. Inspect the flushed fuel. If free from contamination, connect to the throttle and control unit using the appropriate maintenance instructions. If contamination is found, correct the issue before proceeding further. (c) Using the airframe boost pump, flush a minimum of 1 quart of fuel through the throttle and control unit into a clean, dry container while working the throttle control through it’s full range of operation. Inspect the flushed fuel. If free from contamination connect to the manifold valve using the appropriate maintenance instructions. If contamination is found, correct the issue before proceeding further. (d) Using the airframe boost pump, flush a minimum of 1 quart of fuel through the fuel transducer hose into a clean dry container. Inspect the flushed fuel. If free from contamination, install the fuel transducer in accordance with the Diamond maintenance instructions. If contamination is found, correct the issue before proceeding further. (e) Using the airframe boost pump, flush the 4 fuel injector lines into 4 appropriate, clean, dry containers. If the flushed fuel is free from contamination, connect to the fuel injectors using the appropriate maintenance instructions. If contamination is found, correct the issue before proceeding further. MO 03

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3. Before making any checks or adjustments, verify the accuracy of the aircraft tachometer, manifold pressure gauge and fuel flow gauge. Any gauge found to be inaccurate must be repaired or replaced before adjusting the fuel system.

WARNING USE OF INACCURATE GAUGES WILL RESULT IN INCORRECT ADJUSTMENT OF THE ENGINE FUEL SYSTEM, POSSIBLE CYLINDER WEAR DUE TO LEAN OPERATION, PRE-IGNITION, DETONATION, LOSS OF POWER AND SEVERE ENGINE DAMAGE.

3. Remove the engine cowling in accordance with the aircraft manufacturer's instructions. 4. Insure that all fuel system components are of the correct part number and are installed properly. Correct any discrepancies noted. 5. Remove, inspect, clean and reinstall the aircraft and engine fuel screens in accordance with the aircraft manufacturer's instructions. 6. Inspect the aircraft induction air filter and alternate air system for condition, operation and cleanliness. Repair or replace any component that is not airworthy in accordance with the aircraft manufacturer's instructions. 7. Inspect the aircraft vapor return system for proper operation in accordance with the aircraft manufacturer’s instructions. Correct any discrepancies noted. 8. Insure the fuel manifold valve vent and fuel pump drain lines are properly installed, open and free of obstruction. Correct any discrepancies noted. 9. Inspect all engine control rod ends for wear, freedom of movement, proper installation and security in accordance with the aircraft manufacturer's instructions. Correct any discrepancies noted. 10. Inspect the throttle and control assembly link rods (where used) for correct installation, security and wear at the attach points. Correct any discrepancies noted.

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11. Insure all engine controls operate freely throughout their full range of travel and are properly adjusted in accordance with the aircraft manufacturer's instructions.

CAN RESULT IN FITTING AND/OR COMPONENT DAMAGE AND LOSS OF SYSTEM PRESSURE. REFERENCE THE LATEST REVISION OF TCM SERVICE BULLETIN SIL95-5.

12. Lubricate all control rod ends and fuel system components in accordance with the latest revision of TCM Service Bulletin SB95-2 and the Aircraft Maintenance Manual.

NOTE:

WARNING FAILURE TO CORRECTLY INSTALL AND MAINTAIN ENGINE CONTROLS CAN RESULT IN LOSS OF SYSTEM CONTROL AND SUBSEQUENT LOSS OF ENGINE POWER.

13. Locate the IDLE speed stop screw on the throttlebody and turn it counter-clockwise two complete turns. See Figures 6, through 9. During fuel system adjustment, IDLE RPM will be controlled manually using the cockpit throttle control. 14. Inspect the exhaust and induction systems for proper installation, security and leaks. Correct any discrepancies noted. 15. Inspect all lines, hoses and wire bundles for chafing, loose connections, leaks and stains. Correct any discrepancies noted. Turbocharged engine models incorporating a fuel pressure regulator must have the regulator deactivated during initial fuel system adjustment. To deactivate the fuel pressure regulator, loosen and remove the fuel line or hose from the “center” port fitting at the pressure regulator. Refer to Figure 10. Install and torque, to the specified value, a cap on the “center” port fitting. Install and torque, to the value specified, a plug onto the removed line. Pressure test these areas for fuel leaks prior to proceeding with the fuel system adjustments. C.

03

1. Loosen and remove the unmetered fuel supply hose from the fuel pump outlet fitting, the fuel control unit inlet fitting, or the throttle body/metering unit inlet Tee whichever is most accessible. Some engine models have a fuel pressure connection fitting in the fuel control inlet screen that may be utilized for unmetered pressure gauge attachment. 2. For engine models with integral throttle body/metering units, remove and set aside the 639494 cap fitting from the inlet Tee. This cap will be reinstalled after setup is complete. 3. Install and torque the MS51523-B4 swivel tee directly to the fuel pump outlet fitting or to the fuel control inlet fitting as applicable.

NOTE: Some installations may require combinations of different fittings and hoses to facilitate installation of unmetered and metered test equipment connections. 3. Attach the unmetered fuel supply hose to the straight end of the tee connector and torque. 4. Connect the Unmetered test hose from the Porta Test Unit to the tee fitting and torque. If using the alternative procedure, connect the 060 PSI gauge to the swivel tee using a length of hose which will provide proper clearance from the engine cowling and propeller arc. Torque all connections.

SETUP PROCEDURES

5. Loosen and remove the metered fuel supply hose from the manifold valve inlet fitting.

WARNING

6. Install and torque the second MS51523-B4 swivel tee directly to the fuel manifold valve inlet fitting.

DURING REMOVAL AND INSTALLATION OF FUEL LINES AND HOSES, FAILURE TO PROPERLY SUPPORT COMPONENT FITTINGS MO

Adjustments to any component of the fuel injection system can affect other system settings. Always verify the performance of the entire fuel injection system whenever any fuel injection system component is adjusted.

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7. Attach the metered fuel supply hose to the straight end of the tee connector and torque. 8. Connect the metered pressure test hose from the Porta Test Unit to this second tee connector and torque. If using the alternative procedure, connect the 0-30 PSI gauge to the swivel tee using a hose long enough to provide proper clearance from the engine cowling and propeller arc. Torque all connections. 9. On turbocharged engines, connect the PortaTest Manifold Pressure and Upper Deck Pressure hose to the engine following the instructions provided with the Porta Test Unit. If using the alternative procedure, connect the 0 - 30 PSID differential gauge pressure fitting to the metered pressure swivel tee using a hose of sufficient length to provide clearance from the aircraft and propeller arc. Connect an equal length of hose to the "suction" side of the gauge and connect the other end to a location to reference turbocharger compressor discharge (upper deck) pressure. See Figure 12. Torque all connections. 10. Position the throttle control in the FULL OPEN position and the mixture control to FULL RICH. Operate the aircraft boost pump in accordance with the aircraft manufacturer's instructions. Following the instructions provided with the Porta Test Unit, bleed all air from the test unit and hoses. If using the alternative calibrated test gauges, loosen the test connections at each gauge to bleed the lines of any air. Hold the gauge at or slightly above the height of the fuel system component during the bleeding operation. Operate the boost pump only long enough to allow purging of air from the installed test equipment. Verify that all fuel lines, hoses and fittings are secured and torqued and that no fuel leaks exist before proceeding. Insure test hoses have been routed clear of the exhaust system and are supported their entire length to avoid inaccurate gauge readings.

WARNING MAKE CERTAIN ALL FUEL HAS DRAINED FROM THE INDUCTION SYSTEM PRIOR TO MO 03

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ATTEMPTING ENGINE START. FAILURE TO DO SO COULD CAUSE HYDRAULIC LOCK AND SUBSEQUENT ENGINE FAILURE.

11. Install the engine cowling or cooling shroud during ground operation. 12. Refer to TABLE 3, beginning on page 11, for specific data applicable to your engine. Record the applicable IDLE and FULL POWER adjustment points: RPM, fuel pressure, fuel flows, manifold pressure and fuel/air mixture rise provided in this Service Bulletin and Aircraft Maintenance Manual on the operational test form included at the end of this service bulletin. The Operational Test Form may be reproduced for use in recording adjustments and test indications.

NOTE: To insure optimum cooling during FULL POWER operations, the FULL POWER fuel flow should be set to the maximum specification limit.

WARNING BEFORE STARTING THE ENGINE INSURE THAT THE AIRCRAFT WHEELS ARE CHOCKED AND BRAKES ARE SET. 13. Prepare the aircraft for ground run and start the engine in accordance with the aircraft manufacturer's instructions. Advance the throttle to 1500 to 1800 RPM. While monitoring all engine gauges, operate the engine at this speed until the engine temperatures and pressures have stabilized in the operational range. Use the operational test form to record the gauge indications.

NOTE: Test gauge readings must be taken with the gauges held at the same height above the ground as the fuel system component it is attached to. 14. With the mixture control in the FULL RICH position, reduce the throttle to the specified IDLE RPM. Record the unmetered pressure indicated on the gauge. Slowly move the mixture control toward the IDLE CUT-OFF position and record the maximum RPM rise. Return the mixture control to FULL RICH.

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15. Monitoring all engine gauges, slowly advance the throttle control to full rated power for the engine and allow the engine to stabilize for 15 seconds. Record all engine and test gauge indications. DO NOT ALLOW ENGINE TEMPERATURES TO EXCEED 420°F CHT AND 210°F OIL TEMP. Retard throttle control to 800 to 1000 RPM.

achieved. On turbocharged engines insure that the manifold pressure is adjusted in accordance with the aircraft manufacturer’s instructions. Engine driven fuel pumps installed on turbocharged engines are referenced to turbocharger compressor discharge pressure (upper deck pressure) to achieve FULL POWER engine driven fuel pump pressure.

NOTE:

L/TSIO-360 and TSIO-520 model engines with a fixed (ground adjustable) exhaust bypass, verify that the wastegate is adjusted in accordance with the aircraft manufacturer's instructions. Failure to do so can result in an improperly adjusted fuel system and possible engine damage. CAUTION: After FULL POWER operation turbocharged engines must be operated at 800 1000 RPM for a minimum of five (5) minutes allow engine temperatures to stabilize prior engine shutdown.

to to to

16. Compare the recorded IDLE fuel pressure, IDLE RPM fuel/air mixture rise and full power RPM, manifold pressure (as applicable), unmetered fuel pressure, metered fuel pressure and fuel flow indications with the specified values. If all recorded values are within specifications, proceed to paragraph 24.

NOTE:

Turbocharged engines equipped with fuel pressure regulators should indicate a full power metered pressure and fuel flow five (5) percent higher than specified. This is required to insure adequate part-throttle fuel flow. 17. If any of the recorded readings are not within specifications, the fuel system must be completely adjusted. ALL READINGS MUST BE TAKEN WITH MIXTURE CONTROL IN THE FULL RICH POSITION. Install the engine cowling or cooling shroud during all ground operation.

NOTE:

Engine driven fuel pump output pressures vary with engine RPM. During ground operation FULL POWER RPM may not be obtained. Use the Fuel Flow Compensation Table 2 on page 10 to correct the specified metered pressures if FULL POWER RPM cannot be MO 03

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MO 06

WARNING MAKE ALL ADJUSTMENTS WITH THE ENGINE STOPPED AND THE IGNITION AND MASTER SWITCHES IN THE OFF POSITION.

18. To adjust the IDLE RPM unmetered pump pressure, loosen the lock nut on the low pressure relief valve. See Figures 1 through 5. Turning the adjustment clockwise (CW) will increase pressure and counterclockwise (CCW) will decrease pressure. Operate the engine at 1500-1800 RPM for 15 seconds after each adjustment, then retard the throttle to the specified IDLE RPM. Repeat this step until pressure is within specified limits. CAUTION: All adjustments on the IO-240-B engine must be made with the boost pump on.

NOTE:

Maximum part throttle full rich fuel flow will be achieved by setting the idle rpm (low) unmetered fuel pump pressure to the minimum value specified. With the idle rpm fuel/air mixture properly adjusted (step 19) the fuel control metering plate orifices are indexed to the maximum open position. 19. With engine operating at the specified IDLE RPM and unmetered fuel pressure, slowly move the mixture control from the FULL RICH position toward IDLE CUT-OFF to check fuel/air mixture. A rise of 25 to 50 RPM should be obtained. (For the IO-240-B equipped with the standard fuel system mixture rise must be 50-75 RPM) An RPM change greater than 50 (75 for the IO-240-B equipped with the standard fuel system) indicates the mixture is too rich and a change that is less than 25 (50 for the IO-240-B equipped with the standard fuel system) indicates the mixture is too lean. Adjust

REVISED DAY YEAR 17

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6 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

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NUT WILL RESULT IN DAMAGE TO ANEROID HOUSING THREADS AND SUBSEQUENT LOSS OF ADJUSTMENT.

mixture conditions that are too rich or too lean as follows: a) Identify the type of throttle and control assembly that is to be adjusted. See Figures 6, 8 and 9. b) Perform an IDLE fuel/air mixture check and observe RPM rise. If the RPM rise is not within specifications, advance the throttle control to 1500 - 1800 RPM for 15 seconds after each adjustment to clear the engine. Retard the throttle control to IDLE RPM and repeat mixture check. Make the necessary adjustment. Repeat this procedure until the specified RPM rise is achieved. c) Recheck IDLE RPM unmetered pump pressure. If pressure in not within limits, repeat Steps 18, 19, 19-a and 19-b before continuing. 20. On all naturally aspirated engines, adjust the FULL POWER metered fuel pressure to the specified value by turning the adjustable orifice screw clockwise to increase fuel pressure and counterclockwise to decrease fuel pressure. See Figures 1, 2 and 3.

22. For engines equipped with a fuel pressure regulator, the full power metered fuel pressure and fuel flow flow must now be set to the specified limit by adjustment of the regulator as follows. See Figure 10. Reconnect the regulator and torque all connections to the specified value. Loosen the lock nut on the regulator adjustment. Turn the regulator adjusting screw clockwise to increase metered fuel pressure and fuel flow and counterclockwise to decrease metered fuel pressure and fuel flow. After final adjustment is completed, torque the lock nut to the specified value. 23. When full power metered fuel pressure has been adjusted to the specified values, recheck: (a) IDLE RPM, (b) unmetered fuel pressure, (c) fuel/air mixture. If any values are not within specified limits, repeat the adjustment procedures.

21. On turbocharged engines, adjust the full power metered fuel pressure to the specified value as follows:

24. With the fuel system set to the specified metered fuel pressure, set the IDLE RPM to the aircraft manufacturer’s specified value by turning the Idle Speed Stop screw clockwise to increase RPM or counterclockwise to decrease RPM. See Figures 6, 8 and 9.

NOTE: On

D.

turbocharged engines equipped with a fuel pressure regulator, the full power metered fuel pressure and fuel flow must be adjusted to five (5) percent higher than the maximum specified limit.

POST SETUP PROCEDURES

1. Insure that the master switch, ignition switch and fuel selector are in the OFF position.

b. Turn the aneroid adjustment screw counterclockwise to increase metered fuel pressure and clockwise to decrease metered fuel pressure.

2. Remove the engine cowling or cooling shroud in accordance with the aircraft manufacturer's instructions. (a) remove all test gauges, fittings and hoses that were installed for fuel system setup, (b) reconnect all fuel hoses and cap fittings to their original locations, (c) support and torque all fittings to the specified value, see TABLE 1.

c. After final adjustment is accomplished, torque lock nut to 25-30 inch pounds. DO NOT EXCEED LOCK NUT TORQUE LIMITS. OVER-TORQUING OF LOCK

3. ASSURE CAP ASSEMBLY 639494 IS CORRECTLY INSTALLED ON INLET TEE FITTING OF COMBINATION THROTTLE BODY/METERING UNITS. TORQUE TO

a. Loosen the aneroid adjustment screw lock nut. See Figures 4 and 5.

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

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135-190 INCH POUNDS PER TABLE 1 SPECS. UNDER NO CIRCUMSTANCE ALLOW ANY CAP FITTING OTHER THAN 639494 TO BE INSTALLED DURING ENGINE OPERATION. 4. Perform a complete fuel system leak check in accordance with the aircraft manufacturer's instructions. Correct any discrepancies noted. •

Turn aircraft master switch to ON position

•

Adjust mixture control to full rich

•

Adjust throttle control to 1/4 inch open

•

Activate the aircraft boost pump (ON)

•

Inspect entire fuel system for fuel leakage

•

Return mixture and throttle to idle/closed position

•

Turn aircraft boost pump OFF

•

Turn the aircraft master switch OFF

5. Install engine cowling in accordance with the aircraft manufacturer's instructions. 6. Perform a complete operational ground run-up and verify that all fuel system performance specifications are achieved. E.

FLIGHT TEST: Except naturally aspirated engines with altitude compensating fuel pump

4. Repeat the setup and adjustments as required until the fuel injection system is performing within the published specification for the aircraft and engine. F.

FLIGHT TEST: Naturally Aspirated engines with altitude compensating fuel pumps (AUTO LEAN)

1. All naturally aspirated engines utilizing an altitude compensating fuel pump require a flight test at: (a) Initial installation, (b) Every 12 months (Scheduled to coincide with annual or 100 HR inspection), (c) each time adjustments are made due to a fuel system component replacement and (d) at any indication of improper auto-leaning feature operation. 2. Table 5 and Chart 1 provide fuel flow vs. pressure altitude specifications for the IO-240B series engine with altitude compensating fuel pumps. Table 6 and Auto Leaning Chart 3 provide fuel flow vs. pressure altitude specifications for the IO-360-DB engine with altitude compensating fuel pump. Tables 7 & 8 and Auto Leaning Charts 4 & 5 provide fuel flow vs. pressure altitude specifications for the IO-360-ES engine with altitude compensating fuel pump. Tables 9 through 12 and Auto Leaning Charts 6 through 9 provide fuel flow vs. pressure altitude specifications for the IO550- series engine with altitude compensating fuel pumps.

1. Refer to the aircraft manufacturer’s or Supplemental Type Certificate (STC) holder’s POH/AFM for specific operational information.

3. Insure the accuracy of aircraft fuel flow gauge and tachometer has been verified. These gauges must be accurate or the data recorded during flight test will not be valid.

2. A flight test is required whenever an adjustment is made that may affect engine operational characteristics or performance.

4. Locate the correct table and auto leaning chart for the aircraft and engine. On the operational test form provided in this Service Information Directive, record all pressure altitudes and corresponding minimum and maximum fuel flows as specified.

3. If FULL POWER RPM was not obtained during fuel injection system setup and adjustment, a flight test is required to insure that the fuel injection system is performing within specified limits for the engine and aircraft.

MO 03

ISSUED DAY YEAR 24

1997

MO 06

5. In accordance with the aircraft manufacturer’s instructions, perform a complete preflight inspection, engine start and ground runup.

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2008

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6. Set the aircraft altimeter to 29.92 inches Hg. 7. In accordance with the aircraft manufacturer’s instructions, conduct a normal take-off. 8. Climb must be accomplished using full throttle, FULL RICH mixture and maximum rated full power RPM. 9. Using the aircraft fuel flow gauge and altimeter, record fuel flows at all pressure altitudes specified. 10. Compare the recorded fuel flows with the specified fuel flows for all pressure altitudes. If fuel flows are within the minimum and maximum limits at all altitudes, no adjustments are required. 11. If the fuel flows are not within specified limits at all pressure altitudes, the fuel injection system auto leaning schedule requires adjustment. G.

ADJUSTMENT PROCEDURES: Fuel Pump Auto Leaning Schedule

NOTE: On IO-550-A and C model engines do not attempt to adjust the auto leaning schedule if the aircraft is at a field with a pressure altitude greater than 1000 feet. On IO-550-B, D, E, F and L model engines, do not attempt to adjust the auto leaning schedule if the aircraft is at a field with a pressure altitude greater than 3000 feet. Refer to Part C of this Service Information Directive for installation of the required test equipment. 1. If not previously accomplished, adjust the engine fuel injection system in accordance with Part C of this Service Information Directive using the appropriate table for the engine and aircraft. 2. Adjustments to the engine-driven fuel pump variable orifice (aneroid) will result in a change to the auto leaning schedule. One complete revolution of the aneroid adjustment will increase or decrease the auto leaning schedule approximately 1000 feet.

MO 03

ISSUED DAY YEAR 24

1997

MO 06

3. Refer to the charts on pages 19 to 25. The variable orifice (aneroid) adjustment will move you horizontally across the chart. The adjustable orifice will move you vertically. 4. Adjustments to the variable orifice (aneroid) will affect the FULL POWER unmetered fuel pressures (adjustable orifice), metered pressures and fuel flows. It is important to maintain the balance between these adjustments in order to achieve the specified fuel system parameters. CAUTION: Exercise caution when adjustments to the aneroid are accomplished. The aneroid stem has an extra fine thread and over-torqueing the lock nut will damage either the stem or housing threads.

NOTE... It will be necessary to cut and remove the safety wire and manufacturer’s seal from the variable orifice adjustment. Cut the safety wire as close to the variable orifice stem as possible. This will provide a pigtail for the fuel pump through bolts. It is not necessary to resafety the aneroid after adjustments have been completed. 5. By reviewing the data recorded on the operational test flight form, we can determine if the auto leaning schedule is above or below the specified limits at the various pressure altitudes. 6. Adjustment of the variable orifice (aneroid) clockwise will decrease the altitude (move horizontally to the left on the chart) while counterclockwise adjustments will increase the altitude (move horizontally to the right on the chart) at a given pressure altitude. 7. As an example, looking at chart number 5 (IO550-B engine) at a pressure altitude of 4000 feet the recorded fuel flow was 140 PPH (point A). The fuel flow specified for this pressure altitude is 142 PPH to 152 PPH. The recorded fuel flow of 140 PPH would be correct if we were between 5000 feet and 7000 feet. To achieve the specified fuel flow versus pressure altitude we must adjust the variable orifice out. Adjustment of the variable orifice (aneroid) two complete revolutions will move point A two thousand feet to the right to 6000 feet.

REVISED DAY YEAR 17

2008

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8. orifice, torque the lock nut to 25-30 inch pounds. 9. Perform a complete ground run-up and verify that unmetered and metered pressures and fuel flows are within the limits specified in the appropriate table for the pressure altitude. If these parameters are not within the limits specified make adjustments in accordance with PART C to achieve the specified values.

10. Once the adjustments are completed, remove the test equipment in accordance with part D (Post Setup Procedures). 11. Perform a flight test in accordance with part F (Flight Test: Naturally Aspirated engines with Auto Lean). 12. Repeat these procedures until the engine’s fuel injection system meets all published specifications.

NOTE... The adjustable orifice tapered needle may be damaged if forced against its seat. The adjustment should move freely. Do not continue adjustments if rotational resistance increases suddenly.

TABLE 1 Torque Specifications for Hose End and Cap Fittings BRASS or ALUMINUM END FITTINGS/CAPS Hose Size #2 (.31x24) #3 (.38x24) #4 (.4375x20) #5 (.500x20) #6 (.5625x18) #8 (.750x16) #10 (.875x14) #12 (1.063x12)

MO 03

Fitting Material Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum Hose end fitting Brass/Aluminum

ISSUED DAY YEAR 24

1997

MO 06

STEEL HOSE END FITTINGS/CAPS

Torque (inch lbs.) 50 – 80

Hose Size #2 (.31x24)

Fitting Material Steel End Fitting

Torque (inch lbs.) 75 – 120

70 – 105

#3 (.38x24) #4 (.4375x20) #5 (.500x20) #6 (.5625x18) #8 (.750x16) #10 (.875x14) #12 (1.063x12)

Steel End Fitting

95 – 140

Steel End Fitting

135 – 190

Steel End Fitting

170 – 240

Steel End Fitting

215 – 280

Steel End Fitting

470 – 550

Steel End Fitting

620 – 745

Steel End Fitting

855 – 1055

100 – 140 130 – 180 150 – 195 270 – 350 360 – 430 460 – 550

REVISED DAY YEAR 17

2008

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Table 2. Compensation Table For Static Ground Setup Metered Pressure vs. RPM @ 70°F Fuel Temperature Static Engine RPM

Correction Factor

Rated RPM

1

-20

.991

-40

.982

-60

.973

-80

.964

-100

.955

-120

.946

Corrected Metered Pressure (Metered Pressure x Correction Factor)

NOTE: All values are approximate. Variations may occur due to engine and installation specific influences. Example: IO-520-BB, Maximum Rated RPM = 2700 Metered Fuel Pressure Limits = 14.9 - 17.2 If maximum static engine RPM = 2640, (-60 RPM) use Correction Factor .973 Metered Fuel Pressure Limits x Correction Factor = Corrected Metered Pressure Limits 14.9 x .973 = 14.5 (Minimum Metered Pressure Limit) @ 2640 RPM 17.2 x .973 = 16.7 (Maximum Metered Pressure Limit) @ 2640 RPM

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

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TABLE 3. Fuel System Adjustment Values IDLE AND FULL POWER FUEL PRESSURES AND FLOWS ENGINE SEE NOTE 7

Prop. RPM & (MAP)

IO-240-A, B (a)(c) IO-240-A, B (b) (c)

Unmetered Pump PSI (NOTE 3) 9.4 - 9.8

Metered Nozzle PSI (NOTE 4) TABLE 4

Fuel lbs/hr

Fuel gal/hr

(NOTE 5) -

(NOTE6) -

See (b) and (c)

See (b) and (c)

-

-

1000 Full Throttle

(a) For IO-240-A, B with standard fuel pump installed. Boost pump “ON”, idle mixture rise to be 50-75. (b)For IO-240-B series with optional Altitude Compensating Pump and Standard Fuel Manifold Valve, see Chart 1 and Table 5 for instructions. See Note 2 page 18 of 38. (c) For IO-240-B engines, which are equipped with the Altitude Compensating Bypass Fuel System, see the latest revision of TCM bulletin SID07-3.

IO-346-A, B

IO-360-A, AB, C CB, D, DB(d), G, GB, H, HB, J, JB IO-360-ES (d) SEE NOTE 2 IO-360-ES (CIRRUS) (d) SEE NOTE 2&6 Sea Level IO-360-ES (CIRRUS) (d) SEE NOTE 2&6 1,500 Press Alt

600

7.0 - 7.5

2700

19.0 - 21.0

600

7.0 - 9.0

2800

24.0 - 27.0

600

7.0 - 9.0

2800

23.0 –26.0

600

7.0 - 9.0

2700

21.0 - 24.0

600

7.0 - 9.0

2700

19.0 – 22.0

-

-

78 - 85

13.3 - 14.5

-

-

100 - 106

17.0 - 18.1

-

-

100 - 107

17.0 - 18.1

-

-

96 - 102

16.4 – 17.4

-

-

94 - 98

16.0 – 16.6

-

-

93.5 - 97.5

15.9 - 16.6

-

-

119 - 124

20.1 - 21.0

-

-

115 - 124

20.1 - 21.0

-

-

135 - 145

23.0 - 24.7

12.5 - 14.0

15.8 - 18.2

14.3 – 16.5

13.8 – 15.5

13.3 – 14.6

(d) Engines with Altitude Compensating fuel pumps See Note 2 page 18 of 38.

IO-360-K, KB

TSIO-360-A, AB

600

7.0 - 9.0

2600

21.0 - 24.0

600

6.5 - 7.5

2800 (32.0) 600

TSIO-360-B, BB

2800 (32.0) 600

TSIO-360-C, CB

2800 (37.0)

MO 03

ISSUED DAY YEAR 24

1997

MO 06

27.2 - 31.2

14.3 - 16.3

15.8 - 16.7

6.5 - 7.5 27.2 - 31.2

15.8 - 16.7

6.5 - 7.5 34.0 - 37.0

16.7 - 19.3

REVISED DAY YEAR 17

2008

PAGE NO REVISION

12 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

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TABLE 3. Fuel System Adjustment Values (cont’d) IDLE AND FULL POWER FUEL PRESSURES AND FLOWS ENGINE Prop. RPM & Unmetered Metered Fuel lbs/hr SEE NOTE 7 (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 600 6.5 - 7.5 TSIO-360-D, DB 2800 34.0 - 37.0 16.7 - 19.3 135 - 145 (36.0) TSIO-360-E, EB, L/TSIO-360-E, EB

700 2575 (40.0)

6.25 - 6.75 43.0 - 46.0

700

6.25 - 6.75

2575 (41.0)

40.0 - 43.0

700

6.25 - 6.75

2700 (40.0)

45.0 - 49.0

600 2800 (34.5)

6.5 - 7.5 29.0 - 33.0

TSIO-360-F, FB

TSIO-360-G, GB

TSIO-360-H, HB

600

TSIO-360-JB

700

TSIO-360-KB, L/TSIO-360-KB

03

24

06

130 - 140

22.1 - 23.8

-

-

16.7 - 19.3

135 - 145

23.0 - 24.7

14.9 - 17.3

125 - 135

21.3 - 23.0

-

-

134 - 145

22.8 - 24.7

-

-

140 - 155

23.8 - 26.4

-

-

135 - 145

23.0 - 24.7

-

-

15.8 - 18.3

16.7 - 19.3

6.5 - 7.5

2700 (40.0)

34.0 - 38.0

700

6.25 - 6.75

2700 (36.0)

28.0 - 32.0

13.6 - 15.3

125 - 135

21.3 - 23.0

25 Minimum

-

-

-

35.0 - 45.0

-

140 - 150

23.3 - 25.5

2600 (38.0)

1997

-

6.25 - 6.75

700

MO

-

15.8 - 18.3

700

L/TSIO-360-RB

ISSUED DAY YEAR

22.1 - 23.8

36.0 - 39.0

TSIO-360-MB

See Note 1

23.0 - 24.7

2800 (40.0)

TSIO-360-LB

MO

34.5 - 37.5

(NOTE 6) -

130 - 140

6.5 - 7.5

2800 (37.0)

Fuel gal/hr

17.7 - 21.2

14.7 - 16.7

REVISED DAY YEAR 17

2008

PAGE NO REVISION

13 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

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TABLE 3. Fuel System Adjustment Values (cont’d) IDLE AND FULL POWER FUEL PRESSURES AND FLOWS Prop. RPM & Unmetered Metered Fuel lbs/hr (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 700 6.25 - 6.75 -

ENGINE SEE NOTE 7 TSIO-360-SB

O-470-GCI IO-470-C, G, P, R IO-470-D, E, F, H L, M, N, S, U

2600 (39.0)

31 - 36

600 2600

9.0 - 11.0 23.8 - 25.3

600 2600

9.0 - 11.0 24.7 - 27.7

600 2625

9.0 - 11.0 25.0 - 28.0

600

5.5 - 7.0

2600

24.7 - 27.7

600

6.5 - 7.5

2625

28.3 - 29.8

600

6.5 - 7.5

2625

28.8 - 31.0

450

9.0 - 11.0

2400

26.0 - 28.0

600

5.5 - 6.0

IO-470-J, K IO-470-V IO-470-VO GIO-470-A TSIO-470-B, C, D

2600 (35.0)

28.0 - 30.0

600

9.0 - 11.0

2700

29.0 - 32.0

600

9.0 - 11.0

2700

28.0 - 31.0

600

9.0 - 11.0

2850

30.0 - 33.0

600

9.0 - 11.0

2850

29.0 - 32.0

IO-520-A, J IO-520-B, BA, BB C, CB IO-520-D, F, K, L

IO-520-E

MO 03

ISSUED DAY YEAR 24

1997

MO 06

2008

(NOTE 6) -

15.1 - 17.8

131 - 151

22.3 - 25.7

14.7 - 16.9

122 - 129

20.8 - 22.0

14.8 - 17.3

123 - 130

21.0 - 22.1

15.0 - 17.5

124 - 131

21.1 - 22.3

-

-

123 - 130

21.0 - 22.1

-

-

123.5 - 131

21.0 - 22.3

-

-

132 - 137.5

22.5 - 23.4

-

-

145 - 155

24.7 - 26.4

-

-

145 - 155

24.7 - 26.4

-

-

136 - 146

23.2 - 24.9

-

-

136 - 146

23.2 - 24.9

-

-

143 - 153

24.4 - 26.1

-

-

143 - 153

24.4 - 26.1

14.8 - 17.3 17.8 - 18.8 17.8 - 18.8 15.5 - 16.5 15.0 - 17.0

15.9 - 18.2 14.9 - 17.2

17.0 - 19.4

16.1 - 18.3

REVISED DAY YEAR 17

Fuel gal/hr

PAGE NO REVISION

14 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

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TABLE 3. Fuel System Adjustment Values (cont’d) ENGINE SEE NOTE 7 IO-520-M, MB

IDLE AND FULL POWER FUEL PRESSURES AND FLOWS Prop. RPM & Unmetered Metered Fuel lbs/hr (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 600 6.0 - 7.0 -

IO-520-P LIO-520-P TSIO-520-AE, L/TSIO-520-AE

2700

29.0 - 32.0

600

6.0 - 7.0

2500

26.2 - 26.9

600

7.5 - 8.5

2400 (32.5) 600

TSIO-520-AF

2700 (35.5) 600

TSIO-520-B, BB

2700 (32.0) 600

TSIO-520-BE

2600 (38.0) 600

TSIO-520-C, H

2700 (32.5) 600

TSIO-520-CE

2700 (37.0) TSIO-520-D, DB

600 2700 (32.5)

TSIO-520-E, EB

600 2700 (34.5)

MO 03

ISSUED DAY YEAR 24

1997

MO 06

34.5 - 38.0

16.7 - 19.3 14.3 - 16.2 15.2 - 16.5

18.4 - 19.9

23.2 - 24.9

-

-

130 - 140

22.1 - 23.9

-

-

160 - 165

27.3 - 28.1

-

-

180 - 186

30.7 - 31.7

-

-

165 - 175

28.1 - 29.8

-

-

214 - 224

36.5 - 38.2

-

-

160 - 170

27.3 - 29.0

-

-

215 - 225

36.6 - 38.3

-

-

160 - 170

27.3 - 29.0

-

-

175 - 185

29.8 - 31.5

5.5 - 7.0 29.0 - 32.0

16.0 - 17.9

5.5 - 7.0 25.0 - 28.0

12.7 - 14.1

5.5 - 7.0 29.0 - 32.0

15.3 - 17.2

5.5 - 6.5 33.0 - 36.0

16.2 - 18.0

5.5 - 7.0 29.0 - 32.0

13.3 - 15.1

5.5 - 6.5 31.0 - 34.0

15.6 - 17.7

REVISED DAY YEAR 17

2008

(NOTE 6) -

136 - 146

5.5 - 6.5 35.0 - 39.0

Fuel gal/hr

PAGE NO REVISION

15 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

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TABLE 3. Fuel System Adjustment Values (cont’d) IDLE AND FULL POWER FUEL PRESSURES AND FLOWS Prop. RPM & Unmetered Metered Fuel lbs/hr (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 600 5.5 - 6.5 -

ENGINE SEE NOTE 7 TSIO-520-G

2700 (35.0) 600

TSIO-520-J, JB

2700 (36.0) 600

TSIO-520-K, KB

2700 (33.0) 2700 (38.0) 600

TSIO-520-M, R

2700 (36.5) 600

TSIO-520-N, NB

TSIO-520-P

600 2700 (36.0)

TSIO-520-VB

600 2700 (40.5)

24

1997

06

30.8 - 32.5

-

-

170 - 178

29.0 - 30.3

-

-

15.1 - 17.4

163 - 175

27.8 - 29.8

-

-

-

-

180 - 190

30.7 - 32.4

-

-

170 - 186

29.0 - 31.7

-

-

16.9 - 19.9

170 - 186

28.9 - 31.7

18.4 - 19.9

180 - 186

30.7 - 31.7

-

-

185 - 195

31.5 - 33.2

-

-

195 - 205

33.2 - 34.9

-

-

200 - 210

34.1- 35.8

16.9 - 18.7

5.5 - 6.5 33.0 - 37.0

16.9 - 19.9

5.5 - 6.5

5.5 - 6.5 33.0 - 37.0

TSIO-520-UB

MO

45.0 - 55.0

600 2700 (36.5)

2700 (39.5)

03

29.0 - 32.0

5.5 - 6.5 33.0 - 37.0

16.3 - 18.1

5.5 - 6.5 33.0 - 37.0

14.4 - 16.0

5.6 - 6.5 36.0 - 39.5

16.9 - 18.7

REVISED DAY YEAR 17

2008

(NOTE 6) -

181 - 191

5.5 - 7.0

32.0 - 35.0

600

ISSUED DAY YEAR

31.0 - 34.0

2700 (38.0)

TSIO-520-T

15.8 - 17.6

5.5 - 6.5

600 25 - Minimum

TSIO-520-L, LB SEE NOTE 1

MO

31.0 - 34.0

Fuel gal/hr

PAGE NO REVISION

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TABLE 3. Fuel System Adjustment Values (cont’d) ENGINE SEE NOTE 7 TSIO-520-WB SEE NOTE 1

IDLE AND FULL POWER FUEL PRESSURES AND FLOWS Prop. RPM & Unmetered Metered Fuel lbs/hr (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 600 25 - Minimum 2700 (39.5) 525

GTSIO-520-C

2400 (34.5) 467

GTSIO-520-D, H

GTSIO-520-F, K SEE NOTE 1 GTSIO-520-L

30.0 - 33.0

600

6.75 - 7.25

2267 (44.5)

38.0 - 41.0

467 2234 (39.0)

4.0 - 7.0 29.5 - 35.0

2234 (40.0) 467

-

-

215 - 225

36.6 - 38.3

-

-

250 - 260

42.6 - 44.3

-

-

17.4 - 18.8

300 - 310

51.1 - 52.8

16.4 - 17.9

255 - 265

43.4 - 45.1

-

-

255 - 265

43.4 - 45.1

-

-

255 - 265

43.4 - 45.1

-

-

142 - 150

24.2 - 25.6

16.5 - 17.5

15.7 - 17.3

16.4 - 17.9

4.0 - 7.0

2234 (39.0)

29.5 - 35.0

600

8.0 - 10.0

2700

32.0 - 36.0

IO-550-A →

32.4 - 34.1

4.0 - 7.0 29.5 - 35.0

(NOTE 6) -

190 - 200

4.0 - 7.0 30.5 - 35.0

467

-

4.0 - 7.0

2267 (39.5)

GTSIO-520-M

GTSIO-520-N SEE NOTE 1

45.0 - 55.0

Fuel gal/hr

16.4 - 17.9

17.7 - 20.0

→ Engines with Altitude Compensating fuel pumps See Note 2 page 18 of 38. IO-550-B ↓ SEE NOTE 2

600

8.0 - 10.0

2700

29.2 - 36.2

16.5 - 18.4

-

-

146 - 156

24.9 - 26.6

↓ Engines with Altitude Compensating fuel pumps See Note 2 page 18 of 38. IO-550-C ° SEE NOTE 2

600

8.0 - 10.0

2700

31.6 - 37.8

17.6 - 19.6

-

-

152 - 160

25.9 - 27.3

° Engines with Altitude Compensating fuel pumps See Note 2 page 18 of 38.

MO 03

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1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 3. Fuel System Adjustment Values (cont’d) ENGINE SEE NOTE 7 IO-550-D, E, F, L ± SEE NOTE 2

IDLE AND FULL POWER FUEL PRESSURES AND FLOWS Prop. RPM & Unmetered Metered Fuel lbs/hr (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 600 8.0 - 10.0 2700

32.0 - 36.0

17.2 - 20.0

143 - 155

Fuel gal/hr (NOTE 6) 24.4 - 26.4

± Engines with Altitude Compensating fuel pumps See Note 2 page 18 of 38. 600

8.0 - 10.0

2500

22.0 - 26.0

600

8 - 10

2700

28 - 32

600

8 - 10

2700

28 - 32

600

8 - 10

2700

28 - 32

IO-550-G IO-550-N IO-550-P IO-550-R

600 25-Minimum

-

-

125 - 130

21.3 - 22.1

-

-

150 - 160

25.6 - 27.3

-

-

150 - 160

25.6 - 27.3

-

-

19 - 21.3

150 - 160

25.6 - 27.3

-

-

29.8 - 31.5

14.7 - 16.0 19 - 21.3 19 - 21.3

GIO-550-A See NOTE 1

2267

45 - 55

-

175 - 185

TSIO-550-B

SEE

Maintenance

Manual

M-18

TSIO-550-C

SEE

Maintenance

Manual

M-18

TSIO-550-E

SEE

Maintenance

Manual

M-18

TSIO-550-G

SEE

Maintenance

Manual

M-18

TSIO-550-G

600

7.0-9.0

2500

20.0-23.0

10.4-11.6

177-180

MOONEY

30.0-30.7

(33.5) Consult current Mooney Aircraft Maintenance Manual for any changes to fuel setup procedures or values

TSIOL-550-A

600

5.5 - 6.5

2600

32.5 - 35.5

17.0 - 19.0

170 - 180

29.0 - 30.7

(35.0) MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 3. Fuel System Adjustment Values (cont’d) IDLE AND FULL POWER FUEL PRESSURES AND FLOWS Prop. RPM & Unmetered Metered Fuel lbs/hr (MAP) Pump PSI Nozzle PSI (NOTE 3) (NOTE 4) (NOTE 5) 600 6.0 - 8.0 -

ENGINE SEE NOTE 7 TSIOL-550-B

2700 (35.0) 600

TSIOL-550-C

6-285 (TIARA)

Fuel gal/hr (NOTE 6) -

36.0 - 40.0

20.0 - 22.5

175 - 185

29.8 - 31.5

6.0 - 8.0

-

-

-

2600 37.0 - 40.0 15.0 – 16.5 204 - 216 34.8 – 36.8 (39.5) See latest revision of Teledyne Continental Motors Service Bulletin M79-4.

NOTE 1:

Refer to the aircraft manufacturer’s instructions for adjustment procedures.

NOTE 2:

Flight test required to verify fuel flow vs. pressure altitude values are within the limits specified. See applicable Tables 5 through 12 and Charts 2 through 9 for specified values by engine model.

NOTE 3:

FULL POWER unmetered fuel pump pressure limits are provided for reference only. Use metered fuel pressure specifications for adjustments at full power.

NOTE 4:

Use for full power, maximum RPM adjustment only. reference only, see note → above.

NOTE 5:

May be determined using a calibrated in-line flow measuring device. Otherwise use metered fuel pressure specifications. Refer to Aircraft Manufacturer’s Maintenance Manual for method of verifying accuracy of fuel flow indicator.

NOTE 6:

This engine installed in Cirrus SR20 aircraft. IO-360-ES (6) B engine has been derated by Cirrus from original 210 HP at 2800 RPM to 200 HP at 2700 RPM. Engine data plate reflects original TC and PC data of 210 HP at 2800 RPM. Refer to Cirrus SR20 Maintenance Manual and Pilots Operating Handbook.

NOTE 7:

The setup procedures contained in this bulletin are only for use on engines that have not been modified from their original configuration as shipped from the factory by Teledyne Continental Motors. Engines which have been modified by the installation of aftermarket components such as turbo-normalizing systems, turbocharging systems, intercoolers, after-coolers, fuel nozzles, etc, whether by STC or field approval, must use the instructions provided by the STC holder or installer. TCM will not accept any responsibility or liability for any modified engine set up in accordance with procedures contained in this Service Information Directive.

All other parameters for

TABLE 4 IO-240-A,B Without Altitude Compensating (Aneroid Equipped) Pump MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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FULL THROTTLE STATIC RPM METERED FUEL PRESSURE SPECIFICATIONS FULL THROTTLE STATIC ENGINE RPM 1800 RPM 1850 RPM 1900 RPM 1950 RPM 2000 RPM 2050 RPM 2100 RPM 2150 RPM 2200 RPM 2250 RPM 2300 RPM 2350 RPM 2400 RPM

NOMINAL METERED FUEL PRESSURE 7.8 8.1 8.3 8.6 8.8 9.1 9.4 9.6 9.9 10.2 10.5 10.8 11.2

ALLOWED VARIATION ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3 ± 0.3

CHART 1 MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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IO-240-B with Altitude Compensating (Aneroid Equipped) Fuel Pump and Standard Fuel Manifold Valve

Idle (Step 1) Set Unmetered pump pressure and RPM rise at 1000 +/- 25 rpm to 9.6 +/- 0.2 psi (sea level / standard day). If pressure altitude is different from sea level, determine required unmetered pressure setting from the plot below (Reference Figure 15 ) NOTE: Pressure altitude must be used for the figures below when determining fuel system set-up values. To determine pressure altitude, set your altimeter to 29.92 in hg, and the altimeter will indicate your pressure altitude.

Unmetered Pressure (psi)

IO240B Idle Unmetered Pressure Altitude Plot @ 1000 RPM 10 9.8 9.6 9.4 9.2 9 8.8 8.6 8.4 8.2 8 7.8 7.6 7.4 7.2 7 6.8 6.6 6.4 6.2 6 5.8 5.6 5.4 5.2 5 -500

0

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000

Pressure Altitude (ft)

Adjust idle mixture screw to set RPM rise during mixture check at 1000 rpm to 20 - 50 rpm.

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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CHART 1 (Con’t) Full Throttle (Step 2)

Adjust the aneroid rod to obtain the metered nozzle pressure (+/- 0.3 psi) at pressure altitude and RPM per the chart above. Turn clockwise to decrease pressure and counter-clockwise to increase pressure. After adjustment, recheck idle unmetered pressure setting using the instructions in step 1 of this chart. (Reference Figure 15) Full throttle ground fuel pump set-up Full Rich mixture setting 13.5 13.0 12.5

Metered Nozzle Pressure (psi)

12.0 11.5 11.0 10.5 10.0

2450 rpm

9.5

2350 rpm 2250 rpm

9.0

2150 rpm

8.5

2050 rpm 1950 rpm

8.0 7.5 7.0 -1000

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

Pressure Altitude (ft)

NOTE: At conclusion of setup, reset the idle speed to 850 RPM (+/- 25 RPM) and verify idle cutoff mixture rise, acceleration / deceleration without excessive idle speed dip, and idle stability.

Table 5

MO 03

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1997

MO 06

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2008

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Flight Test Verification, IO-240-B equipped with Altitude Compensating Pump and Standard Fuel Manifold Valve This test is for reference only, actual RPM may vary due to the fixed pitch prop. NOTE: Pressure altitude must be used for the table and chart below when determining fuel system setup values. To determine pressure altitude, prior to take-off set your altimeter to 29.92 in hg, and the altimeter will indicate your pressure altitude. IO-240-B Engine with Aneroid Fuel Pump, Full Throttle, Full Rich Mixtu @ 2450 RPM Pressure Altitude (Set Altimeter at 29.92 in. Hg) (feet) Sea Level 1,000 2,000 3,000 4,000 5,000 6,000 8,000 10,000 12,000 14,000

Fuel Flow (lbs/hr) Minimum Maximum 53.5 60 50.2 56.7 46.7 53.2 43.9 50.4 40.8 47.3 38.4 44.9 36.9 43.4 34.0 40.5 32.1 38.6 31.1 37.6 30.4 36.9

Fuel Flow (gals/hr) Minimum Maximum 9.1 10.2 8.5 9.7 7.9 9.1 7.5 8.6 6.9 8.0 6.5 7.6 6.3 7.4 5.8 6.9 5.5 6.6 5.3 6.4 5.2 6.3

Metered Fuel Pressure PSID Minimum Maximum 10.8 14.8 9.5 13.3 8.7 12.3 8.1 11.5 7.6 10.8 7.2 10.2 6.8 9.6 6.5 9.1 6.3 8.7 6.2 8.4 6.2 8.2

CHART 2 Typical IO240B (with altitude compensating fuel pump) fuel flow leaning curve during flight test.

IO240B Altitude Leaning Schedule @ 2450 RPM, full rich mixture 65 Fuel Flow (pph)

60 55 50 45 40 35 30 25

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

13000

14000

15000

Pressure Altitude (ft) TABLE 6. ALTITUDE FUEL SCHEDULE

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1997

MO 06

REVISED DAY YEAR 17

2008

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IO-360-DB ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE BHP @ 2800 RPM Pressure Altitude Fuel Flow Fuel Flow Metered Fuel (Set Altimeter at (lbs/hr) (gals/hr) Pressure PSID 29.92 in. Hg.) Min. Max. Min. Max. Min. Max. Sea Level 102.9 112.9 17.5 19.2 16.0 18.8 1,000 98.4 108.4 16.8 18.5 15.0 17.8 2,000 94.1 104.1 16.0 17.7 14.1 16.8 3,000 90.0 100.0 15.3 17.0 13.3 15.9 4,000 86.1 96.1 14.7 16.4 12.6 15.1 5,000 82.3 92.3 14.0 15.7 11.9 14.4 6,000 78.8 88.8 13.4 15.1 11.3 13.7 8,000 72.2 82.2 12.3 14.0 10.2 12.5 10,000 66.4 76.4 11.3 13.0 9.3 11.5 12,000 61.3 71.3 10.4 12.1 8.6 10.7 14,000 56.9 66.9 9.7 11.4 8.0 10.0 16,000 53.3 63.3 9.1 10.8 7.5 9.5 Gasoline = 5.87 lbs per gallon @ 70° F. IO-360-DB Installed in T-41 ACFT Refer to Cessna SL 81-2 date 28 July 1981 for amplified instructions.

Altitude Leaning Schedule IO-360-DB-(34) 120 115 110 105 100

Fuel Flow

95 90 85 80 75 70 65 60 55

S/l

1

2

3

4

5

50

6 7 8 9 10 Pressure Altitude (X 1000 ft)

11

12

13

14

15

16

CHART 3

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 7. ALTITUDE FUEL SCHEDULE IO-360 ES ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE BHP @ 2800 RPM Pressure Altitude Fuel Flow Fuel Flow (Set Altimeter at (lbs/hr) (gals/hr) 29.92 in. Hg.) Min. Max. Min. Max. Sea Level 100.0 107.0 17.0 18.1 1,000 97.7 103.7 16.6 17.7 2,000 93.7 99.7 16.0 17.0 3,000 90.3 96.3 15.4 16.4 4,000 87.3 93.3 14.9 15.9 5,000 85.0 91.0 14.5 15.5 6,000 83.3 89.3 14.2 15.2 8,000 80.0 86.0 13.6 14.7 10,000 77.3 83.3 13.2 14.2 12,000 74.4 80.4 12.7 13.7 14,000 71.3 77.3 12.1 13.2 16,000 69.3 75.3 11.8 12.8 Gasoline = 5.87 lbs per gallon @ 70° F.

Metered Fuel Pressure PSID Min. Max. 14.3 16.5 13.9 15.8 13.1 14.9 12.3 14.1 11.7 13.6 11.5 13.2 11.1 12.8 10.6 12.2 10.1 11.8 9.6 11.2 9.2 10.7 8.9 10.3

ALTITUDE LEANING SCHEDULE IO-360-ES 2800 R.P.M. and FULL RICH MIXTURE FULL OPEN THROTTLE 110 105

Fuel- 100/100LL Full Rich, 2800 PRM Fuel Temp 72°F

100

Fuel Flow (pph)

95 90 85 80 75 70 65 60

S/l

MO 03

1

2

ISSUED DAY YEAR 24

1997

3

MO 06

4

5

6 7 8 9 10 11 Pressure Altitude (X 1000 ft) CHART 4

12

REVISED DAY YEAR 17

2008

13

14

15

16

17

PAGE NO REVISION

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TABLE 8. ALTITUDE FUEL SCHEDULE IO-360 ES ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE BHP @ 2700 RPM Pressure Altitude Fuel Flow Fuel Flow Metered Fuel (Set Altimeter at (lbs/hr) (gals/hr) Pressure PSID 29.92 in. Hg.) Min. Max. Min. Max. Min. Max. Sea Level 96.0 102.0 16.4 17.4 13.4 15.1 1,000 94.5 99.7 16.0 17.0 13.1 15.0 2,000 89.5 95.7 15.3 16.3 12.2 14.3 3,000 86.3 92.3 14.7 15.7 12.0 13.5 4,000 83.3 89.3 14.2 15.2 11.5 13.0 5,000 81.0 87.0 13.8 14.8 11.0 12.5 6,000 79.3 85.3 13.5 14.5 10.8 12.3 8,000 76.0 82.0 12.9 14.0 10.3 11.8 10,000 73.3 79.3 12.5 13.5 9.8 11.3 12,000 70.4 76.4 12.0 13.0 9.3 10.8 14,000 67.3 73.3 11.5 12.5 8.8 10.3 16,000 65.3 71.3 11.1 12.1 8.5 10.0 Gasoline = 5.87 lbs. per gallon @ 70° F.

ALTITUDE LEANING SCHEDULE IO-360-ES (6) AT 2700 RPM FULL RICH MIXTURE & FULL OPEN THROTTLE 105

Recommended Setup for 100

Cirrus SR20 Installation 2700 rpm @ WOT

Fuel- 100/100LL Full Rich, 2700 RPM Fuel Temp 72°F

95

Fuel Flow (PPH)

90

85

80

75

70

65

60

S/l

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Pressure Altitude (X 1000 ft) CHART 5

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 9. ALTITUDE FUEL SCHEDULE IO-550-A ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE 300 BHP @ 2700 RPM Pressure Altitude (Set Altimeter at 29.92 in. Hg.)

Fuel Flow (lbs/hr) Min.

Fuel Flow (gals/hr) Max.

Sea Level 142 150 1000 141 149 2,000 138 146 3000 133 141 4,000 128 136 5000 123 131 6,000 120 128 8,000 113 121 10,000 108 116 12,000 103 111 14,000 98 106 Gasoline = 5.87 lbs per gallon @ 70° F

Metered Fuel Pressure PSID

Min.

Max.

Min.

Max.

24.2 24.0 23.5 22.6 21.8 21.0 20.4 19.2 18.4 17.5 16.7

25.6 25.4 24.9 24.0 23.2 22.3 21.8 20.6 19.8 18.9 18.1

16.5 16.3 15.9 15.1 14.3 13.6 13.2 12.3 11.6 11.0 10.4

17.2 17.1 16.6 15.7 14.9 14.1 13.7 12.7 12.1 11.4 10.7

Altitude Leaning Schedule IO-550-A Full Rich, 2700 RPM 160

Fuel Flow

150

140 130 120 110 100 90 0

1

2

3

4

5

6 7 8 9 Pressure Altitude (X 1000 ft)

10

11

12

13

14

CHART 6

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 10. ALTITUDE FUEL SCHEDULE IO-550-B ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE 300 BHP @ 2700 RPM Pressure Altitude (Set Altimeter at 29.92 in. Hg.)

Fuel Flow (lbs/hr)

Fuel Flow (gals/hr)

Metered Fuel Pressure PSID

Min. Max. Min. Sea Level 146 156 24.9 1000 145.5 155.5 24.8 2,000 145 155 24.7 3000 144 154 24.5 4,000 142 152 24.2 5000 139 149 23.7 6,000 135.5 145.5 23.1 8,000 127 137 21.6 10,000 117 127 19.9 12,000 110 120 18.7 14,000 105 115 17.9 Gasoline = 5.87 lbs per gallon @ 70° F.

Max. 26.6 26.5 26.4 26.3 25.9 25.4 24.8 23.3 21.6 20.4 19.6

Min. 17.2 17.1 17.0 16.9 16.5 16.1 15.5 14.2 12.8 11.9 11.3

Max. 18.3 18.2 18.1 17.9 17.5 17.0 16.5 15.1 13.6 12.6 11.9

Altitude Leaning Schedule IO-550-B Full Rich, 2700 RPM 160

Point A Aneroid adjusted out two turns

Fuel Flow (pph)

150

140

Point A 130

120

110

100 0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Pressure Altitude (X 1000 ft)

CHART 7

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 11. ALTITUDE FUEL SCHEDULE IO-550-C ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE 300 BHP @ 2700 RPM Pressure Altitude (Set Altimeter at 29.92 in. Hg.)

Fuel Flow (lbs/hr)

Fuel Flow (gals/hr)

Min. Max. Min. Sea Level 152 160 25.9 1000 151 159 25.7 2,000 148 156 25.2 3000 143 151 24.4 4,000 138 146 23.5 5000 134 142 22.8 6,000 130 138 22.1 8,000 123 131 21.0 10,000 118 126 20.1 12,000 113 121 19.3 14,000 108 116 18.4 Gasoline = 5.87 lbs per gallon @ 70° F.

Metered Fuel Pressure PSID Max. 27.2 27.1 26.6 25.7 24.9 24.2 23.5 22.3 21.5 20.6 19.8

Min. 18.2 18.0 17.5 16.7 15.9 15.3 14.7 13.6 12.9 12.3 11.7

Max. 18.9 18.7 18.2 17.4 16.5 15.9 15.3 14.1 13.4 12.7 12.1

Altitude Leaning Schedule IO-550-C Full Rich, 2700 RPM 170

Fuel Flow (pph)

160 150 140 130 120 110 100 0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Pressure Altitude (X 1000 ft)

CHART 8

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

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TABLE 12. ALTITUDE FUEL SCHEDULE IO-550-D,-E, F, L ENGINE FULL OPEN THROTTLE, FULL RICH MIXTURE 300 BHP @ 2700 RPM Pressure Altitude (Set Altimeter at 29.92 in. Hg.)

Fuel Flow (lbs/hr)

Fuel Flow (gals/hr)

Min. Max. Min. Sea Level 143 155 24.4 1000 142.5 154.5 24.3 2,000 142 154 24.2 3000 141 153 24.0 4,000 139 151 23.7 5000 136 148 23.2 6,000 133 145 22.6 8,000 124 136 21.1 10,000 114 126 19.4 12,000 107 119 18.2 14,000 102 114 17.4 Gasoline = 5.87 lbs per gallon @ 70° F.

Metered Fuel Pressure PSID

Max. 26.4 26.3 26.2 26.1 25.7 25.2 24.7 23.2 21.5 20.3 19.4

Min. 17.2 17.1 17.0 16.9 16.5 16.0 15.5 14.0 12.5 11.5 10.8

Max. 20.0 19.9 19.8 19.6 19.2 18.7 18.2 16.6 15.0 13.9 13.1

Altitude Leaning Schedule IO-550-D, -E, -F, -L Full Rich, 2700 RPM 160

150

Fuel Flow

140

130

120

110

100 0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Pressure Altitude (X 1000 ft) CHART 9

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MO 06

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VAPOR RETURN

ADJUSTABLE ORIFICE CW = INCREASE

FUEL INLET

FUEL INLET

FUEL RETURN LOW PRESSURE RELIEF VALVE CW = INCREASE

LOW PRESSURE RELIEF VALVE CW = INCREASE FUEL OUTLET (UNMETERED PRESSURE)

DRAIN

FUEL OUTLET (UNMETERED PRESSURE)

FIGURE 1 - NATURALLY ASPIRATED ENGINE FUEL PUMP

VAPOR RETURN (LOCATED ON OPPOSITE SIDE ON MOST FUEL PUMPS) VAPOR RETURN ADJUSTABLE ORIFICE CW = INCREASE

FUEL INLET FUEL INLET LOW PRESSURE RELIEF VALVE CW = INCREASE

LOW PRESSURE RELIEF VALVE CW = INCREASE

DRAIN FUEL OUTLET (UNMETERED PRESSURE)

IDLE CUTOFF

FULL RICH

FIGURE 2 - NATURALLY ASPIRATED ENGINE (MIXTURE CONTROL EQUIPPED) FUEL PUMP

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VAPOR RETURN

VAPOR RETURN

FUEL INLET

ADJUSTABLE ORIFICE CW = INCREASE

FUEL INLET

LOW PRESSURE RELIEF VALVE CW = INCREASE

DRAIN AMBIENT PRESSURE REFERENCE

ANEROID ADJUSTMENT FACTORY SET ADJUSTMENT NOT NORMALLY REQUIRED

FUEL OUTLET (UNMETERED PRESSURE)

FIGURE 3 - ALTITUDE COMPENSATING FUEL PUMP

VAPOR RETURN FUEL INLET

FUEL INLET

FUEL RETURN

ANEROID ADJUSTMENT CCW = INCREASE

FUEL OUTLET (UNMETERED PRESSURE)

DRAIN

TURBOCHARGE DISCHARGE PRESSURE REFERENCE

LOW PRESSURE RELIEF VALVE CW = INCREASE

FIGURE 4 - ANEROID EQUIPPED FUEL PUMP TURBOCHARGED ENGINE

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

32 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

E

VAPOR RETURN

VAPOR RETURN FUEL INLET

TURBOCHARGE DISCHARGE PRESSURE REFERENCE

ANEROID ADJUSTMENT CCW = INCREASE FULL RICH

IDLE CUTOFF

LOW PRESSURE RELIEF VALVE CW = INCREASE

DRAIN FUEL OUTLET (UNMETERED PRESSURE)

FIGURE 5 - ANEROID & MIXTURE CONTROL EQUIPPED FUEL PUMP TURBOCHARGED ENGINE STEEL CAP FITTING (Currently 639494)

IDLE MIXTURE ADJUSTMENT CW = LEAN CCW = ENRICH

FUEL OUTLET (METERED PRESSURE)

IDLE SPEED STOP SCREW CW = INCREASE CCW = DECREASE

FUEL INLET (UNMETERED PRESSURE)

FIGURE 6 - THROTTLE & METERING ASSEMBLY

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

33 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

E

TH R O T TLE LE V E R

IN LE T SC R E EN F U E L IN LE T F ITTIN G (U N M E TE R E D P R E S S U R E )

M IX TU R E LE V E R FU E L R E TU R N (TO F U E L P U M P )

F U E L O U TLE T (M E TE R E D PRESSURE)

FIG U R E 7 - TH R O TTL E & C O N TR O L A S S E M B LY FR O N T V IE W (E X C E P T G T SIO -520-D ,F,H ,K ,L,M ,N )

ID L E SP EED ST O P SC R EW C W = IN C R E AS E

ID L E M IXT U R E AD JU ST M EN T C W = EN R IC H

FIG U R E 8 - TH R O TTL E & C O N TR O L A S S E M B LY S ID E V IE W (E X C E P T G T S IO -520-D , F , H ,, K , L, M , N )

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

34 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

E

INLET SCREEN

THROTTLE BODY

FUEL CONTROL IDLE MIXTURE ADJUSTMENT CCW =ENRICH

IDLE SPEED STOP SCREW CW = INCREASE

FIGURE 9 - THROTTLE & CONTROL ASSEMBLY (ALL GTSIO-520 EXCEPT GTSIO-520-C, F & K)

LOCK NUT

FUEL PRESSURE ADJUSTMENT CW - INCREASE

TURBOCHARGER DISCHARGE PRESSURE REFERENCE

CENTER PORT (OUTLET)

INLET (UNMETERED PRESSURE)

FIGURE 10 - FUEL PRESSURE REGULATOR FOR TURBOCHARGED ENGINES MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

35 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

E

4 2

6 8 10

FUEL PRESSURE P.S.I.

METERED FUEL PRESSURE

12 14

20 18

16

VAPOR VENT RETURN TO FUEL TANK FUEL RETURN FROM FUEL CONTROL

MANIFOLD VALVE ASSEMBLY

FUEL INLET FROM FUEL TANK

FUEL PUMP ASSEMBLY

FUEL CONTROL r

LOW PRESSURE RELIEF VALVE

FUEL INJECTORS

ADJUSTABLE ORIFICE

THROTTLE BODY IDLE MIXTURE ADJUST 4

DRAIN 6

2

IDLE SPEED STOP SCREW

UNMETERED FUEL PRESSURE

8 10

FUEL PRESSURE P.S.I.

12 14

20 18

16

FIGURE 11-Typical Naturally Aspirated Fuel System Schematic FROM TURBOCHARGER 4 2

6 8

FUEL PRESSURE P.S.I.

10

METERED FUEL PRESSURE

THROTTLE AND CONTROL ASSEMBLY

12 14

20 18

16

UPPER DECK PRESSURE

FUEL PRESSURE REGULATOR FUEL MANIFOLD VALVE ASSEMBLY INLET FUEL FROM ACFT

UPPER DECK PRESSURE

FUEL INJECTOR NOZZLE

VAPOR RETURN

UNMETERED FUEL PRESSURE

4u

2

6 8

FUEL PRESSUREu P.S.I. 20 18

FUEL PUMP

10

u

12 14

u

16

FIGURE 12-Typical Turbo-Charged Fuel System Schematic (With Regulator)

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

36 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

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MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

37 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

E

VAPOR RETURN

VAPOR RETURN

FUEL INLET AMBIENT PRESSURE REFERENCE

ANEROID ADJUSTMENT CCW = INCREASE FULL RICH

IDLE CUTOFF

LOW PRESSURE RELIEF VALVE CW = INCREASE

DRAIN

FUEL OUTLET (UNMETERED PRESSURE)

FIGURE 15 - ANEROID & MIXTURE CONTROL EQUIPPED FUEL PUMP

MO 03

ISSUED DAY YEAR 24

1997

MO 06

REVISED DAY YEAR 17

2008

PAGE NO REVISION

38 of 38 P.O. Box 90 Mobile Alabama • 251-438-3411

SID97-3

E

Location:

Date:

Elevation:

OAT:

Field “Hg:

Aircraft Make & Model:

Aircraft Registration #:

Engine Model:

Engine Position:

Engine Serial Number:

Engine Total Time - New - Overhaul

Left

Fuel System Adjustment - Record engine specifications and actual

Right

Front

Rear

guage indications.

R.P.M. Spec

Actual

M.A.P. Spec

Actual

Unmetered Spec

Actual

Adjustment

Metered Spec

Actual

Fuel Flow Spec

Actual

EGT o

TIT o

F

F

1

Cylinder Head Temp. -

o

Fuel Pressure

2

5

3

4

F

Oil 6

# of turns o

PSI

F

CW

Flight Test Data - Record gauge indications R.P.M. Spec

Actual

M.A.P. Spec

Actual

Pressure Altitude - (Set altimeter to 29.92” Hg)

Remarks: (Idle RPM mixture rise, magneto drop, etc.)

Signature:

Fuel Flow Spec

Actual

EGT Spec

o

F

Actual

TIT Spec

o

F

Actual

CHT Spec

o

F

Actual

Oil PSI Spec

Actual

Oil Temp. Spec

o

F

I.A.S. Actual knots

CCW

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy of Operation

CATEGORY 4

SID97-4C TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

CYLINDER BORE AND PISTON FIT SPECIFICATIONS

PURPOSE:

Provide dimensions and limits for TCM’s cylinders and non Graphite coated and Graphite coated pistons

COMPLIANCE: MODELS AFFECTED:

At cylinder repair, replacement or engine major overhaul. All engine models.

GENERAL INFORMATION This service bulletin provides the following information: 1. Cylinder bore dimensions - New minimum / maximum, service limits (for continuing cylinders in service between major overhauls) and Oversize Service Limits. 2. Piston to cylinder clearance specifications for graphite coated and non-graphite coated pistons. 3. Piston ring gaps and location in cylinder to measure ring gaps. 4. Piston diameters, piston skirt diameters and pin to dome height dimensions. The “New Limits MIN & MAX” dimensions are given for D, X & Y diameters so the cylinder barrel can be ground to a specific configuration for standard or oversized barrels. Only the D and the X diameters are used to determine the serviceability of the cylinder barrel. No wear limit is given for Y diameter because it is used as a machining reference only.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

 TELEDYNE INDUSTRIES, INC. 1999

New or oversize cylinder bore dimensions must be used at engine overhaul. Oversize dimensions and service limits may be used to return cylinders to service on engines that have not reached their published TBO. Do not return to service any cylinder exceeding the limits specified in this service bulletin. Piston ring gaps and cylinder dimensions must be maintained within the specifications provided in this bulletin. The Piston information is presented in tabular form, (Table 1). Columns from left to right are: Engine Model, Manganese Phosphate Graphite Coated Piston P/N, Uncoated Piston P/N, Graphite Coated Piston P/N, Piston Diameter, Skirt Diameter, & Pin to Dome Height. CAUTION Verify that all ring, piston and cylinder part numbers are the specified part number for the installation. Installation of incorrect parts will cause engine damage and engine malfunction.

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

1 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

4.50” 4.00” LENGTH FOR “D” DIA.

CHOKE AREA

“D” DIA.

6.50 “Y” DIA.

5.75” “X” DIA.

FIGURE 1. 5.25 INCH CYLINDER ALL IO-520, IO-550, TSIO-520 except as listed in the following. Refer to Figure 1 CYLINDER DIAMETER DIMENSIONS SIZE

“D” DIAMETER NEW

“D” DIAMETER SERVICE LIMITS

“X” DIAMETER NEW

“X” DIAMETER SERVICE LIMITS

“Y” DIAMETER NEW

“Y” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

STD.

5.251

5.253

5.256

5.248

5.250

5.257

5.245

5.247

N/A

.005

5.256

5.258

5.261

5.253

5.255

5.262

5.250

5.252

N/A

.010

5.261

5.263

5.266

5.258

5.260

5.267

5.255

5.257

N/A

.015

5.266

5.268

5.271

5.263

5.265

5.272

5.260

5.262

N/A

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS. IO-550-G, N, TSIO-520-BE, GTSIO-520-C, D, H, K, L, M & N Refer to Figure 1 CYLINDER DIAMETER DIMENSIONS SIZE

“D” DIAMETER NEW

“D” DIAMETER SERVICE LIMITS

“X” DIAMETER NEW

“X” DIAMETER SERVICE LIMITS

“Y” DIAMETER NEW

“Y” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

STD.

5.251

5.253

5.256

5.248

5.250

5.257

5.245

5.247

N/A

.005

5.256

5.258

5.261

5.253

5.255

5.262

5.250

5.252

N/A

.010 

5.261

5.263

5.266

5.258

5.260

5.267

5.255

5.257

N/A

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.  Applies to cylinder Part Numbers 653452, 653454 or later revisions only. ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

 TELEDYNE INDUSTRIES, INC. 1999

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

2 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

TSIO-550-A, B, C, & E Refer to Figure 1 CYLINDER DIAMETER DIMENSIONS SIZE

“D” DIAMETER NEW

“D” DIAMETER SERVICE LIMITS

“X” DIAMETER NEW

“X” DIAMETER SERVICE LIMITS

“Y” DIAMETER NEW

“Y” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

STD.

5.252

5.254

5.257

5.249

5.251

5.258

5.246

5.248

N/A

.005

5.257

5.259

5.262

5.254

5.256

5.263

5.251

5.253

N/A

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.

ALL IO-520, IO-550, TSIO-520 & GTSIO-520 Refer to Figure 1 PISTON TO CYLINDER CLEARANCE 5.25” PISTON

PISTON IN CYLINDER MEASURED BELOW 4th RING GROOVE

ALL NON GRAPHITE COATED

.008 - .011 LOOSE

GRAPHITE COATED

.006 - .010 LOOSE

Measure clearance perpendicular to pin bore and at “D” Diameter. TSIOL-550-A, B & C Refer to Figure 1 CYLINDER DIAMETER DIMENSIONS SIZE

“D” DIAMETER NEW

“D” DIAMETER SERVICE LIMITS

“X” DIAMETER NEW

“X” DIAMETER SERVICE LIMITS

“Y” DIAMETER NEW

“Y” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

STD.

5.251

5.253

5.256

5.248

5.250

5.257

5.245

5.247

N/A

.005

5.256

5.258

5.261

5.253

5.255

5.262

5.250

5.252

N/A

.010

5.261

5.263

5.266

5.258

5.260

5.267

5.255

5.257

N/A

.015

5.266

5.268

5.271

5.263

5.265

5.272

5.260

5.262

N/A

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS. TSIOL-550- A, B & C Refer to Figure 1 PISTON TO CYLINDER CLEARANCE 5.25” PISTON

PISTON IN CYLINDER MEASURED BELOW 4th RING GROOVE

ALL NON GRAPHITE COATED

.007 - .010 LOOSE

GRAPHITE COATED

.005 - .009 LOOSE

Measure clearance perpendicular to pin bore and at “D” Diameter.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

3 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

5.25 CYLINDER ALL 520’s & ALL 550’s

RING GAP

1 INCH ± .50

FIGURE 2. LOCATION FOR INSPECTING RING GAP 5.25 CYLINDER ALL 520’s & ALL 550’s

RING GAP SPECIFICATIONS Refer to Figure 2 Measure 1.00 ± .50 in bore. ⊥ RING

PART NUMBER

RING SET

654716A1

N/A

Top

648005

.028 - .044

2nd

654719

Oil Control

|

GAPS

.034 - .050

{

654717

.020 - .036

4th/Skirt 648008 .015 - .031 nd { Gap for 2 ring must be at least .006 larger than gap for top ring. | P/N 654717 consists of P/N 654718 Expander and 649250-1 ring.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

4 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

4.50” 4.00” LENGTH FOR “D” DIA.

CHOKE AREA

“D” DIA.

6.50 “Y” DIA.

5.75” “X” DIA.

FIGURE 3. 5.00 INCH CYLINDER E-SERIES, ALL O-470, IO-470, TSIO-470 Refer to Figure 3 CYLINDER DIAMETER DIMENSIONS SIZE

“D” DIAMETER NEW

“D” DIAMETER SERVICE LIMITS

“X” DIAMETER NEW

“X” DIAMETER SERVICE LIMITS

“Y” DIAMETER NEW

“Y” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

STD.

5.001

5.003

5.006

4.998

5.000

5.007

4.995

4.997

N/A

.005

5.006

5.008

5.011

5.003

5.005

5.012

5.000

5.002

N/A

.010

5.011

5.013

5.016

5.008

5.010

5.017

5.005

5.007

N/A

.015

5.016

5.018

5.021

5.013

5.015

5.022

5.010

5.012

N/A

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.

ALL 470’S EXCEPT O-470-K, L, R, S & TSIO-470-B, C, & D Refer to Figure 3 PISTON TO CYLINDER CLEARANCE 5” PISTON

PISTON IN CYLINDER MEASURED AT THE BOTTOM OF THE PISTON SKIRT

ALL GRAPHITE COATED

.008 - .012 LOOSE

GRAPHITE COATED

.006 - .011 LOOSE

E-SERIES, O-470-K, L, R, S & TSIO-470-B, C, & D Refer to Figure 3 5” PISTON

PISTON IN CYLINDER MEASURED AT THE BOTTOM OF THE PISTON SKIRT

ALL GRAPHITE COATED

.009 - .012 LOOSE

GRAPHITE COATED

.007 - .011 LOOSE

Measure clearance perpendicular to pin bore and at “D” Diameter. ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

5 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

5.00 CYLINDER ALL 470’s

RING GAP

1 INCH ± .50

FIGURE 4. LOCATION FOR INSPECTING RING GAP E-SERIES, O-470, IO-470, TSIO-470 RING GAP SPECIFICATIONS Refer to Figure 4 Measure 1.00 ± .50 into bore. ⊥ RING

PART NUMBER

RING SET

GAPS

649226A1

Top

648009

2nd

648010

Oil Control

648011

N/A .026 - .042 {

.032 - .048 .018 - .034

4th/Skirt 648012 .015 - .031 nd { Gap for 2 ring must be at least .006 larger than gap for top ring.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

6 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

4.875 ± .25 STRAIGHT

“D” DIA.

6.375 REF “Y” DIA. “X” DIA.

5.625 REF {

2.31

{ CLASSIFY “D” AT THIS POINT FIGURE 5. 4.44 INCH CYLINDER ALL IO-240, IO-360, TSIO-360, LTSIO-360 Refer to Figure 5 CYLINDER DIAMETER DIMENSIONS SIZE

“D” DIAMETER NEW

“D” DIAMETER SERVICE LIMITS

“X” DIAMETER NEW

“X” DIAMETER SERVICE LIMITS

“Y” DIAMETER NEW

“Y” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

MIN.

MAX.

MAX.

STD.

4.437

4.439

4.442

4.434

4.436

4.443

4.431

4.433

N/A

.005

4.442

4.444

4.447

4.439

4.441

4.448

4.436

4.438

N/A

.015

4.452

4.454

4.457

4.449

4.451

4.458

4.446

4.448

N/A

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.

ALL IO-240, IO-360, TSIO-360, LTSIO-360 Refer to Figure 5

PISTON TO CYLINDER CLEARANCE 4.44” PISTON

PISTON BOTTOM OF SKIRT IN CYLINDER

ALL NON GRAPHITE COATED

.006 - .010 LOOSE

GRAPHITE COATED

.004 - .009 LOOSE

Measure clearance perpendicular to pin bore and at “D” Diameter.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

7 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

4.44 CYLINDER ALL 360’s & 240’s

RING GAP

1 INCH ± .50

FIGURE 6. LOCATION FOR INSPECTING RING GAP ALL IO-240, IO-360, TSIO-360, LTSIO-360 RING GAP SPECIFICATIONS Refer to Figure 6. Measure 1.00 ± .50 into bore. ⊥ RING

PART NUMBER

RING GAP

RING SET

649225A2

N/A

Top

648039

2nd

648040

Oil Control

648041

.026 - .042 {

.032 - .048 .019 - .035

4th/Skirt 648042 .015 - .031 { Gap for 2nd ring must be at least .006 larger than gap for top ring.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

8 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

O .001

O .002

OUT OF ROUND IN X NOT TO EXCEED 0.001” “X” DIA.

OUT OF ROUND IN THIS AREA NOT TO EXCEED 0.002”

FIGURE 7. 4.06 INCH CYLINDER C SERIES, ALL O-200, O-300, GO-300 Refer to Figure 7 CYLINDER DIAMETER DIMENSIONS “X” DIAMETER NEW SIZE

“X” DIAMETER SERVICE LIMITS

MIN.

MAX.

MAX.

STD.

4.0615

4.0635

4.0665

.005

4.0665

4.0685

4.0715

.015

4.0765

4.0785

4.0815

STRAIGHT BARREL NO CHOKE

CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .001 AT X DIAMETERS. SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.

C SERIES, ALL O-200, O-300, GO-300 Refer to Figure 7.

PISTON TO CYLINDER CLEARANCE 4.06” PISTON

PISTON IN CYLINDER MEASURED ABOVE 4th RING GROOVE

ALL NON GRAPHITE COATED

.009 - .012 LOOSE

GRAPHITE COATED

.007 - .011 LOOSE

Measure clearance perpendicular to pin bore and at “D” Diameter.

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

9 of 11

P.O. Box 90 Mobile AL 36601

SID97-4

334-438-3411

C

4.06 CYLINDER C-SERIES, O-200, O-300 & GO-300’s

R IN G G AP

1 INCH ± .50

FIGURE 8. LOCATION FOR INSPECTING RING GAP 4.06 CYLINDER C-SERIES, O-200, O-300 & GO-300’s RING GAP SPECIFICATIONS Refer to Figure 8. Measure 1.00 ± .50 into bore. ⊥ RING

PART NUMBER

GAPS

RING SET

649632A2

N/A

Top

649632

.023 - .036

2nd

638110

.015 - .028

3rd

638110

.015 - .028

Oil Control

638111

.015 - .028

ISSUED MO

DAY

03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile AL 36601

334-438-3411

PAGE NO REVISION

10 of 11 SID97-4

C

TABLE 1. Piston to Engine Reference Manganese Phosphate, Graphite Coated 654840

Engine Model

Piston Diameter

Skirt Diameter

Pin to Dome Height

654724

5.25”

5.2420-5.2430

1.835-1.839

Uncoated

Graphite Coated

648044

GTSIO520C, D, H, K, L, M, N, TSIO520AF, B, BB, BE, C, CE, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, UB, VB, WB

654840P010

648044P010

654724P010

5.26”

5.2520-5.2530

654840P015

648044P015

654724P015

5.265”

5.2570-5.2580

IO520A, B, BA, BB, C, CB, D, E, F, J, K, L, M, MB, N, NB,

654850 654850P010 654850P015

648045 648045P010 648045P015

5.25 5.26” 5.265”

5.2420-5.2430 5.2520-5.2530 5.2570-5.2580

1.617-1.621

IO550A, B, C, D, E, F, G, L, N,

654857 654857P010 654857P015

648046 648046P010 648046P015

654726 654726P010 654726P015

5.25” 5.26” 5.265”

5.2420-5.2430 5.2520-5.2530 5.2570-5.2580

1.775-1.779

IO346A, TSIO550A, B, C, E, TSIOL550A, B, C

654867

649805

654731

5.25”

5.2432-5.2442

1.775-1.779

654836 654836P010 654836P015

648037 648037P010 648037P015

654723 654723P010 654723P015

5.25” 5.26” 5.265”

5.2420-5.2430 5.2520-5.2530 5.2570-5.2580

1.775-1.779

IO470C, O470G, O470GCI, O470M

654829

648028

654721

5.00”

4.9887-4.9897

2.01572.0197

IO470D, E, F, H, L, M, N, S, U, V, O470U

654832

648029

654722

5.00”

4.9887-4.9897

2.06652.0705

654832P015

648029P015

654722P015

5.015”

5.0037-5.0047

654862

649044

654729

5.00”

4.9887-4.9897

654862P015

649044P015

654729P015

5.015”

5.0037-5.0047

O470K, L, R, S

654833 654833P015

646263 646263P015

654744 654744P015

5.00” 5.015

4.9907-4.9922 5.0057-5.0072

1.977-1.981

LTSIO360E, EB, KB, RB, TSIO360A, AB, C, CB, D, DB, E, EB, F, FB, GB, H, HB, JB, KB, LB, MB, RB, SB

654859 654859P015

648048 648048P015

654727 654727P015

4.44” 4.455”

4.4270-4.4280 4.4420-4.4430

1.598-1.602

IO240A, B, IO360A, AB, C, CB, D, DB, G, GB, H, HB, J, JB, K, KB, LB

654861 654861P015

648049 648049P015

654728 654728P015

4.44” 4.455”

4.4270-4.4280 4.4420-4.4430

1.591-1.595

O200A, B, O300A, C, D,

654853 654853P015

646255 646255P015

654749 654749P015

4.06” 4.075”

4.0517-4.0532 4.0667-4.0682

1.591-1.596

GO300

654858 654858P015

646279 646279P015

4.06” 4.075”

4.0517-4.0532 4.0667-4.0682

1.611-1.616

C75

654841 654841P015

646287 646287P015

4.06” 4.075”

4.0514-4.0524 4.0664-4.0674

1.698-1.708

IO520P, LTSIO520AE, LIO520P, TSIO520AE

IO470K, J

ISSUED MO

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03

24

REVISED YEAR 97

MO

DAY

YEAR

04

01

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile AL 36601

334-438-3411

1.76891.7729

PAGE NO REVISION

11 of 11 SID97-4

C

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy of Operation SUBJECT: MSA-10 PURPOSE: COMPLIANCE: MODELS AFFECTED:

CATEGORY 4

SID97-7 FAA APPROVED

PRECISION AIRMOTIVE CORPORATION SERVICE BULLETIN Inform customers of accessory manufacturer’s service bulletin instructions. As specified in subject service bulletin. O-470-A, K, L, R, S and U.

Teledyne Continental Motors requires compliance with the attached Precision Airmotive Corporation Service Bulletin MSA-10 as specified in Part 1 paragraph D.

MO 05

ISSUED DAY YEAR 07

MO

97

 Teledyne Industries Inc.

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 1 SID97-7

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION DIRECTIVE Compliance Will Enhance Safety, Maintenance or Economy of Operation

CATEGORY 4

SID97-8 FAA APPROVED

SUBJECT:

INTERFERENCE OF TCM 24 VOLT 60 AMPERE GEAR DRIVEN ALTERNATOR AND CRANKCASE THROUGH BOLT

PURPOSE:

To require inspection for interference between alternator drive end housing and through bolt, to detail alternator housing rework, and to ensure clearance between the alternator housing and adjacent through bolt at the time of alternator installation.

COMPLIANCE: MODELS AFFECTED:

Refer to Engine Models:

At each alternator installation or engine overhaul. All New and Rebuilt Teledyne Crittenden and Teledyne Continental Motors 24 Volt, 60 Ampere Gear Driven Alternators, P/N's: 642055, 646490, 646843, 646845, and all spare drive end housings 642957 and 646496. IO-520-B IO-520-BA IO-520-BB IO-520-C IO-520-CB IO-520-M IO-520-MB TSIO-520-B TSIO-520-BB TSIO-520-D TSIO-520-DB TSIO-520-E TSIO-520-EB

TSIO-520-J TSIO-520-JB TSIO-520-K TSIO-520-KB TSIO-520-L TSIO-520-LB TSIO-520-N TSIO-520-NB TSIO-520-UB TSIO-520-VB TSIO-520-WB GTSIO-520-C GTSIO-520-D

GENERAL INFORMATION: Occasionally interference is experienced between one of the engine through bolts and the drive end housing of affected alternators. This bulletin provides instructions to rework the alternator drive end housing to insure clearance between the alternator housing and the crankcase through bolt.

ISSUED MO

DAY

05

28

REVISED YEAR

MO

DAY

YEAR

97

 1997 TELEDYNE INDUSTRIES INC.

GTSIO-520-H GTSIO-520-K GTSIO-520-L GTSIO-520-M GTSIO-520-N IO-550-B IO-550-C IO-550-G IO-550-N TSIO-550-B TSIO-550-C TSIO-550-E

NOTE: New and Rebuilt P/N 646843 and 646845 alternators subsequent to serial number F179601.OR (June 17, 1996) and all spare drive end housings P/N’s 642957 and 646496, shipped from TCM after June 16, 1996 have been modified in accordance with this Service Information Directive. Refer to Service Bulletin M92-12, Figure 1, to interpret alternator manufacturing Serial Numbers.

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

1 of 3

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

SID97-8

DETAILED INSTRUCTIONS: 1. Pre-installation - Viewing the alternator mount pad on the Right Crankcase Half, insure the end of through bolt at lower left corner of alternator mounting pad extends no further than .850 inch from surface of crankcase. If bolt height in excess of .850 inch is noted: a. Gain access to both sides of through bolt, loosen, and remove cadmium plated washer and nuts. b. Reposition through bolt as required to obtain .850 inch maximum height from the surface of the crankcase. c. Lubricated threads with clean 50 weight aviation engine oil, install cadmium plated washer, nuts, and torque both through bolt nuts to the specified values.

a. Using an appropriate grinding tool or a .750 - .812 diameter end mill cutter, contour housing as specified in Figure 1. Insure a minimum radius at all corners of .005” and wipe away chips or dust. Treat with Accelagold Aluminum Conversion Coating, and apply enamel paint. b. Reinstall alternator in accordance with the current applicable engine overhaul manual. Verify through bolt does not contact housing. 3. At time of alternator overhaul or replacement, insure alternator housing is contoured as specified in Figure 1. 4. Make logbook entries indicating compliance with this Service Bulletin. WARRANTY CONSIDERATION

2. Install alternator on engine in accordance with the current applicable engine overhaul manual. Inspect for clearance between through bolt and alternator housing. If interference occurs, remove alternator and perform modification as follows:

AFFECTED PUBLICATIONS:

ISSUED MO

DAY

05

28

We recommend that you make the appropriate annotations to applicable manuals to call attention to this service bulletin.

REVISED YEAR 97

MO

All affected equipment will be covered by the TCM Gold Medallion warranty as applicable, subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. Up to .5 hours labor will be allowed per alternator.

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

2 of 3

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

SID97-8

1.27 - 1.29 (center line of grind stone or cutter)

.38 - .41 R(ref) (.750 - .812 dia. grind stone or cutter) .24 - .26 (center line of grind stone or cutter)

.38 - .41 R(ref)

.85 - .88

Figure 1

ISSUED MO

DAY

05

28

REVISED YEAR

MO

DAY

YEAR

97

 1997 TELEDYNE INDUSTRIES INC.

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

An Allegheny Teledyne Company

3 of 3

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

SID97-8

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER

Contains Useful Information Pertaining To Your Aircraft Engine

REASON FOR REVISION :

SUBJECT:

CATEGORY 5

SIL 00-11B Technical Portions FAA Approved

This Service Information Letter is being revised to add the IO-550-G, N, P and R to the Models Affected section. RELEASE OF NEW CYLINDER INDUCTION PORT DRAIN CONNECTOR

PURPOSE:

To Notify Owners, Operators and FBO’s of the availability of P/N 655742 Cylinder Induction Port Drain Connector, Replacing Drain Connector P/N 632068, To Enhance Cold Weather Engine Starting Characteristics.

COMPLIANCE:

At Engine Overhaul, Cylinder Replacement or to Enhance Cold Weather Starting Characteristics.

MODELS AFFECTED:

All IO-240-B; IO-360 series; LTSIO-360 series; TSIO-360 series; IO-550-G, N, P and R model series engines.

This Service Information Letter provides instruction for the installation of cylinder induction port fuel drain connectors P/N 655742. Refer to the aircraft manufacturer’s maintenance manual for instruction on removing engine cowling and associated hardware to facilitate access to engine and cylinder induction port fuel drain lines and plumbing. Refer to the applicable IO-240, IO-360, TSIO-360 and IO-550 Overhaul or Maintenance Manual for instructions on removing cylinder induction port drain connectors and attaching drain lines and plumbing. To install the P/N 655742 drain connectors: 1. Sparingly coat the male threads of drain connector P/N 655742 with TCM P/N 646940 (Loctite 569) sealant. 2. Install the drain connector P/N 655742 into the tapped hole in the bottom of each cylinder induction port. Torque the drain connector to 60 – 80 inch lbs. Repeat the procedure for each cylinder. 3. Reinstall fuel drain lines and plumbing removed to facilitate installation of cylinder induction port drain connectors.

ISSUED

REVISED

PAGE NO REVISION TM

MO

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12

12

00

MO

DAY

YEAR

05

26

04

© 2004 Teledyne Continental Motors, Inc.

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

1 of 2 SIL 00-11

B

4. In accordance with the aircraft manufacturer’s maintenance manual, pressurized the fuel injection system and insure that the cylinder induction system drains are functioning correctly and no excess fuel remains in the cylinder induction port. Correct any discrepancies noted CAUTION Refer to TCM SB 96-11 for precautions on preventing cylinder Hydraulic Lock. 5. In accordance with the aircraft manufacturer’s maintenance manual, reinstall the engine cowling and any other hardware removed to facilitate installation of cylinder drain connectors. 6. Make and engine logbook entry noting installation of cylinder drain connectors P/N 655742.

.020 Hole Thru One Side

.125 NPTF

.44-24 UNS-2A

.125 NPTF

P/N 655742

.44-24 UNS-2A

P/N 632068

.090 .50

FIGURE 1 Cylinder Induction Port Fuel Drain Fittings

WARRANTY: Compliance with this Service Information Letter is not covered by warranty.

ISSUED

REVISED

PAGE NO REVISION TM

MO

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12

12

00

MO

DAY

YEAR

05

26

04

CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

2 of 2 SIL 00-11

B

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER CONTAINS USEFUL INFORMATION PERTAINING TO THE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SIL 00-7A TECHNICAL PORTIONS FAA APPROVED Supersedes SIL94-6 and SIL 00-7

SUBJECT:

OIL GAUGE ROD APPLICATION

PURPOSE:

This Service Information Letter provides engine/aircraft oil gauge rod application and instruction for ordering oil gauge rods for certain engine specifications as detailed in Table 1.

COMPLIANCE: MODELS AFFECTED:

Not Applicable

All

This Service Information Letter (SIL) provides owners, operators and FBO’s with oil gauge rod application data by engine model and aircraft. Part one of this SIL lists new and rebuilt engines, by engine model and specification, that require a separate “no charge” purchase order at the time of engine order to ensure the correct oil gauge rod is provided. Part two of this SIL provides the oil gauge rod part number by engine and aircraft application. When ordering a replacement oil gauge rod, verify currently installed oil gauge rod part number with the part number specified in the SIL. In recent years, TCM has supplied oil gauge rods with new and rebuilt engines. At times, TCM has not been able to identify the specific oil gauge rod required for an engine, or supplied the incorrect oil gauge rod due to field conversion of the engine from one model to another or a change in engine specification in the field. Therefore, whenever an order for an engine listed in Part one, Table 1, is placed TCM will require a separate “no charge” purchase order from the distributor for the oil gauge rod to ensure that the correct oil gauge rod is provided. See Part One for specific instructions

ISSUED

REVISED

PAGE NO REVISION TM

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23

YEAR 00

MO

DAY

YEAR

02

05

2001

CONTINENTAL MOTORS

© 2000 TELEDYNE TECHNOLOGIES, INC.

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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PART 1: The following new and rebuilt engine models and model specifications are not shipped with oil gauge rods at the time of engine shipment from TCM. When placing an order: 1. Review the engine listing provided in Part One, Table 1, and determine if the engine model and specification being ordered is listed. NOTE: If the engine being ordered is not listed in Part One, Table 1 the oil gauge rod will be automatically included with the engine. 2. If the engine being ordered is listed, obtain the part number of the currently installed oil gauge rod. On twin engine aircraft, the position of the engine will be installed in (left / right or front / rear). 3. Refer to Part Two, Table 2, and select the oil gauge rod part number for the engine being ordered, engine position (left / right or front / rear) and aircraft application. 4. Verify correct selection of oil gauge rod by confirming part numbers obtained in steps 2 and 3 above. 5. Place a separate “no charge” purchase order for the oil gauge rod when placing the engine order. Ensure that the correct shipping information is provided with the “no charge” purchase order because the oil gauge rod may be shipped separately from the engine.

TABLE 1 ENGINE MODEL

New / Rebuilt ENGINE SPECIFICATION

O-200-A

Rebuilt

O-300-A IO-360-A IO-360-CB IO-360-D, DB IO-360-LB TSIO-360-D, DB O-470-GCI O-470-L

Rebuilt Rebuilt New Rebuilt Rebuilt Rebuilt Rebuilt Rebuilt

O-470-R

New

O-470-R

Rebuilt

O-470-S

New

ISSUED

14B, 14F, 41B, 41F, 42B, 57B, 62B, 65B, 68B, 71B, 72B, 74B, 75B. 1B, 23B 6B, 8B, 8A, 8B 22B 1B 3B, 4B 1B 1B, 9B, 9F, 10B, 10F, 16B, 16F, 22B, 23B, 32B, 33B, 34B, 35B, 36B, 37B 13B, 15B, 25B, 25U, 35B, 37B, 39B, 41B, 42B, 46B, 50B, 54B, 57B, 60B, 61B, 62B, 63B, 64B, 65B, 67B 3B, 5B, 5C, 6B, 13B, 14B, 15B, 17B, 25B, 25F, 25K, 25U, 25M, 35B, 37B, 39B, 40B, 41B, 42B, 43B, 44B, 45B, 46B, 47B, 48B, 49B, 50B, 51B, 52B, 53B, 54B, 66B, 67B, 68B 1B, 2B, 3B, 4B, 6B, 7B, 9B, 10B, 11B

REVISED

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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ENGINE MODEL

TABLE 1 (continued) New / Rebuilt ENGINE SPECIFICATION

O-470-S

Rebuilt

O-470-U

New

O-470-U

Rebuilt

IO-470-C IO-470-D IO-470-E IO-470-F

Rebuilt Rebuilt Rebuilt Rebuilt

IO-470-H IO-470-L IO-470-L

Rebuilt New Rebuilt

IO-470-M IO-470-N

Rebuilt Rebuilt

IO-470-V, VO IO-470-V, VO IO-520-C

New Rebuilt Rebuilt

IO-520-CB

New

IO-520-CB

Rebuilt

IO-520-D IO-520-D IO-520-MB IO-520-M, MB IO-550-A IO-550-A IO-550-C

New Rebuilt New Rebuilt New Rebuilt New

ISSUED

1B, 2B, 2K, 3B, 4B, 5B, 6B, 7B, 8B, 9B, 10B, 11B 1B, 2B, 5B, 6B, 9B, 10B, 11B, 12B, 13B, 14B, 17B, 18B, 19B, 20B, 21B, 22B, 23B, 24B, 25B, 28B, 29B, 31B, 33B, 35B, 36B, 38B, 40B, 41B, 42B, 44B, 45B 1B, 2B, 5B, 6B, 9B, 10B, 11B, 12B, 13B, 14B, 14K, 17B, 18B, 18M, 19B, 20B, 21B, 22B, 23B, 24B, 25B, 26B, 27B, 28B, 29B, 20B, 31B, 32B, 33B, 34B, 35B, 36B, 37B, 38B, 39B, 40B, 41B, 42B, 43B, 44B 45B 1B, 8B, 9B, 12B, 19B, 27B, 30B, 42B, 44B, 53B, 54B, 56B, 1B, 6B, 13B, 17B, 18B, 19B, 20B 1B, 3B, 4B, 7B, 18B, 19B, 19K,27B, 28B, 29B, 30B, 31B, 32B, 33B, 34B, 36B 1B, 6B 12B, 15B, 19B, 20B, 21B, 22B, 27B 5B, 8B, 9B, 11B, 12B, 15B, 19B, 20B, 21B, 22B, 25B, 26B, 27B, 28B, 29B 1B, 5B, 6B 10B, 10K, 11B, 12B, 13B, 16B, 17B, 18B, 19B, 20B 9B, 16B 9B, 16B 2B, 3B, 5B, 6B, 7B, 8B, 9B, 10B, 11B, 12B, 13B, 14B, 15B, 16B, 17B 2B, 3B, 5B, 7B, 8B, 9A, 9B, 9F, 12B, 13B, 14B, 15B, 17B, 20B, 22B, 23B, 25B, 28B, 30B, 34B, 36B, 37B, 38B, 41B 2B, 3B, 5B, 7B, 8B, 8F, 8W, 9B, 9F, 9W, 10B, 11B, 12B, 15B, 17B, 18B, 19B, 20B, 21B, 22B, 23B, 25B, 26B, 27B, 28B, 29B, 30B, 31B, 33B, 34B, 35B, 36B, 37B, 38B, 39B, 40B, 41B 169B, 184B 11B, 169B 1A, 1B, 2B 1B, 2B 2A, 2B, 3B, 4B, 5B, 6B, 7B, 8B 2B, 2F, 3B, 4B, 5B, 6B, 7B 1F, 2A, 2F, 3F, 4B, 5F, 6A, 6F, 7F, 8B, 9B, 10B, 11B, 12B, 13B, 14B, 15B, 16B, 17B, 18B, 19B, 21B, 22B, 24B, 25B, 27B, 28B, 29B, 30B, 31B, 32B, 33B, 34B, 35B, 36B

REVISED

PAGE NO REVISION TM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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ENGINE MODEL

TABLE 1 (continued) New / Rebuilt ENGINE SPECIFICATION

IO-550-C

Rebuilt

IO-550-E IO-550-E TSIO-520-L TSIO-520-LB TSIO-520-LB TSIO-520-WB TSIO-520-WB GTSIO-520-K GTSIO-520-K GTSIO-520-M GTSIO-520-M TSIOL-550-A TSIOL-550-A

New Rebuilt Rebuilt New Rebuilt New Rebuilt New Rebuilt New Rebuilt New Rebuilt

ISSUED

1F, 2U, 2F, 3F, 5F, 6F, 7F, 10B, THRU 22B, 24B, 25B, 26B, 28B, 30B, 33B, 34B, 35B 1A, 1B, 6B 1B 1B, 4B, 7B 1B, 4B 1B, 4B, 6B 1B, 1F, 3A, 3B, 3F, 5A, 5B, 5F, 6B 1B, 1F, 3B, 3F, 5B, 5F, 6B 1B 1B, 5B 1A, 1B, 2A, 2B 1B, 2B, 3B 1A, 1B, 1G, 3B, 5B, 6B, 7B, 8B 1G

REVISED

PAGE NO REVISION TM

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MO

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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PART 2: Use the following data to determine the correct oil gauge rod for the engine and aircraft application. Note that the same engine model may be used in several aircraft applications and that some twin engine aircraft utilize identical engine models and specifications in both the left and right or front and rear position. As such, it is the responsibility of the individual ordering the replacement oil gauge rod to verify aircraft application and engine position. Not all oil gauge rods listed are available. TCM reserves the right to discontinue supplying oil gauge rods for non production engines without prior notice.

ENGINE MODEL A 50-7 & 8 A50-8 A50-7 & 8 A50-7 & 8 A65-8 A65-7, 8 & 9 A65-8 A65-8 & 9 A65-8 & 9 A65-8 A65-8 & 9 A65-8 A65-8 & 9 A75-8 A75-8 & 9 A75-8 & 9 A75-8 A75-8 A75-8 & 9 A75-8 A75-9 C75-12 C75-12 C75-12 A80-9 A80-9 A80-8 & 9 A80-9 A80-8 & 9 C85-8 & 12 C85-8 & 12

ISSUED

TABLE 2 OIL GAUGE ROD APPLICATION AIRCRAFT OIL GAUGE ROD APPLICATION PART NUMBER Piper J 3 A3970 Porterfield 649608-17 Aeronca A35919 Aeronca A36127 Rearwin A3970 Piper 649608-16 Taylorcraft 649608-17 Aircoupe A5473 Aeronca 649608-15 Interstate Cadet A3680 Aeronca A36127 Call Aircraft 649608-17 Porterfield 649608-17 Rearwin A3970 Rearwin 649608-14 Piper 649608-16 Taylorcraft 649608-17 Porterfield 649608-17 Culver A35017 Culver A3680 Rearwin A36127 Fleet Aircraft 649608-15 Taylorcraft 649608-17 Aircoupe A36037 Aircoupe A36037 Rearwin A36037 Stinson A3896 Culver A36127 Stinson A36105 Taylorcraft 649608-17 Aeronca 649608-15

REVISED

FOOTNOTES 1, 2, 4 2, 5 1, 6 1, 7 1, 2, 3 2, 5 2, 5 1, 8 1, 2, 6 1, 9 1, 7 2, 5 2, 5 1, 4 2, 5 2, 10 2, 5 2, 5 1, 11 1, 7 1, 7 1, 2, 6 2, 5 1, 8 1, 8 1, 8 1, 12 1, 7 1, 12 2, 5 1, 2, 6

PAGE NO REVISION TM

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CONTINENTAL MOTORS A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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TABLE 2 (continued) ENGINE MODEL C85-12 C85-8 C85-12 C85-12 C85-12 C85-12 C85-12 C85-8 & 12 C85-12 C85-12F C85-12J C85-12J C-85-12 C90-8 C90-8 C90-12F & 14F C90-8F & 12F C90-8F & 12F C90-8F & 12F C90-12F C90-8F, 12F & 14F C125-2 O-200-A O-200-B O-200-A O-200-A O-200-A O-240-Rolls Royce Sump P/N A50351A2 O-240-Rolls Royce Sump P/N 637078A1 IO-240-A IO-240-B (3, 5, 7, 9) IO-240-B “E” Series O-300-A(3) O-300-A, B, C & D O-300-A GO-300 O-470-A, J & K O-470-B O-470-G, GCI

ISSUED

AIRCRAFT APPLICATION Fleet Aircraft Call Aircraft Cessna Commonwealth Funk Cub Columbia Piper Globe Durand Cessna (5qt sump) Cessna (6qt sump) Aircoupe Call Aircraft Piper Cessna Luscombe (6qt sump) Luscombe (5qt sump) Aeronca Champion Cessna Swift Cessna (6qt sump)

OIL GAUGE ROD PART NUMBER 649608-15 649608-17 649608-17 649608-17 649608-17 649608-17 649608-17 649608-16 649608-24 649608-25 649608-26 A36209 A36037 649608-17 649608-16 649608-17 649608-9 649608-25 633233-20 633233-20 649608-9 A36218 649608-9

1, 2, 6 2, 5 2, 5 2, 5 2, 5 2, 5 2, 5 2, 5 1, 2, 13 2, 14 2, 15 1, 15 1, 8 2, 5 2,5 2, 5 2, 16 2, 16 2, 17 2, 18 2, 16 1 2, 16

Cessna (5qt sump) Cessna Taylorcraft Reims-Cessna 150

649608-18 649608-20 649608-20 633233-10

2, 19 2, 16 2, 16 Gasket P/N 533355

Reims-Cessna 150

637079

Gasket P/N 533355

Eagle Aircraft Diamond Eagle

649608-20 649608-45 649608-43 A36114 628410A1 628413A1 629664A1 628412A1 537298A1 539948 626807

2, 20 2, 20 2, 20 1

Cessna 170 B Cessna 172 Maule Cessna 175 Cessna 180 Cessna 310 Bonanza

FOOTNOTES

1 1 1

REVISED

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TABLE 2 (continued) ENGINE MODEL O-470-L O-470-L O-470-M O-470-M O-470-P O-470-R (below engine S/N 84084) O-470-R O-470-R, S & U O-470-S & U O-470-S & U IO-470-C (below engine S/N 71474) IO-470-C (above engine S/N 71474) IO-470-D IO-470-D IO-470-D (42, 56) IO-470-E IO-470-F IO-470-F IO-470-G IO-470-H IO-470-J IO-470-K IO-470-L (Left Engine) IO-470-L (Right Engine) IO-470-M IO-470-N IO-470-N (10) (11) & (12) IO-470-P IO-470-R IO-470-S IO-470-U IO-470-V & VO (6, 8) IO-470-V / VO (9)

ISSUED

AIRCRAFT APPLICATION Cessna 182 Cessna 180 Cessna 310 Meyers Navion Conversion Cessna 182

OIL GAUGE ROD PART NUMBER 539792A1 628565 637261A1 637261A1 539133A1 539792

FOOTNOTES

Cessna 182 (Above S/N 18255059) Cessna 180 Cessna 182 Cessna 182 (Above S/N 18255059) Bonanza

632062-29A1

2

632062-3A1 632062-2A1 632062-29A1

2 2 2

Bonanza

627555A1

Cessna 310 Meyers Cessna 310 Cessna 210 Cessna 185 Bellanca Lockheed Navion Beech Debonair Beech Bonanza Beech B-55 Baron

627995A2 627995A1 539776A1 628021A2 632062-14A1 628032 626807 628230A1 627555A1 629294A1 629327-1

Beech B-55 Baron

629327-2

Aero Commander Beech Bonanza Beech Bonanza

628021A1 629294A1 638152A1

1

Lane Marchetti Lockheed LASA 60 Cessna 205, 210 Cessna 310 Cessna 310 Cessna 310 (Left Engine)

627285-1 628021A2 632062-2A1 627995A2 627995A2 639589-1A1

1

1

626807

REVISED

1 1 2

1

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TABLE 2 (continued) ENGINE MODEL IO-470-V / VO (9) GIO-470-A TSIO-470-B TSIO-470-C & D IO-346-A IO-360-A & AB IO-360-A & AB IO-360-A & AB IO-360-A & AB (5) IO-360-C, CB, D, & DB IO-360-D & DB (22) IO-360-D & DB (6) IO-360-D & DB (33) IO-360-ES

IO-360-G & GB IO-360-G & GB IO-360-H (1,4,6,7) & HB (1,4,6,7) IO-360-H (2,3,5) & HB (2,3,5) IO-360-HB (9) IO-360-J (1,2,4) & JB (1,2,4) IO-360-J (3,5) & JB (3,5) IO-360-K & KB TSIO-360-A, AB, B, BB TSIO-360-C (3,4) CB (3,4) TSIO-360-C (5,6) CB (5,6) TSIO-360-D & DB TSIO-360-D (1,2) DB (1,2) TSIO-360-E & EB (left hand engine)

ISSUED

AIRCRAFT APPLICATION Cessna 310 (Right Engine) Beagle Cessna 320 Cessna 320 Beech Model 19 Musketeer Cessna 336 (10qt sump) Cessna 336 (8qt sump) Maule Maule Cessna 337

OIL GAUGE ROD PART NUMBER 639589-2A1

Goodyear Aerospace Cessna T-41 B Maule Lancair ES, Questair Spirt, Express, Irkutsk, Ilyushin, YAK 112 Cessna 337 Cessna 337 Cessna 337

632062-13A1 632062-1A1 632062-1A1 649536-1

2 2 2

632062-20A1 632062-19A1 632062-23A1

2 2 2

Cessna 337

632062-1A1

2

Pacific Aerospace CT-4 Reims-Cessna (10qt sump) Reims- Cessna (8qt sump) Cessna Hawk XP Cessna T-337

632062-1A1 632062-1A1

2 2

632062-23A1

2

632062-23A1 629851-1A1

2

P-337

632062-20A1

2

P-337

632062-19A1

2

Reims-Cessna (8qt sump) Reims- Cessna (10qt sump) Piper Seneca II

632062-19A1

2

629460A1 628021A2 627995A2 649608-3

FOOTNOTES

1

1, 2

629851A1 632062-20A1 629851A1 632062-7A1 629851A1

2 2

629851A1 632062-27A1

REVISED

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TABLE 2 (continued) ENGINE MODEL LTSIO-360-E & EB (right hand engine) TSIO-360-F & FB TSIO-360-G, GB & LB TSIO-360-H, HB, J & JB TSIO-360-KB (left hand engine) LTSIO-360-KB (right hand engine) TSIO-360-MB, SB IO-520-A IO-520-A IO-520-B, BA & BB IO-520-B, BA & BB (7th Stud crankcase) IO-520-C & CB (left hand engine) IO-520-C & CB (left hand engine 7th Stud crankcase) IO-520-C & CB (right hand engine) IO-520-C & CB (right hand engine 7th Stud crankcase) IO-520-D IO-520-D (10) IO-520-D (11) IO-520-E (1,2) IO-520-E (3) IO-520-F IO-520-J IO-520-K IO-520-L (3,4) IO-520-M & MB (left hand engine) IO-520-M & MD (left hand engine7th Stud crankcase) IO-520-M & MB (right hand engine)

ISSUED

AIRCRAFT APPLICATION Piper Seneca II

OIL GAUGE ROD PART NUMBER 632062-28A1

2

Piper Arrow Mooney 231 Cessna T-337

632062-24A1 632062-25A1 632062-19A1

2 2 2

Piper Seneca III & IV

632062-27A1

2

Piper Seneca III & IV

632062-28A1

2

Mooney 252 Cessna 206 & 210 Meyers Beech Bonanza Beech Bonanza

649536-1 632062-2A1 632062-2A1 652171-1 652171-4

2 2 2 2, 3

Beech Baron

649608-4

2

Beech Baron

652171-18

2, 3

Beech Baron

652171-2

2

Beech Baron

652171-16

2, 3

Cessna 185 & Seaplane Bellanca Bellanca Colemill Conversion Colemill Conversion Cessna 206 & 207 Cessna 210 Bellanca Cessna 210 Cessna 310

632062-14A1 632062-30A1 632062-12A1 632062-2A1 632062-18A1 632062-2A1 632062-16A1 632062-30A1 632062-16A1 649608-32

2 2 2 2 2 2 2 2 2 2

Cessna 310

652171-19

2, 3

Cessna 310

649608-31

2

REVISED

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TABLE 2 (continued) ENGINE MODEL IO-520-M & MD (right hand engine7th Stud crankcase) IO-520-P (left hand engine) LIO-520-P (right hand engine) TSIO-520-AE LTSIO-520-AE TSIO-520-AF TSIO-520-B & BB (left hand engine) TSIO-520-B & BB (left hand engine7th Stud crankcase) TSIO-520-B & BB (right hand engine) TSIO-520-B & BB (right hand engine7th Stud crankcase) TSIO-520-BE TSIO-520-C TSIO-520-CE TSIO-520-D, DB TSIO-520-D, DB (7th Stud crankcase) TSIO-520-E & EB (left hand engine) TSIO-520-E & EB (left hand engine - 7th Stud crankcase) TSIO-520-E & EB (right hand engine) TSIO-520-E & EB (right hand engine - 7th Stud crankcase) TSIO-520-G TSIO-520-H TSIO-520-J & JB (left hand engine) TSIO-520-J & JB (left hand engine -7th Stud crankcase )

ISSUED

AIRCRAFT APPLICATION Cessna 310

OIL GAUGE ROD PART NUMBER 652171-14

2, 3

632062-40

2

632062-41

2

Cessna T-303 Cessna T-303 Cessna P 210 N Cessna 310

642821-1 642821-2 632062-16A1 649608-27

2 2

Cessna 310

652171-17

2, 3

Cessna 310

649608-28

2

Cessna 310

652171-12

2, 3

Piper Malibu PA 46-310P Cessna Turbo 206 & 210 Cessna P-210-R Beech V-35-TC Beech V-35-TC

652171-7 632062-2A1 632062-16A1 652171-1 652171-15

2 2 2 2 2, 3

Cessna 401 & 402

649608-27

2

Cessna 401 & 402

652171-17

2, 3

Cessna 401 & 402

649608-28

2

Cessna 401 & 402

652171-12

2, 3

Cessna 207 Cessna T-210 Cessna 414

632062-2A1 632062-16A1 649608-27

2 2 2

Cessna 414

652171-17

2, 3

REVISED

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TABLE 2 (continued) ENGINE MODEL TSIO-520-J & JB (right hand engine) TSIO-520-J & JB (right hand engine -7th Stud crankcase ) TSIO-520-K & KB (left hand engine) TSIO-520-K & KB (left hand engine -7th Stud crankcase ) TSIO-520-K & KB (right hand engine) TSIO-520-K & KB (right hand engine -7th Stud crankcase ) TSIO-520-L, LB & WB (left hand engine) TSIO-520-L, LB & WB (left hand engine - 7th Stud crankcase) TSIO-520-L, LB & WB (right hand engine) TSIO-520-L, LB & WB (right hand engine - 7th Stud crankcase) TSIO-520-M TSIO-520-N (1) & NB (1) (left hand engine) TSIO-520-N (1) & NB (1) (left hand engine - 7th Stud crankcase) TSIO-520-N (5,9, & 13) & NB (5,9, & 13) (left hand engine) TSIO-520-N (5, 9 & 13) & NB (5,9 & 13) (left hand engine - 7th Stud crankcase) TSIO-520-N (2,4,6& 8) & NB (2,4,6 & 8) (right hand engine)

ISSUED

AIRCRAFT APPLICATION Cessna 414

OIL GAUGE ROD PART NUMBER 649608-28

2

Cessna 414

652171-12

2, 3

Cessna 414

649608-27

2

Cessna 414

652171-17

2, 3

Cessna 414

649608-28

2

Cessna 414

652171-12

2, 3

Beech 58P & 58 TC Baron Beech 58P & 58 TC Baron

652171-3

2

652171-11

2, 3

Beech 58P & 58 TC Baron Beech 58P & 58 TC Baron

652171-2

2

652171-16

2, 3

Cessna Turbo 206 & 207 Cessna 340

632062-2A1 649608-27

2 2

Cessna 340

652171-17

2, 3

Cessna 340 & 414

649608-29

2

Cessna 340 & 414

652171-13

2, 3

Cessna 340 & 414

649608-28

2

REVISED

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TABLE 2 (continued) ENGINE MODEL TSIO-520-N (2,4,6& 8) & NB (2,4,6 & 8) (right hand engine - 7th Stud crankcase) TSIO-520-NB (7th Stud crankcase) TSIO-520-P TSIO-520-R TSIO-520-T TSIO-520-UB TSIO-520-UB (7th Stud crankcase) TSIO-520-VB (left hand engine) TSIO-520-VB (left hand engine - 7th Stud crankcase) TSIO-520-VB (right hand engine) TSIO-520-VB (right hand engine - 7th Stud crankcase) GTSIO-520-C,D,H, L, &N (left hand engine) GTSIO-520-C,D,H, L, N (right hand engine) GTSIO-520-M (left hand engine) GTSIO-520-M (right hand engine) GTSIO-520-F & K (left hand engine) GTSIO-520-F & K (right hand engine) IO-550-A IO-550-A (left hand engine) IO-550-A (right hand engine) IO-550-B

ISSUED

AIRCRAFT APPLICATION Cessna 340 & 414

OIL GAUGE ROD PART NUMBER 652171-12

2, 3

Mooney 231 & 252 (Rocket Conversion) Cessna P-210-N Cessna Turbo Centurion Cessna Turbo Ag Husky Beech A 36 TC & B 36 TC Bonanza Beech A 36 TC & B 36 TC Bonanza Cessna 402 C

652171-1

2

632062-16A1 632062-16A1 632062-14A1 652171-1

2 2 2 2

652171-4

2, 3

649608-29

2

Cessna 402 C

652171-13

2, 3

Cessna 402 C

649608-28

2

Cessna 402 C

652171-12

2, 3

Cessna 411 & 421

635160-2A1

Cessna 411 & 421

635160-1A1

Cessna 404

635160-10 LH

Cessna 404

635160-11 RH

Aero Commander

635160-8LH

Aero Commander

635160-9RH

Mooney Conversion 310 Conversion

652171-1 652171-5

2

310 Conversion

652171-6

2

Beech A 36 Bonanza

652171-4

2

REVISED

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TABLE 2 (continued) ENGINE MODEL IO-550-C (left hand engine) IO-550-C (right hand engine) IO-550-D

IO-550-E IO-550-F IO-550-L IO-550-G IO-550-N IO-550-P IO-550-R TSIO-550-B & E TSIO-550-C TSIOL-550-A (left hand engine) TSIOL-550-A (right hand engine) TSIOL-550-C 6-285-B & C/ 6-320-B 1. 2.

3. 4. 5.

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

AIRCRAFT APPLICATION Beech 58 Baron

OIL GAUGE ROD PART NUMBER 652171-5

FOOTNOTES 2

Beech 58 Baron

652171-6

2

Cessna 185 & 188 Conversions and Melex Wilga Cessna 310 & Beech Baron Conversions Cessna 206 Conversions Cessna 210 Conversions Cirrus, Lancair, Mooney & Questair Cessna - Conversion Bonanza - Conversion Cirrus, Harbin, Lancair Piper Malibu Conversion RAM 414 Conversion

632062-4A1

2

632062-32A1

2

632062-16A1

2

652171-8

2

652171-22 652171-4 649608-41 652171-7 652171-13

2 2 2 2 2

RAM 414 Conversion

652171-12

2

Extra EA-400 Piper Pawnee Brave

652171-23 635275-2

2 2

FOOTNOTES No longer available from TCM. Rod and cap assemblies that contain a leaf spring use P/N 533355 gasket (1/8 inch thick). Rod and cap assemblies that contain a coil spring use P/N 633240 gasket (1/16 inch thick). Rod and cap assemblies P/N 649608 and 652171 use gasket P/N 642892. Oil gauge rod P/N 632062 uses “O” ring P/N MS 9021-011. For use on engines with 7th cylinder deck stud crankcase configuration. Use with P/N A5461 oil sump. Use with P/N A5230 oil sump. Oil sump P/N 530091 is identical to P/N A5230 except for addition of an oil drain back connection. Use P/N 649608-16 oil gauge rod with P/N 530091 oil sump. Use with P/N A50331 oil sump. Use with P/N A5363 oil sump. Use with P/N A5473 oil sump. Use with P/N A5520 oil sump. Use with P/N A5320 oil sump. Use with P/N A5479 oil sump. Use with P/N A5458 oil sump. Use with P/N A50374 oil sump. Use with P/N A50372 oil sump. Use with P/N A50337oil sump. Use with P/N A50351 oil sump. Use with P/N 530473A1 oil sump. Use with P/N 627374 oil sump. Use with P/N A50352 oil sump. Use with P/N 653633 oil sump.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

CATEGORY 5

SIL 00-8 Technical Portions FAA Approved

SUBJECT:

PRECISION AIRMOTIVE CORPORATION SIL RS-56

PURPOSE:

To provide inspection and rework instructions for the RSA-5AD2 fuel injection servos; Precision Airmotive Corporation parts list 2576540-5, TCM Part Number 654353, used on TCM L/TSIO-360-RB engines installed in Piper PA34-220T Seneca V aircraft.

COMPLIANCE:

As specified in Precision Airmotive SIL RS-56

MODELS AFFECTED:

All LTSIO-360-RB and TSIO-360-RB engines.

Teledyne Continental Motors recommends compliance with the attached Precision Airmotive Corporation SIL RS-56 as specified in that document. NOTE: TCM Part Number 654353 identifies all dash (-) numbers of Precision Airmotive Corporation Part Number 2576540-servo units. Before complying with this SIL and Precision Airmotive Corportation SIL RS-56 verify the part number and dash number of the fuel servo unit installed. If the fuel servo unit is a Precision Airmotive Corporation Part Number 2576540-4 comply with TCM SIL 99-7, Precision Airmotive Corporation SIL RS-46. The Precision Airmotive Corporation Part Number is found on the identification plate attached to the fuel servo unit.

ISSUED

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CONTINENTAL MOTORS

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© 2000 TELEDYNE TECHNOLOGIES, INC.

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

1 of 1 SIL 00-8

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

Contains useful information pertaining to your aircraft engine SUBJECT: PURPOSE: COMPLIANCE:

SIL00-9A

Technical Portions FAA Approved Supersedes SIL00-9, ENGINE DATA PLATES M87-18R1 To provide procedures for acquiring replacement engine data plates. Whenever an engine data plate must be replaced due to being damaged, lost or stolen.

MODELS AFFECTED:

All TCM engine models, including engines manufactured under license by Rolls Royce. REASON FOR REVISION: Price Change

Replacement engine data plates may be obtained from Teledyne Continental Motors by following the procedure provide below. 1. Request for replacement data plates must be made in writing. 2. Contact your local FAA office and obtain written approval from them as specified in 14 CFR 45.13 paragraph (b) and (d). 3. If the engine data plate has been lost or stolen, or if the removed data plate is being retained by the FAA, you must obtain written certification from the FAA on official FAA letterhead verifying the engine model and serial number for which the data plate is being requested. 4. The old, removed data plate, unless it is being retained by the FAA as noted in step 3 above, must be returned to TCM with your written request for a replacement data plate and the above documentation. 5. Enclose a check or money order made payable to Teledyne Continental Motors, in US funds, in the amount of $100.00.

Send request to: Teledyne Continental Motors P.O. Box 90 Mobile, Al 36601 ATTN: CUSTOMER SERVICE DEPARTMENT

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02

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2001

09

09

2004

PO Box 90 Mobile AL 36601 • 251-438-3411

© 2004 Teledyne Continental Motors, Inc.

A Teledyne Technologies Company

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Removal And Installation Of Engine Data Plates. The technician is encouraged to read AC 43-17 and AC 45-3 prior to removing or installing an engine data plate. A. Data Plate Removal: Exercise extreme caution to not mar or damage the crankcase during this procedure. The engine data plate is attached to the engine crankcase with 6 each drive rivets. Drive rivets may be removed by carefully inserting a wide blade gasket scraper between the data plate and the crankcase adjacent to each drive rivet. As the data plate is lifted, the drive rivet should back out. Repeat this process for each drive rivet. B. Drive Screw Hole Repair/Patching: If drive screw hole will not be used to re-install engine data plate they may be repaired/patched using either 3M “Scotch Weld” structural adhesive, 3M part number 1838, or Loctite “Fast Cure” epoxy adhesive part number 44581. C. Installation of New or Originally removed Data Plate: New crankcase: 1. 2. 3. 4. 5.

On a #51 drill (.067 diameter) install a drill stop set for .19 inch depth Install the #51 drill into the chuck of a drill motor Use the data plate as a template to locate the drive screw holes Place the data plate on the machined data plate pad on the 1-3-5 crankcase half. Drill the 6 drive screw rivet holes (.067 diameter) using the # 51 drill to a depth of .19 inch 6. Clean aluminum shavings from crankcase exterior and interior surface 7. Fasten data plate to 1-3-5 crankcase half using 6 ea. P/N 24764 drive screws

Used, rebuilt or repaired crankcase with existing data plate holes: a. Data plate hole pattern and existing hole pattern on crankcase align. 1. On a #44 drill (.086 diameter) install a drill stop set for .19 inch depth 2. Install the #44 drill into the chuck of a drill motor 3. Drill the 6 existing data plate hole to .086 diameter with the #44 drill to a depth of .19 inch 4. Clean aluminum shavings from crankcase exterior and interior surfaces 5. Fasten data plate to 1-3-5 crankcase half using 6 ea. P/N 21007 drive screws

b. Data plate hole pattern and crankcase hole pattern do not align. ISSUED

REVISED

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09

2004

PO Box 90 Mobile AL 36601 • 251-438-3411

A Teledyne Technologies Company

SIL00-9

1. 2. 3. 4. 5. 6. 7. 8.

On a #51 drill install a drill stop set for .19 inch depth Install the #51 drill into the chuck of a drill motor Use the data plate as a template to locate the drive screw holes. Place the data plate on the machined data plate pad on the 1-3-5 crankcase half. Locate the data plate holes adjacent to the existing holes on the data plate pad Drill the 6 drive screw rivet holes, .19 inch depth. Clean aluminum shaving from crankcase interior and exterior surface Fasten data plate to 1-3-5 crankcase half using 6 ea. P/N 24764 drive screws

D. Rolls Royce Manufactured Engines: The issuance of a replacement data plate by Teledyne Continental Motors does not change or modify the original certification basis of these engines. Replacement data plates for engines originally manufactured by Rolls Royce under license agreement with Teledyne Continental Motors will have the engine model prefixed with the letter designation RR. These engines will retain the original Rolls Royce engine serial number and Type Certificate number issued by the CAA.

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09

2004

PO Box 90 Mobile AL 36601 • 251-438-3411

A Teledyne Technologies Company

SIL00-9

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

CATEGORY 5

SIL 01-2B Technical Portions FAA Approved Supersedes SIL 99-7, SIL 00-8 and SIL 01-2A

SUBJECT:

PRECISION AIRMOTIVE CORPORATION SIL RS-59 REVISION 2

PURPOSE:

To advise Owners, Operators and FBO’s operating and/or maintaining Piper Aircraft Seneca V Aircraft of the release of Precision Airmotive Corporative SIL RS-59 REV.2.

COMPLIANCE: 1. For aircraft that are experiencing stiff or rough throttle movements, comply with Precision Airmotive Corporation SIL RS-59 REV.2 on receipt of this Service Information Letter. 2. For aircraft that are not experiencing stiff or rough throttle movement difficulties, comply with Precision Airmotive Corporation SIL RS-59 REV.2 at the next scheduled maintenance event; i.e. 50 hour (oil change), 100 hour or annual inspection, whichever occurs first. MODELS AFFECTED:

All LTSIO-360-RB and TSIO-360-RB engines.

Teledyne Continental Motors recommends compliance with the attached Precision Airmotive Corporation SIL RS-59 Revision 2 as specified. Precision Airmotive Corporation SIL RS-59 Revision 2 supersedes Precision Airmotive Corporation SIL RS-46 (TCM SIL 99-7), SIL RS-56 (TCM SIL 00-8) and SIL RS59 Revision 1(TCM SIL 01-2A). Note: TCM part number 654353 (Precision Airmotive Corporation part number 2576540-4 , 2576540-5 and 2576540-6) is superseded by TCM part number 655892 (Precision Airmotive Corporation part number 2576540-7). Warranty: Warranty claims for parts, labor and materials required to comply with Precision Airmotive Corporation SIL RS-59 REV.2 (attached) should be submitted to Precision Airmotive Corporation.

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MO 09

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© 2001 TELEDYNE TECHNOLOGIES, INC.

A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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SIL 01-2

B

SIL RS-59 Revision 2

Service Information Letter - Fuel Systems SUBJECT: PURPOSE:

SMALL RECIPROCATING ENGINES RSA-5AD2 Issued 8/15/01 Page 1 of 2

2576540-4 and 2576540-5 Throttle Friction To provide instructions for RSA-5AD2 fuel injection servos installed on Piper Seneca V aircraft. Revision 1 changes the description in paragraph B. Revision 2 changes the 2576540-6 to 2576540-7 (see SIL RS-60)

A. EFFECTIVITY: This service information letter is applicable to the RSA-5AD2 fuel injection servos, parts list 2576540-4,and 2576540-5 used on Continental L/TSI0-360-RB engines in Piper PA34-220T Seneca V aircraft. B. DESCRIPTION: This document supercedes SIL RS-46 and SIL RS-56. This letter addresses corrective action for high throttle friction on the 2576540-4 and 2576540-5 fuel injection servos. All suspect units must be removed from the aircraft and sent to Precision Airmotive for update or replacement. C. INSPECTION PROCEDURE: If your aircraft has a 2576540-4 or 2576540-5 fuel injection servo and if the throttle movement is excessively stiff or rough (with the throttle friction off), inspect the idle lever assembly on the RSA-5AD2 fuel control servo for excessive friction. Disconnect the idle mixture linkage at the idle lever arm and throttle arm by removing the cotter pins; be sure to save the flat washers and spring washers for reassembly (see Figure 1). Rotate the idle lever by hand; if the lever action catches, grabs or the force measured directly on the linkage using a linear scale exceeds 4 lbs the servo should be reworked. Insure that measurements are taken perpendicular to the arm of the lever to obtain an accurate reading. The servo should be removed and replaced with a 2576540-7 fuel injection servo. NOTE: Many servos which exhibit high throttle friction will also exhibit unstable idle mixture and/or pressure sensitivity. If you are experiencing idle instability or excessive pressure sensitivity with the idle mixture set per specification, perform the inspection procedure in paragraph C. REPLACEMENT OPTIONS: Several options are available for replacement of 2576540-4 and 2576540-5 units: •

Precision Airmotive will update your servo, at no cost, to a 2576540-7. Remove the servo(s) and call Precision Airmotive Corporation at (360) 651-8282 for a Return Material Authorization (RMA) number. Your servo will be updated and returned as a time-continued unit with a priority turn around.

S.I.L. RS-59 Revision 2 •

Page 2 of 2

If you need to minimize down time or would like a zero time unit, we have arranged a discounted price for zero-time factory remanufactured units. Please call Precision Airmotive Sales for pricing and lead times.

NOTE: Servos that are replaced per the above instructions require installation and setup in accordance with applicable TCM and Piper Maintenance and Overhaul manuals. All updated, overhauled, or new servos installed may exhibit a gradual richening at idle during operation. This is normal for RSA fuel injection servos, and may require periodic readjustment of idle mixture to maintain desirable idle performance. D. ADDITIONAL INFORMATION: Contact Precision Airmotive Corporation Product Support at (360) 651-8282 for information.

Figure 1 RSA-5AD2

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

CATEGORY 5

SIL 01-4 Technical Portions FAA Approved

SUBJECT:

PRECISION AIRMOTIVE CORPORATION SIL RS-60

PURPOSE:

To advise Owners, Operators and FBO’s operating and/or maintaining Piper Aircraft Seneca V Aircraft of the release of Precision Airmotive Corporative SIL RS-60.

COMPLIANCE: On receipt of this Service Information Letter for Piper Seneca V aircraft utilizing the Precision Airmotive Corporation RSA-5AD2 fuel servo parts list 2576540-6 manufactured between February 15, 2001 and July 24, 2001. MODELS AFFECTED:

All LTSIO-360-RB and TSIO-360-RB engines.

Teledyne Continental Motors recommends compliance with the attached Precision Airmotive Corporation SIL RS-60. Warranty: Warranty claims for parts, labor and materials required to comply with Precision Airmotive Corporation SIL RS-60 (attached) should be submitted to Precision Airmotive Corporation.

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A Teledyne Technologies Company P.O. BOX 90 MOBILE ALABAMA 36601 • 334-438-3411

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SIL 01-4

SIL RS-60

Service Information Letter - Fuel Systems SUBJECT: PURPOSE:

SMALL RECIPROCATING ENGINES RSA-5AD2 Issued 8/17/01 Page 1 of 1

2576540-6 Servo – Boost Pump Pressure Interaction To provide service information for 2576540-6 and 2576540-7 fuel injection servos.

A. EFFECTIVITY: This service information letter is applicable to the RSA-5AD2 fuel injection servos, parts list 2576540-6 manufactured between February 15, 2001 and July 24, 2001. These servos are used on Continental L/TSI0-360-RB engines in Piper PA34-220T Seneca V aircraft. B. DESCRIPTION: This letter addresses corrective action for an overly rich fuel mixture after abrupt power reduction with the airframe boost pump on. There is a possibility that the servo can go rich after an abrupt power reduction if the fuel pressure to the servo is close to the upper factory limit of the airframe boost pump output pressure. All Servos manufactured after July 24, 2001 incorporate a new spring that will prevent this richening effect. These servos will be identified with parts list no. 2576540-7 stamped on the data tag. 2576540-6 servos updated on the aircraft in accordance with this letter will be identified with a “7” etched on the end of the metering cam's shaft. D. UPDATE OPTIONS: Two options are available for servo update: •

Precision Airmotive will update your 2576540-6 servo, at no cost, to a 2576540-7. The servos should be removed and returned to Precision Airmotive or an authorized Precision Airmotive Warranty Repair Station.

•

Maintenance technicians who are familiar with RSA fuel injection may perform the update on the aircraft. An update kit (parts list number 2576604) with instructions will be supplied upon request. The installation of the new spring does not require the removal of the servo from the engine or a recalibration of the flow schedule.

E. ADDITIONAL INFORMATION: Contact Precision Airmotive Corporation Product Support at (360) 651-8282 for further information

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining to Your Aircraft Engine

SUBJECT: PURPOSE:

SIL 02-1 Technical Portions FAA Approved

PISTON POSITION IDENTIFICATION AND PISTON WEIGHTS To advise Owners, Operators and FBO’s operating and/or maintaining Teledyne Continental Motors engines of the elimination of piston position marking on New and Rebuilt engines and provide piston weights by piston part number and weight code

COMPLIANCE:

At the next piston replacement

MODELS AFFECTED:

All

Teledyne Continental Motors has discontinued the practice of marking the piston position number on the crown of the piston. Piston weight is identified by a two letter weight code stamped on the crown of the piston during manufacturer. See Table 1 for piston weights by piston part number and weight grade. Table 2 provides piston application information. If you find it necessary to mark the position number on the crown of the piston use the following procedure. 1.

Use a 1/8inch numerical steel stamp tool, similar to Snap On Tool set number YA 817, to identify piston position 1 through 6. Position the piston so that the piston pin bores are at the 3 o’clock and 9 o’clock position. Mark the 1,3, & 5 pistons at the 2 o’clock position ¾ of an inch from the edge of the piston Mark the 2,4, & 6 pistons at the 10 o’clock position ¾ of an inch from the edge of the piston. Pistons are to be installed in the cylinder so that the number on the piston crown is facing forward.

2. 3. 4. 5.

Piston Position Marking Location

Weight Code Piston Pin Bore Center line

FIGURE 2

FIGURE 1

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TABLE 1 PISTON WEIGHTS BY PISTON PART NUMBER AND WEIGHT CODE Piston P/N 654829 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WX

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1347 1349 1349 1351 1351 1353 1353 1355 1355 1357 1357 1359 1359 1361 1361 1363 1363 1365 1365 1367 1367 1369 1369 1371 1371 1373 1373 1375 1375 1377 1377 1379 1379 1381 1381 1383 1383 1385

Piston P/N 654832 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1393 1395 1395 1397 1397 1399 1399 1401 1401 1403 1403 1405 1405 1407 1407 1409 1409 1411 1411 1413 1413 1415 1415 1417 1417 1419 1419 1421 1421 1423 1423 1425 1425 1427 1427 1429 1429 1431

Piston P/N 654833 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1034 1036 1036 1038 1038 1040 1040 1042 1042 1044 1044 1016 1046 1048 1048 1050 1050 1052 1052 1054 1054 1056 1056 1058 1058 1060 1060 1062 1062 1064 1064 1066 1066 1068 1068 1070 1070 1072

Piston P/N 654836 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW WX

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1449 1451 1453 1455 1457 1459 1461 1463 1465 1467 1469 1471 1473 1475 1477 1479 1481 1483 1485 1487

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TABLE 1 (continued) PISTON WEIGHTS BY PISTON PART NUMBER AND WEIGHT CODE Piston P/N 654840 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW WX

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1523 1525 1525 1527 1527 1529 1529 1531 1531 1533 1533 1535 1535 1537 1537 1539 1539 1541 1541 1543 1543 1545 1545 1547 1547 1549 1549 1551 1551 1553 1553 1555 1555 1557 1557 1559 1559 1561 1561 1563

Piston P/N 654841 WEIGHT GRADE

Piston P/N 654850 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW WX

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1602 1604 1604 1606 1606 1608 1608 1610 1610 1612 1612 1614 1614 1616 1616 1618 1618 1620 1620 1622 1622 1624 1624 1626 1626 1628 1628 1630 1630 1632 1632 1634 1634 1636 1636 1638 1638 1640 1640 1642

Piston P/N 654853 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS

ISSUED MO 06

DAY 06

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING

WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS

729 731 733 735 737 739 741 743 745 747 749 751 753 755 757 759

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 706 708 708 710 710 712 712 714 714 716 716 718 718 720 720 722 722 724 724 726 726 728 728 730 730 732 732 734 734 736 736 738

REVISED YEAR 2002

MO

DAY

YEAR

731 733 735 737 739 741 743 745 747 749 751 753 755 757 759 761

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TABLE 1 (continued) PISTON WEIGHTS BY PISTON PART NUMBER AND WEIGHT CODE

Piston P/N 654857 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW WX

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1453 1455 1455 1457 1457 1459 1459 1461 1461 1463 1463 1465 1465 1467 1467 1469 1469 1471 1471 1473 1473 1475 1475 1477 1477 1479 1479 1481 1481 1483 1483 1485 1485 1487 1487 1489 1489 1491 1491 1493

Piston P/N 654858 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 716 718 718 720 720 722 722 724 724 726 726 728 728 730 730 732 732 734 734 736 736 738 738 740 740 742 742 744 744 746 746 748

Piston P/N 654859 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 938 940 940 942 942 944 944 946 946 948 948 950 950 952 952 954 954 956 956 958 958 960 960 962 962 964 964 966 966 968 968 970 970 972

Piston P/N 654861 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 983 985 985 987 987 989 989 991 991 993 993 995 995 997 997 999 999 1001 1001 1003 1003 1005 1005 1007 1007 1009 1009 1011 1011 1013 1013 1015 1015 1017

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TABLE 1 (continued) PISTON WEIGHTS BY PISTON PART NUMBER AND WEIGHT CODE Piston P/N 654862 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1193 1195 1195 1197 1197 1199 1199 1201 1201 1203 1203 1205 1205 1207 1207 1209 1209 1211 1211 1213 1213 1215 1215 1217 1217 1219 1219 1221 1221 1223 1223 1225 1225 1227 1227 1229 1229 1231

Piston P/N 654867 WEIGHT GRADE WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW WX

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1397 1399 1399 1401 1401 1403 1403 1405 1405 1407 1407 1409 1409 1411 1411 1413 1413 1415 1415 1417 1417 1419 1419 1421 1421 1423 1423 1425 1425 1427 1427 1429 1429 1431 1431 1433 1433 1435 1435 1437

ISSUED MO 06

DAY 06

BARE PISTON WEIGHT (GRAMS) OVER UP TO & INCLUDING 1300 1302 1302 1304 1304 1306 1306 1308 1308 1310 1310 1312 1312 1314 1314 1316 1316 1318 1318 1320 1320 1322 1322 1324 1324 1326 1326 1328 1328 1330 1330 1332 1332 1334 1334 1336 1336 1338 1338 1340 1340 1342 1342 1344 1344 1346 1346 1348 1348 1350 1350 1352 1352 1354 1354 1356 1356 1358 1358 1360 1360 1362 1362 1364 1364 1366 1366 1368 1368 1370 1370 1372 1372 1374 1374 1376 1376 1378

Piston P/N 655988 WEIGHT GRADE XN XP XR XS XT XV XW XX XY XZ WA WB WC WD WE WF WG WH WJ WK WL WM WN WP WR WS WT WV WW WX WY WZ TA TB TC TD TE TF TG

REVISED YEAR 2002

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Piston Part Number 654829 654832 654833 654836 654840

654841 654850 654853 654857 654858 654859 654861 654862 654867 655988

TABLE 2 PISTON APPLICATION Compression Ratio Application 8.0 : 1 O-470-G, GCI, M; IO-470-C 8.6 : 1 O-470-U; IO-470-D, E, F, H, L, M, N, S, U, V 7.0 : 1 O-470-K, L, R, S 8.5 : 1 IO-520-P, LIO-520-P; LTSIO-520-AE, TSIO-520-AE 7.5 : 1 GTSIO-520-C, D, H, K, L, M, N; TSIO-520-AF, B, BB,BE, C, CE, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, UB, VB, WB 6.3 : 1 C-75; C-85; C-115; C-125 8.5 : 1 IO-520-A, B, BB, C, CB, D, E, F, J, K, L, M, MB 7.0 : 1 O-200-A,B; O-300-A, C, D 8.5 : 1 IO-550-A ,B, C, D, E, F, G, L, N, P, R; IOF-550-B, G, N 7.3 : 1 GO-300-A, B, C D, E; GIO-300-A 7.5 : 1 LTSIO-360-E, EB, KB, RB; TSIO-360-A, AB, C, CB, D, DB, E, EB, F, FB, GB, H, HB, JB, KB, LB, MB, RB, SB 8.5 : 1 IO-240-A, B; IO-360-A, AB, C, CB, D, DB, G, GB, H, HB, J, JB, K, KB, LB 7.0 : 1 O-470-J; IO-470-J, K 7.5 : 1 TSIO-550-A, B, C, E; TSIOL-550-A, B, C; TSIOF-550-E 7.5 : 1 TSIO-470-A, B, C

Note: TCM provides parts history and application data on line via FBO Services and Information Services. Visit TCM’s website at www.tcmlink.com for full details.

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL 02-4

Contains Useful Information Pertaining To Your Aircraft Engine

Technical Portions FAA Approved

SUBJECT:

Production Release of New Light Weight Starter Motors

PURPOSE:

To advise Owners, Operators and FBO’s of the production release a new permanent magnet starter motor replacing the TCM Energizer starter motor

COMPLIANCE: MODELS AFFECTED:

On release of this Service Information Letter or the next time the starter motor is replaced.

O-300-D; IO-346; All 360; 470; 520 and 550 series engines.

Teledyne Continental Motors has production released a new, light weight, permanent magnet starter motor. The starter motor, manufactured by Iskra, is available in 12 and 24 volt versions, with and without starter relays. The Iskra starter utilizes permanent magnet technology and planetary gearing which allows this new starter to achieve a high starting torque while reducing overall weight by 7 pounds. The starter is designed to be a direct, bolt on replacement for previous starter motors used on TCM engines with the 90 degree starter drive adapter. Service information for the Iskra starter motor are provided in Service Instruction Manual form number STR-01.

Superseded and replacement part numbers are provided below.

TCM Energizer P/N 646238 646238-1 646238-2 646238-3 646238-4 646275 646275-1 646275-11

ISSUED

TCM Iskra P/N 655565 655564 655565 655564 655565 655566 655566 655566

Description 12 volt starter 12 volt starter with relay 12 volt starter 12 volt starter with relay 12 volt starter 24 volt starter 24 volt starter 24 volt starter

REVISED

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© 2002 Teledyne Continental Motors, Inc.

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SIL 02-5 Technical Portions FAA Approved

SUBJECT:

INDUCTION HOSE CLAMP

PURPOSE:

To advise Owners, Operators and FBO’s of a production change regarding the induction hose clamps installed on certain engines as listed in the models affected section of this bulletin.

COMPLIANCE: MODELS AFFECTED:

On release of this Service Information Letter.

All IO-550-C series engines.

This Service Information Letter (SIL) is being issued to notify owners, operators and FBO’s of a production change that affects the IO-550-C engines installed on the Raytheon Aircraft Corporation (formerly Beech Aircraft Corp.) model 58 Baron aircraft. Teledyne Continental Motors has not been able to locate a supplier for the P/N 36151L induction hose clamp. This clamp has been installed on the induction hose located between the number 4 and 6 cylinder. Raytheon Aircraft Corporation utilizes this clamp to attach the bracket that supports the propeller governor control cable. Raytheon Aircraft Corporation has designed an alternate method of attaching the propeller governor cable support bracket. Figure 1 shows the earlier method of attaching the propeller governor support bracket to the P/N 36151L induction hose clamps. Figure 2 shows the new method of attachment. At the request of Raytheon Aircraft Corporation new engines will be shipped from Teledyne Continental Motors with P/N 631972 hose clamps installed. These clamps are torqued to 45 inch pound. For required hardware and instructions for installing new bracket, Raytheon Aircraft Corp. P/N 58-940039-001, and attaching propeller governor control cable contact Raytheon Aircraft Corporation.

ISSUED

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© 2002 Teledyne Continental Motors, Inc.

P/N 96-940035-1 Bracket

P/N 36151L Clamp FIGURE 1 Old Configuration P/N 96-940035-1 Bracket Attach to P/N 58-940039-0001 using Two each AN3-4A bolts.

P/N 58-940039-0001 Bracket Assembly Locate bracket under existing clamps as shown. Position clamp 45 degrees below horizontal on outboard side of induction manifold.

P/N 631972 Clamps Torque to 45 inch pounds FIGURE 2 New Configuration ISSUED

REVISED

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

REASON FOR REVISION :

CATEGORY 5

SIL 02-6A Technical Portions FAA Approved

Correct intake valve part number for Special Edition and Platinum Engines

SUBJECT:

PRODUCTION RELEASE OF OPTIONAL INTAKE AND EXHAUST VALVES

PURPOSE:

To advise Distributors, FBO’s and Engine Overhaul Facilities of the production release and incorporation of optional intake and exhaust valves in TCM TopCare Cylinders

COMPLIANCE:

MODELS AFFECTED:

During cylinder repair or overhaul.

C-75; C-85; C-90; E-185; E-225; O-200; O-300; O-240; IO-240; IOF-240; IO-346; IO-360; LTSIO-360; TSIO-360; O-470; IO-470; TSIO-470; IO-520; TSIO-520; GTSIO-520; IO-550; IOF-550; TSIO-550; TSIOF-550; TSIOL-550; series engines.

GENERAL INFORMATION: Teledyne Continental Motors has certified and production released optional part number intake and exhaust valves for use in our Top Care Cylinders. These valves may also be used as service replacements for other TCM Cylinders. Table 1 provides valve application by engine model, cylinder part number, intake valve part number and exhaust valve part number.

ISSUED

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MO

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06

28

2002

10

25

2002

© 2002 Teledyne Continental Motors, Inc.

PAGE NO REVISION P.O. Box 90 Mobile Alabama • 251-438-3411

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A

TABLE 1 ENGINE, CYLINDER AND VALVE APPLICATION ENGINE MODEL C-75, C-85 Swaged push rod housings C-75, C-85 Removable push rod housings C-90 Swaged push rod housings C-90, 0-200-A, B Removable push rod housings 0-200-A, B Swaged push rod housings 0-300-A, C, D Swaged push rod housings 0-300-A, C. D Removable push rod housings GO-300 Swaged push rod housings GO-300 Removable push rod housings O-240-A (Rolls Royce) IO-240-A, B IO-346-A

CYLINDER PART NUMBER 654377

INTAKE VALVE 641792 or 655968

EXHAUST VALVE 654064 or 655969

653816

653783 or 655970

654004 or 655971

654377

641792 or 655968

654064 or 655969

653816

653783 or 655970

654004 or 655971

654377

641792 or 655968

654064 or 655969

654377

641792 or 655968

654064 or 655969

653816

653783 or 655970

654004 or 655971

654377

641792 or 655968

654064 or 655969

653816

653783 or 655970

654004 or 655971

654971

646459 or 655867

654067 or 655866

654974

646283 or 655783

652956 or 655771

IO-360-A, AB, C, CB, D, DB, G, GB, H, HB, J, JB, K KB IO-360-ES

654970

646459 or 655867

654067 or 655866

654971

646459 or 655867

654067 or 655866

E-165, E-185, E-225

654972

646283 or 655783

652956 or 655771

0-470-A, E, J

654967

646283 or 655783

652956 or 655771

0-470-G7, G10, M, GCI IO470C 0-470-G, K, L, R, S (Except G7, G10, GCI, M) 0-470-U

655467

646283 or 655783

652956 or 655771

655467

646283 or 655783

652956 or 655771

655468

646283 or 655783

652956 or 655771

IO-470-J, K

654967

646283 or 655783

652956 or 655771

IO-470-D, E, F, H, L, M, N, S, U, V IO-520 – All Models

655468

646283 or 655783

652956 or 655771

655469

646283 or 655783

652956 or 655771

655469

646283 or 655783

652956 or 655771

IO-550-A, B, C (Except Platinum & Special Edition Engines)

ISSUED

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10

25

2002

PAGE NO REVISION P.O. Box 90 Mobile Alabama • 251-438-3411

2 of 3 SIL 02-6

A

TABLE 1 (continued) ENGINE, CYLINDER AND VALVE APPLICATION ENGINE MODEL IO-550-B, IO-550-C Platinum Engines Only

CYLINDER PART NUMBER 655472

INTAKE VALVE 654448 or 655868

EXHAUST VALVE 652956 or 655771

IO-550-B, IO-550-C Special Edition Engines Only IO-550-D, E, F, L (Except Platinum Engines) IO-550-D, F, L Platinum Engines Only IO-550-G

655484

654448 or 655868

652956 or 655771

655471

646283 or 655783

652956 or 655771

655485

654448 or 655868

652956 or 655771

655474

646283 or 655783

652956 or 655771

IO-550-N, P, R

655465

646283 or 655783

652956 or 655771

TSIO-360-A, AB, C, CB, D, DB, E, EB, F, FB, GB, H, HB, KB, LB LTSIO-360-E, EB, KB TSIO-360-MB, RB, SB LTSI0-360-RB TSIO-520-BE

654970

646459 or 655867

654067 or 655866

654971

646459 or 655867

654067 or 655866

655474

646283 or 655783

652956 or 655771

TSIO-520-B, BB, C, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R, T, VB, WB TSIO-520-AE LTSI0-520-AE

655470

646283 or 655783

652956 or 655771

654968

646283 or 655783

652956 or 655771

TSIO-520-AF, CE, UB (Except UB17 Special Edition) TSIO-520-UB17B Special Edition Engine TSIO-550-A, B, C, E

655469

646283 or 655783

652956 or 655771

655484

654448 or 655868

652956 or 655771

655477

646283 or 655783

652956 or 655771

TSIOL-550-A, B, C

654958

646283 or 655783

652956 or 655771

GTSI0-520-C, D, H

654965

646283 or 655783

652956 or 655771

GTSI0-520-F, K

655474

646283 or 655783

652956 or 655771

GTSI0-520-L, M, N

655474

646283 or 655783

652956 or 655771

ISSUED

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06

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25

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PAGE NO REVISION P.O. Box 90 Mobile Alabama • 251-438-3411

3 of 3

SIL 02-6

A

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER

SIL 03-1

Contains Useful Information Pertaining To Your Aircraft Engine

Technical Approved

SUBJECT:

COLD WEATHER OPERATION – ENGINE PREHEATING

PURPOSE:

To provide instructions for engine pre-heating during cold weather operation

COMPLIANCE:

MODELS AFFECTED:

A.

Portions

On release of this Service Information Letter during cold weather engine and aircraft operation.

ALL

GENERAL INFORMATION:

Preheating is required whenever the engine has been exposed to temperatures at or below 20° Fahrenheit / 7 degrees Centigrade (wind chill factor) for a period of two hours or more. Refer to the Pilot’s Operating Handbook/Airplane Flight Manual for specific instructions that apply to your aircraft.

WARNING Failure to properly preheat a cold-soaked engine may result in oil congealing within the engine, oil hoses, and oil cooler with subsequent loss of oil flow, possible internal damage to the engine, and subsequent engine failure. Superficial application of preheat to a cold soaked engine can cause damage to the engine. An inadequate application of preheat may warm the engine enough to permit starting but will not de-congeal oil in the sump, lines, cooler, filter, etc. Congealed oil in these areas will require considerable preheat. The engine may start and appear to run satisfactorily, but can be damaged from lack of lubrication due to the congealed oil blocking proper oil flow through the engine. The amount of damage will vary and may not become evident for many hours. However, the engine may be severely damaged and may fail shortly following application of high power. Proper procedures require thorough application of preheat to all parts of the engine. Hot air must be applied directly to the oil sump and external oil lines as well as the cylinders, air intake and oil cooler. Because excessively hot air can damage non-metallic components such as seals, hoses, and drives belts, do not attempt to hasten the preheat process. The preferred method of preheating your engine is to place the aircraft in a heated hangar for a minimum of four hours prior to flight. Optional methods of preheating your aircraft engine are to use either a high volume combustion heater with ducts directed to the engine oil sump, cylinders and oil cooler or to install an engine mounted preheating system. ISSUED MO 01

DAY 28

REVISED YEAR

MO

DAY

PAGE NO REVISION

YEAR

2003

© 2003 Teledyne Continental Motors, Inc.

1 of 5 P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 03-1

FAA

Prior to operation and/or storage in cold weather, ensure that the engine is serviced with the correct viscosity oil for the ambient temperature. Refer to the latest revision of TCM service bulletin SIL 99-2A. In the event of temporary cold weather operation, consideration should be given to storing the aircraft in a heated hangar between flights. CAUTION:

Attempting to start your engine with a partially discharged aircraft battery may result in damage to the starter relay, possible engine kick-back resulting in a broken starter adapter clutch spring.

Engine starting during extreme cold weather is generally more difficult. Cold soaking causes the oil to become thicker (more viscous), making it difficult for the starter to crank the engine. This results in slow cranking speeds and an abnormal drain on the battery capacity. At low temperatures, aviation gasoline does not vaporize readily, further complicating the starting procedure. Always use an external power source when attempting to start your aircraft engine in cold weather.

WARNING Over priming can cause a flooded intake resulting in a "hydraulic lock" event and subsequent engine malfunction or failure. If you over prime, or flood your engine, make certain that all fuel has drained from the intake manifold and/or cylinder prior to attempting engine starting. False starting (failure to continue running after starting) often results in condensation on spark plug electrodes. This moisture can freeze and must be eliminated either by preheating the engine or removing and cleaning the spark plugs. B.

APPLICATION OF PREHEAT USING COMBUSTION HEATER:

If a heated hangar is not available and the aircraft and engine have been exposed to temperatures below 20 degrees Fahrenheit / -7 degrees Centigrade (wind chill factor) for 2 hours or more, and does not have an engine mounted preheating system the following procedure may be used. The following procedure is required for preheating, starting, warm-up, run-up and takeoff. 1. Select a high volume hot air heater. Small electric heaters which are inserted into the cowling opening do not appreciably warm the oil and may result in superficial preheating.

2. Proper procedures require thorough application of preheat to all parts of the engine. Apply preheated air directly to the oil sump, oil filter, external oil lines, oil cooler, coolant radiator and cylinder assemblies. Continue to apply heat for a minimum of 30 minutes. 3. Start the engine immediately after completion of the preheating process. Since the engine will be warm, use the normal start procedure. CAUTION:

If oil pressure is not indicated within 30 seconds, shut the engine down and determine the cause.

4. Operate the engine at 1000 RPM until some oil temperature is indicated. Monitor oil pressure closely, if necessary retard throttles to maintain oil pressure below 100 PSI. If oil pressure is less than 30 PSI, or

ISSUED MO 01

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2 of 5 P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 03-1

cannot be maintained below 100 PSI, shut the engine down and repeat the preheat process. Do not close the cowl flaps to facilitate engine warm-up. CAUTION:

Do not operate the engine at speeds above 1700 RPM unless oil temperature is 75° Fahrenheit or higher and oil pressure is within specified limits of 30-60 PSI.

5. Run the engine up to 1700 RPM, approach this rpm in increments to prevent oil pressure from exceeding 100 PSI.

WARNING Operation of the engine above 1700 RPM before reaching minimum oil temperature may result in engine malfunction, engine failure, injury or death. 6. At 1700 RPM, adjust the propeller control to Full DECREASE until minimum governing RPM is observed, then return the control to Full INCREASE RPM. Repeat this procedure three or four times to circulate warm oil into the propeller dome. If the aircraft manufacturer recommends checking the propeller feathering system, move the control to the FEATHER position but do not allow the RPM to drop more than 300 RPM below minimum governing speed. CAUTION:

Continually monitor oil pressure during run up.

7. Check magnetos as specified in the aircraft POH/AFM. 8. When oil temperature has reached 100 degrees Fahrenheit and oil pressure does not exceed 60 PSI at 2500 RPM, the engine has been warmed sufficiently to accept full rated power. C.

APPLICATION OF PREHEAT USING ENGINE MOUNTED PREHEATER SYSTEM:

If a heated hangar is not available and the aircraft and engine have been exposed to temperatures below 20 degrees Fahrenheit / -7 degrees Centigrade and has an engine mounted preheating system the following procedure may be used. Engine mounted preheating systems should include individual cylinder head heater thermocouples, oil sump heater pad and crankcase heater pad. The use of a nacelle blanket will increase the effectiveness of engine preheating. 1. Follow the specific instruction provided by the manufacturer of the preheating system for its operation. 2. Begin preheating of the engine at least 5 hours prior to expected departure. However, do not leave the engine preheating system in operation for more than 24 hours. NOTE:

The use of an approved thermal blanket or cover will help to reduce the effects of wind and cold air circulation when the aircraft is not hangered. Normally the manufacturer of the preheating system has thermal blankets available for purchase. 3. Start the engine immediately after completion of the preheating process. Since the engine will be warm, use the normal start procedure. CAUTION:

If oil pressure is not indicated within 30 seconds, shut the engine down and determine the cause.

ISSUED MO 01

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MO

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3 of 5 P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 03-1

4. Operate the engine at 1000 RPM until some oil temperature is indicated. Monitor oil pressure closely, if necessary retard throttles to maintain oil pressure below 100 PSI. If oil pressure is less than 30 PSI, or cannot be maintained below 100 PSI, shut the engine down and repeat the preheat process. Do not close the cowl flaps to facilitate engine warm-up.

CAUTION:

Do not operate the engine at speeds above 1700 RPM unless oil temperature is 75° Fahrenheit or higher and oil pressure is within specified limits of 30-60 PSI.

5. Run the engine up to 1700 RPM, approach this rpm in increments to prevent oil pressure from exceeding 100 PSI.

WARNING Operation of the engine above 1700 RPM before reaching minimum oil temperature may result in engine malfunction, engine failure, injury or death. 6. At 1700 RPM, adjust the propeller control to Full DECREASE until minimum governing RPM is observed, then return the control to Full INCREASE RPM. Repeat this procedure three or four times to circulate warm oil into the propeller dome. If the aircraft manufacturer recommends checking the propeller feathering system, move the control to the FEATHER position but do not allow the RPM to drop more than 300 RPM below minimum governing speed. NOTE:

Continually monitor oil pressure during run up.

7. Check magnetos as specified in the aircraft POH/AFM. 8. When oil temperature has reached 100 degrees Fahrenheit and oil pressure does not exceed 60 PSI at 2500 RPM, the engine has been warmed sufficiently to accept full rated power.

WARNING Do not leave an engine-mounted pre-heater system on for more than twenty- four hours prior to flight. Continuous operation of engine-mounted preheater systems may result in aggressive corrosive attack internal to the engine. D.

COLD WEATHER START WITHOUT PREHEAT:

At ambient temperature between 20 and 40 degrees Fahrenheit the following procedure is recommended. 1. Use an external power source or ensure that the aircraft battery is fully charged. CAUTION:

Attempting to start your engine with a partially discharged aircraft battery may result in damage to the starter relay, possible engine kick-back resulting in a broken starter adapter clutch spring.

ISSUED MO 01

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REVISED YEAR 2003

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DAY

PAGE NO REVISION

YEAR

4 of 5 P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 03-1

2. Use the normal start procedure, as detailed in the aircraft manufacturers POH / AFM, being careful to not over prime the engine.

WARNING Over priming can cause a flooded intake resulting in a "hydraulic lock" event and subsequent engine malfunction or failure. If you over prime, or flood your engine, make certain that all fuel has drained from the intake manifold and/or cylinder prior to attempting engine starting. CAUTION:

If oil pressure is not indicated within 30 seconds, shut the engine down and determine the cause.

3. Operate the engine at 1000 RPM until some oil temperature is indicated. Monitor oil pressure closely, if necessary retard throttles to maintain oil pressure below 100 PSI. If oil pressure is less than 30 PSI, or cannot be maintained below 100 PSI, shut the engine down and repeat the preheat process. Do not close the cowl flaps to facilitate engine warm-up.

CAUTION:

Do not operate the engine at speeds above 1700 RPM unless oil temperature is 75° Fahrenheit or higher and oil pressure is within specified limits of 30-60 PSI.

4. Run the engine up to 1700 RPM, approach this RPM in increments to prevent oil pressure from exceeding 100 PSI.

WARNING Operation of the engine above 1700 RPM before reaching minimum oil temperature may result in engine malfunction, engine failure, injury or death. 5. At 1700 RPM, adjust the propeller control to Full DECREASE until minimum governing RPM is observed, then return the control to Full INCREASE RPM. Repeat this procedure three or four times to circulate warm oil into the propeller dome. If the aircraft manufacturer recommends checking the propeller feathering system, move the control to the FEATHER position but do not allow the RPM to drop more than 300 RPM below minimum governing speed. NOTE:

Continually monitor oil pressure during run up.

6. Check magnetos as specified in the aircraft POH/AFM. 7. When oil temperature has reached 100 degrees Fahrenheit and oil pressure does not exceed 60 PSI at 2500 RPM, the engine has been warmed sufficiently to accept full rated power.

ISSUED MO 01

DAY 28

REVISED YEAR 2003

MO

DAY

PAGE NO REVISION

YEAR

5 of 5 P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 03-1

TELEDYNE CONTINENTAL

®

CATEGORY 5

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER

SIL 03-2B

Contains Useful Information Pertaining To Your Aircraft Engine

Technical Portions FAA Approved Supersedes M85-7

Reason For Revision :

Correction to engine / spark plug application Table 2 and 3.

SUBJECT:

CURRENTLY ACTIVE APPROVED SPARK PLUG APPLICATION

PURPOSE:

Provide listing of currently approved spark plugs for TCM Engines

COMPLIANCE: MODELS AFFECTED:

As Required when replacing spark plugs.

ALL

GENERAL INFORMATION: The following Tables number 1, 2, 3 , and 4 list the most commonly used spark plugs by engine model. Additional listings of approved spark plugs may be found in the engine’s FAA Type Certificate Data Sheet and the spark plug manufacturer’s data. Refer to the spark plug manufacturer’s data for spark plug servicing information and required specialized tools. Spark plugs must be removed, cleaned, inspected, gapped and position rotated every 100 hours. Refer to Chart 1 for spark plug rotation sequence. Always install a new spark plug gasket when servicing spark plugs or installing new spark plugs. Chart 2 provides spark plug electrode gap specifications using an alpha code referenced in Table 1, 2 and 3.

CAUTION:

Failure to install a new spark plug gasket each time the spark plug (s) are installed may result in incomplete sealing of the combustion chamber, loss of spark plug heat transfer, spark plug over heating, possible pre-ignition / detonation and internal engine damage.

GENERAL INSTALLATION PROCEDURES: In the event spark plug manufacturer’s instructions are not available the following procedure may be used. 1. 2. 3. 4. 5. 6.

Always install spark plugs with new copper gasket. Sparingly apply anti-seize to the spark plug threads. DO NOT APPLY ANTI-SEIZE TO THE FIRST THREAD. Always use a six point deep socket. Thread spark plug by hand into cylinder to within one or two threads of the gasket. If this is not possible, cylinder head threads or spark plug threads need to be cleaned. Torque spark plugs to 300 to 360 inch pounds using a currently calibrated torque wrench. Handle spark plug leads with clean, dry hands.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

07

2003

10

26

2004

© 2003 Teledyne Continental Motors, Inc.

Teledyne Continental Motors, Inc.

1 of 14

P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 03-2

B

7.

Before installing the spark plug lead connector, wipe it clean using a lint-free cloth moistened with MEK, acetone, wood alcohol or naphtha. 8. Ensure that inside of spark plug barrel is clean and dry. 9. Insert spark plug lead connector into spark plug barrel with fingers in a straight line with the spark plug. 10. Screw connector nut into place until finger tight. 11. Tighten an additional 1/8 turn with the correct size open end wrench while holding the spark plug lead ferrule stationary. WARNING:

DO NOT INSTALL OR USE ANY SPARK PLUG THAT HAS BEEN DROPPED OR HAS ANY MECHANICAL DAMAGE.

Chart 1 SPARK PLUG ROTATION CHARTS

4 CYLINDER ENGINE SPARK PLUG ROTATION

6 CYLINDER ENGINE SPARK PLUG ROTATION FROM CYLINDER NUMBER 1 TOP 1 BOTTOM 2 TOP 2 BOTTOM 3 TOP 3 BOTTOM 4 TOP 4 BOTTOM 5 TOP 5BOTTOM 6 TOP 6 BOTTOM

FROM CYLINDER NUMBER 1 TOP 1 BOTTOM 2 TOP 2 BOTTOM 3 TOP 3 BOTTOM 4 TOP 4 BOTTOM

TO CYLINDER NUMBER 6 BOTTOM 6 TOP 5 BOTTOM 5 TOP 4 BOTTOM 4 TOP 3 BOTTOM 3 TOP 2 BOTTOM 2 TOP 1 BOTTOM 1 TOP

TO CYLINDER NUMBER 4 BOTTOM 4 TOP 3 BOTTOM 3 TOP 2 BOTTOM 2 TOP 1 BOTTOM 3 TOP

CHART 2 SPARK PLUG ELECTRODE GAP SPARK PLUG GAP CHART GAP CODE ELECTRODE GAP A .015 - .018 B .016 - .021 C .017 - .020 D .018 - .021 E .019 - .022 { NO GAP AVAILABLE

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

07

2003

10

26

2004

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama • 251-438-3411

2 of 14 SIL 03-2

B

TABLE 1 SPARK PLUG APPLICATION

646089

646091

646092

5/8 -24

5/8 -24

3/4 -20

RSH23-3R/1

642098 3/4 -20

RSE23-3R/1

642097 5/8 -24

RSE35-8R/1

641977 3/4 -20

RSH23-3R

639609 3/4 -20

RSE23-3R

646090 3/4 -20

RSH35-8R

649915 3/4 -20

RSH101R

649914 3/4 -20

RSH35-8R/1

649913 5/8 -24

HSR-88

649912 3/4 -20

HSR-87

649910 3/4 -20

SR-87

635860 3/4 -20

HSR-86

632740 3/4 -20

AC-293

632738 3/4 -20

AC-283

635589 3/4 -20

AC-281

630533 3/4 -20

AC-291

63532 3/4 -20

AC-273

627450 3/4 -20

AC-271

627449 5/8 -24

HSR-87

635862 5/8 -24

SR-87

625350 5/8 -24

SR-93

SR-83 P

539432 5/8 -24

A-88

626362 3/4 -20

HSR-88

635861 3/4 -20

HSR-93

626363

Recommended Electrode Gap

3/4 -20

BARREL SIZE

SMITH INDUSTRIES

626364

TCM Part Number

SPITFIRE SERIES

3/4 -20

HSR-86

SPARK PLUG MANUFACTURER PART NUMBER

HSR-83 P

AUBURN SPARK PLUG CO. - AC SPARK PLUG CO.

273

MANUFACTURER

A

A

A

E

E

A

A

E

E

A

A

A

A

A

A

A

A

E

E

E

C

D

C

C

C

C

C

C

A-40; A-50

X

X

X

X

A-65; A-75

X

X

X

X

A-80

X

X

X

X

A-100

X

X

X

X

X

X

X

X

X

X

W-670; R-670

X

X

X

X

X

X

C-75; C-85

X

X

X

X

X

X

X

X

X

X

X

C-90

X

X

X

X

X

X

X

X

X

X

X

O-200-A,B,C

X

X

X

X

X

X

X

X

X

X

X

C-115; C-125

X

X

X

X

X

X

C-145; O-300-A,B,C,D

X

X

X

X

X

X

GO-300-A,B,C,D,E,F

X

X

X

E-165; E-185

X

X

X

X

X

X

E-225

X

X

X

X

X

X

X

X

X

X

X

O-470-2

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

O-470-4,11,13,13A,15

X

X

ISSUED

X

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

3 of 14 SIL 03-2

B

TABLE 1 SPARK PLUG APPLICATION (Continued)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

C

C

C

X

X X

RSH23-3R/1

RSE23-3R/1

RSE35-8R/1

RSH23-3R

RSE23-3R

RSH35-8R

RSH101R

RSH35-8R/1

HSR-88

HSR-87

SR-87

HSR-86

D

646092

X

C

3/4 -20

X

E

646091

X

E

5/8 -24

X

E

646089

X

A

5/8 -24

X

642098

X

3/4 -20

A

642097

A

5/8 -24

A

641977

A

3/4 -20

A

639609

A

3/4 -20

A

646090

E

3/4 -20

E

649915

A

3/4 -20

A

649914

E

3/4 -20

E

649913

A

5/8 -24

649910 3/4 -20

A

649912

635860 3/4 -20

A

SMITH INDUSTRIES

3/4 -20

632740 3/4 -20

AC-293

632738 3/4 -20

AC-283

635589 3/4 -20

AC-281

630533 3/4 -20

AC-291

63532 3/4 -20

AC-273

627450 3/4 -20

AC-271

627449 5/8 -24

HSR-87

635862 5/8 -24

SR-87

625350 5/8 -24

SR-93

SR-83 P

539432 5/8 -24

A-88

626362 3/4 -20

HSR-88

635861 3/4 -20

HSR-93

626363

Recommended Electrode Gap

3/4 -20

BARREL SIZE

626364

TCM Part Number

SPITFIRE SERIES

3/4 -20

HSR-86

SPARK PLUG MANUFACTURER PART NUMBER

HSR-83 P

AUBURN SPARK PLUG CO. - AC SPARK PLUG CO.

273

MANUFACTURER

C

C

C

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

IO-550-A,B,C,D,E,F,L,N,P,R TSIO-550-A,B,C,E IOF-550-B,C,D,E,F,L,N,P,R O-470-A,E,J,K,L,R,S O-470-B,G,H,M,N,P

X

IO-470-C,G,R,P,T O-470-U,T IO-470-D,E,F,H,L,M,N,S,U,V

X

X

X

X

X

X

X

X

X

X

X

X

X

FSO-470-A FSO-526-A,C GSO-526-A IO-470-J,K IO-360-A,AB,C,CB,D,DB,E,ES, G,GB,H,HB,J,JB,K,KB

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

GIO-470-A

X

X

X

X

X

X

X

LIO-470-A

X

X

X

X

X

ISSUED

X

X

X

X

X

TSIO-470-B,C,D IO-346-A,B

X

X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

4 of 14 SIL 03-2

B

TABLE 1 SPARK PLUG APPLICATION (Continued)

646089

646091

646092

5/8 -24

5/8 -24

3/4 -20

RSH23-3R/1

642098 3/4 -20

A

A

A

E

E

A

A

E

E

A

A

A

A

A

A

A

A

E

E

E

C

D

C

C

C

C

C

C

IO-520-A,B,BA,BB,C,CB,D,,F, J,K,L,M,MB,N,NB LIO-520-P IO-360-B

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

L/TSIO-520-B,C,D,DB,E,EB,G, H,J,JB,K,KB,L,LB,M,N,NB,P, R,T,U,UB,VB,WB,AE,BE,CE

X

X

X

X

X

X

X

GTSIO-520-,D,F,G,H,K,L,M,N

X

X

X

X

X

X

X

TSIO-360-A,B

RSE23-3R/1

642097 5/8 -24

RSE35-8R/1

641977 3/4 -20

RSH23-3R

639609 3/4 -20

RSE23-3R

646090 3/4 -20

RSH35-8R

649915 3/4 -20

RSH101R

649914 3/4 -20

RSH35-8R/1

649913 5/8 -24

HSR-88

649912 3/4 -20

HSR-87

649910 3/4 -20

SR-87

635860 3/4 -20

HSR-86

632740 3/4 -20

AC-293

632738 3/4 -20

AC-283

635589 3/4 -20

AC-281

630533 3/4 -20

AC-291

63532 3/4 -20

AC-273

627450 3/4 -20

AC-271

627449 5/8 -24

HSR-87

635862 5/8 -24

SR-87

625350 5/8 -24

SR-93

SR-83 P

539432 5/8 -24

A-88

626362 3/4 -20

HSR-88

635861 3/4 -20

HSR-93

626363

Recommended Electrode Gap

3/4 -20

BARREL SIZE

SMITH INDUSTRIES

626364

TCM Part Number

SPITFIRE SERIES

3/4 -20

HSR-86

SPARK PLUG MANUFACTURER PART NUMBER

HSR-83 P

AUBURN SPARK PLUG CO. - AC SPARK PLUG CO.

273

MANUFACTURER

X

X

X

X

6-285-B,C,BA,CA 6-320-B & T6-320-A

X

X

X

X

X

X

X

X

X

X

X

L/TSIO-360-A,AB,B,BB,C,CB, D,DB, E,EB,F,FB,G,GB,H,HB, JB,KB,LB,MB,RB,SB

X

X

X

X

TSIOL-550-A TSIOL-550-B TSIOL-550-C IO-240-A,B; IOF-240-B

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

5 of 14 SIL 03-2

B

TABLE 2 SPARK PLUG APPLICATION

X

X

B

B

B

B

B

B

B

X

X

RHU27E

RHU32S

X

654709

X

X

A-100

3/4 -20

X

RHU32E

X

654708

X

3/4 -20

X

X

RHB32S

X

646632

X

3/4 -20

X

RHB36S

X

646631

B

3/4 -20

B

RHM38S

B

646630

B

3/4 -20

B

REM38S

B

646629

B

5/8 24

B

636344

{

3/4 -20

REM38E 628325 5/8 24

RHM38E 630049 3/4 -20

RHB37E N/A 3/4 -20

RHB32E

RHM40E

REM37BY

REM40E

BG-RB955S

634675

X

3/4 -20

X

635149

X

X

UNSHLD

X

627978

X

3/4 -20

{

655707

{

5/8 24

{

627643

{

5/8 24

{

627342

X

{

3/4 -20

X

BG-919SRS

X

627341

A-80

5/8 24

X

BG-919SR

X

626296

X

5/8 24

A-65; A-75

BG-706SR

X

530204

X

5/8 24

X

BG-706R

A-40; A-50

530744

{

5/8 24

{

BG-706

520119 5/8 24

{

530170

BG-707S

520128 5/8 24

{

UNSHLD

BG-613S

520129 5/8 24

{

530574

BG-707 SR

20902 UNSHLD

{

BARREL SIZE

CHAMPION SPARK PLUG COMPANY

5/8 24

BG-706 S 530203 5/8 24

{

TCM Part Number

BG-SU485

BG-417 N/A UNSHLD

Recommended Electrode Gap

BG-482 2305 UNSHLD

SPARK PLUG MANUFACTURER PART NUMBER

RB-485S

B. G. CORPORATION

M41E

MANUFACTURER

X

W-670; R-670

X

X

X

X

X

X

X

X

X

X

X

X

C-75; C-85

X

X

X

X

X

X

X

X

X

X

X

X

X

C-90

X

X

X

X

X

X

X

X

X

X

X

X

X

O-200-A,B,C

X

X

X

X

X

X

X

X

X

X

X

C-115; C-125

X

X

X

X

X

X

X

X

X

X

X

C-145; O-300-A,B,C,D

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

GO-300-A,B,C,D,E,F

X

X

E-165; E-185

X

E-225

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

O-470-2

X

O-470-4,11,13,13A,15

ISSUED

X

X

X

X

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

6 of 14 SIL 03-2

B

TABLE 2 SPARK PLUG APPLICATION (Continued)

654708

654709

3/4 -20

3/4 -20

RHU32S

646632 3/4 -20

RHU32E

646631 3/4 -20

RHB32S

646630 3/4 -20

RHB36S

646629 5/8 -24

RHM38S

636344 3/4 -20

REM38S

628325 5/8 -24

RHU27E

630049 3/4 -20

REM38E

N/A 3/4 -20

RHM38E

634675 3/4 -20

RHB37E

635149 UNSHLD

RHB32E

627978 3/4 -20

RHM40E

655707 5/8 -24

REM37BY

627643 5/8 -24

REM40E

627342 3/4 -20

BG-RB955S

627341 5/8 -24

BG-919SRS

626296 5/8 -24

BG-919SR

530204 5/8 -24

BG-706SR

530744 5/8 -24

BG-706R

530170 UNSHLD

BG-706

530574 5/8 -24

RB-485S

520119 5/8 -24

BG-707S

520128 5/8 -24

BG-613S

520129 5/8 -24

BG-707 SR

20902 UNSHLD

BG-SU485

530203 UNSHLD

{

{

{

{

{

{

{

{

{

{

{

{

{

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

{

Recommended Electrode Gap

BG-706 S

N/A 5/8 -24

BARREL SIZE

2305

TCM Part Number

CHAMPION SPARK PLUG COMPANY

UNSHLD

BG-482

SPARK PLUG MANUFACTURER PART NUMBER

BG-417

B. G. CORPORATION

M41E

MANUFACTURER

IO-550-A,B,C,D,E,F,L,N,P,R TSIO-550-A,B,C,E IOF-550-B,C,D,E,F,L,N,P,R

X

O-470-A,E,J,K,L,R,S

X

X

O-470-B,G,H,M,N,P

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

IO-470-C,G,R,P,T O-470-U,T IO-470-D,E,F,H,L,M,N,S,U,V

X

X

X

X

X X

X

FSO-470-A FSO-526-A,C

X

X

X

X

X

X

GSO-526-A

X

X

IO-470-J,K

X

X

IO-360-A,AB,C,CB,D,DB,E,G, GB,H,HB,J,JB,K,KB

X

X

X

X

X

X

TSIO-470-B,C,D

X

X

X

GIO-470-A

X

X

X

IO-346-A,B

X

X

LIO-470-A

X

X ISSUED

REVISED

X

X

X

X

X

X

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

7 of 14 SIL 03-2

B

TABLE 2 SPARK PLUG APPLICATION (Continued)

654708

654709

3/4 -20

3/4 -20

RHU32S

646632 3/4 -20

RHU32E

646631 3/4 -20

RHB32S

646630 3/4 -20

RHB36S

646629 5/8 -24

RHM38S

636344 3/4 -20

REM38S

628325 5/8 -24

RHU27E

630049 3/4 -20

REM38E

N/A 3/4 -20

RHM38E

634675 3/4 -20

RHB37E

635149 UNSHLD

RHB32E

627978 3/4 -20

RHM40E

655707 5/8 -24

REM37BY

627643 5/8 -24

REM40E

627342 3/4 -20

BG-RB955S

627341 5/8 -24

BG-919SRS

626296 5/8 -24

BG-919SR

530204 5/8 -24

BG-706SR

530744 5/8 -24

BG-706R

530170 UNSHLD

BG-706

530574 5/8 -24

RB-485S

520119 5/8 -24

BG-707S

520128 5/8 -24

BG-613S

520129 5/8 -24

BG-707 SR

20902 UNSHLD

BG-SU485

530203 5/8 -24

BG-706 S

N/A

Recommended Electrode Gap

UNSHLD

BARREL SIZE

2305

TCM Part Number

CHAMPION SPARK PLUG COMPANY

UNSHLD

BG-482

SPARK PLUG MANUFACTURER PART NUMBER

BG-417

B. G. CORPORATION

M41E

MANUFACTURER

{

{

{

{

{

{

{

{

{

{

{

{

{

{

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

IO-520-A,B,BA,BB,C,CB,D,E,F, J,K,L,M,MB,N,NB LIO-520-P

X

IO-360-B

X

X

X

X

X

X

X

X

L/TSIO-520-B,C,D,DB,E,EB,G, H,J,JB,K,KB,L,LB,M,N,NB,P,R, T,U,UB,VB,WB,AE,BE,CE

X

X

X

GTSIO-520-C,D,F,G,H,K,L,M,N

X

X

X

TSIO-360-A,B

X

6-285-B,C,BA,CA 6-320-B & T6-320-A

X

X

X

X

X

L/TSIO-360-A,AB,B,BB,C, CB,D,DB, E,EB,F,FB ,G ,GB, H,HB,JB,KB,LB,MB,RB,SB

X

X

TSIOL-550-A

X

TSIOL-550-B TSIOL-550-C

X

X

X

X X

IO-240-A,B; IOF-240-B

X

ISSUED

REVISED

X

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

8 of 14 SIL 03-2

B

TABLE 3 SPARK PLUG APPLICATION

X

X

X

SJ-270-P

X

X

632514

X

X

3/4 -20

A

SE-270-P

A

632513

A

5/8 -24

A

D

LJ-630

D

D

632520

LJ-310 632516

X

3/4 -20

X

LE-310

X

632515

X

5/8 -24

A-65; A-75

SJ-270

X

632512

X

3/4 -20

X

SE-270

X

632511

A-40; A-50

5/8 -24

B

SJ-230

B

632508

B

3/4 -20

B

SE-230

B

632507

B

5/8 -24

B

SJ-190

X

B

632504

SE-190 632503 5/8 -24

X

B

3/4 -20

SA-190 632501 UNSHLD

X

Recommended Electrode Gap

A-80

URHB32E 655908

X

655906

X

3/4 -20

X

655904

X

5/8 -24

X

655918

X

3/4 -20

X

655915

X

3/4 -20

3/4 -20

URHB37E

UREB37E

URHM42E

URHM38E

UREM37BY

X

656082 X

5/8 -24

UREM38E

X

655902

X

5/8 -24

URHM40E

X

655914

X

3/4 -20

D

655901

D

5/8 -24

B

655899

BARREL SIZE

RED SEAL

5/8 -24

TCM Part Number

UREM40E

SPARK PLUG MANUFACTURER PART NUMBER

UREM42E

AUTOLITE BY UNISON

3/4 -20

MANUFACTURER

A

A

A

X

X

A-100 W-670; R-670

X

X

X

C-75; C-85

X

X

X

X

X

X

X

X

X

X

X

X

C-90

X

X

X

X

X

X

X

X

X

X

X

X

O-200-A,B

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

C-115; C-125

X

X

X

C-145; O-300-A,B,C,D

X

X

X

X

X

X

GO-300-A,B,C,D,E,F

X

X

X

X

X

E-165; E-185

X

X

X

X

X

X

X

X

X

X

X

X

E-225

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

O-470-2 O-470-4,11,13,13A,15

ISSUED

X

X

X

X

X

X

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

9 of 14 SIL 03-2

B

TABLE 3 SPARK PLUG APPLICATION (Continued) MANUFACTURER

SA-190

SE-190

SJ-190

SE-230

SJ-230

SE-270

SJ-270

LE-310

LJ-310

LJ-630

SE-270-P

SJ-270-P

655908

632501

632503

632504

632507

632508

632511

632512

632515

632516

632520

632513

632514

3/4 -20

UNSHLD

5/8 -24

3/4 -20

5/8 -24

3/4 -20

5/8 -24

3/4 -20

5/8 -24

3/4 -20

3/4 -20

5/8 -24

3/4 -20

URHB32E

655906 3/4 -20

URHB37E

655904 5/8 -24

UREB37E

655918 3/4 -20

URHM42E

655915 3/4 -20

URHM38E

655902 5/8 -24

UREM38E

655914 3/4 -20

URHM40E

655901

Recommended Electrode Gap

655899

BARREL SIZE

5/8 -24

TCM Part Number

RED SEAL

5/8 -24

UREM40E

SPARK PLUG MANUFACTURER PART NUMBER

UREM42E

AUTOLITE BY UNISON

B

B

B

B

B

B

B

B

B

D

D

D

D

D

A

A

A

A

A

A

A

IO-550-A,B,C,D,E,F,L,N,P,R TSIO-550-A,B,C,E IOF-550-B,C,D,E,F,L,N,P,R

X

O-470-A,E,J,K,L,R,S

X

X

X

X

O-470-B,G,H,M,N,P

X

X

X

X

X

IO-470-C,G,R,P,T

X

X

X

X

X

O-470-U,T IO-470-D,E,F,H,L,M,N,S,U,V

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

FSO-470-A FSO-526-A,C

X

X

X

X

GSO-526-A IO-470-J,K

X

X

X

IO-360-A,AB,C,CB,D,DB,E,G, GB,H,HB,J,JB,K,KB

X

X

X

X

X

X

X

X

X X

X

X

TSIO-470-B,C,D

X

X

GIO-470-A

X

X

IO-346-A,B

X

X

X

X

LIO-470-A

X

X

X

X

ISSUED

X

X

X

REVISED

X

X

X

X

X

X

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

10 of 14 SIL 03-2

B

TABLE 3 SPARK PLUG APPLICATION (Continued)

LJ-310

632511

632512

632515

632516

5/8 -24

3/4 -20

5/8 -24

3/4 -20

B

B

D

D

D

D

A

A

A

A

IO-360-B

D

X X

X

X

X

X

X

SJ-270-P

LE-310

632508 3/4 -20

B

632514

SJ-270

632507 5/8 -24

B

3/4 -20

SE-270

632504 3/4 -20

B

SE-270-P

SJ-230

632503 5/8 -24

B

632513

SE-230

632501 UNSHLD

B

5/8 -24

SJ-190

655908 3/4 -20

B

IO-520-A,B,BA,BB,C,CB,D,E, F,J,K,L,M,MB,N,NB LIO-520-P

LJ-630

SE-190

655906 3/4 -20

B

Recommended Electrode Gap

632520

SA-190

655904 5/8 -24

URHB32E

655918 3/4 -20

URHB37E

655915 3/4 -20

UREB37E

655902 5/8 -24

URHM42E

655914 3/4 -20

URHM38E

655901

BARREL SIZE

5/8 -24

UREM38E

TCM Part Number

655899

URHM40E

RED SEAL

5/8 -24

UREM40E

SPARK PLUG MANUFACTURER PART NUMBER

UREM42E

AUTOLITE BY UNISON

3/4 -20

MANUFACTURER

A

A

A

X X

X

X

L/TSIO-520-B,C,D,DB,E,EB,G, H,J,JB,K,KB,L,LB,M,N,NB,P,R, T,U,UB,VB,WB,AE,BE,CE

X

X

GTSIO-520-C,D,F,G,H,K,L,M,N

X

X

TSIO-360-A,B

X

X

X

X

X

X

X

X

X

X

X

X

X

X

6-285-B,C,BA,CA 6-320-B & T6-320-A L/TSIO-360-A,AB,B,BB,C,CB, D,DB, E,EB,F,FB,G,GB,H,HB, JB,KB,LB,MB,RB,SB TSIOL-550-A TSIOL-550-B TSIOL-550-C IO-240-A,B; IOF-240-B ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

11 of 14 SIL 03-2

B

TABLE 4 SPARK PLUG APPLICATION MANUFACTURER

BENDIX AUTO-LITE CORPORATION

SH15

SH200A

SH26

SH260

SH150

PH26

PH260

SL300A

SL350

PL350

632460

632461

632462

632463

632467

635146

635147

627991

632465

635148

632274

5/8 -24

3/4 -20

5/8 -24

3/4 -20

3/4 -20

3/4 -20

5/8 -24

3/4 -20

3/4 -20

3/4 -20

UNSHLD

A

E

A

A

A

E

A

A

A

A

A

E

A-65; A-75

X

X

X

A-80

X

X

X

X

X

TCM Part Number

BARREL SIZE

Recommended Electrode Gap

H15

SH20A 627892

5/8 -24

SPARK PLUG MANUFACTURER PART NUMBER

A-40; A-50

A-100 W-670; R-670

X

X

C-75; C-85

X

X

X

C-90

X

X

X

O-200-A,B,C

X

X

C-115; C-125

X

X

X

C-145; O-300-A,B,C,D

X

X

X

GO-300-A,B,C,D,E,F

X

E-165; E-185

X

X

X

E-225

X

X

X

X

X

X

X

X

X

X

O-470-2 O-470-4,11,13,13A,15

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

12 of 14 SIL 03-2

B

TABLE 4 SPARK PLUG APPLICATION (Continued) MANUFACTURER

632274 UNSHLD

H15

635148 3/4 -20

PL350

632465 3/4 -20

SL350

627991 3/4 -20

SL300A

635147 5/8 -24

PH260

635146 3/4 -20

PH26

632467 3/4 -20

SH150

632463 3/4 -20

SH260

632462 5/8 -24

SH26

632461 3/4 -20

SH200A

632460 5/8 -24

SH15

627892

BARREL SIZE

5/8 -24

TCM Part Number

SH20A

SPARK PLUG MANUFACTURER PART NUMBER

BENDIX AUTO-LITE CORPORATION

Recommended Electrode Gap IO-550-A,B,C,D,E,F,L,N,P,R TSIO-550-A,B,C,E IOF-550-B,C,D,E,F,L,N,P,R

A

E

A

A

A

E

A

A

A

A

A

E

O-470-A,E,J,K,L,R,S

X

O-470-B,G,H,M,N,P

X

X X

IO-470-C,G,R,P,T

X

X

X

X

O-470-U,T IO-470-D,E,F,H,L,M,N,S,U,V

X

X

FSO-470-A FSO-526-A,C

X

GSO-526-A IO-470-J,K

X

X

IO-360-A,AB,C,CB,D,DB,E,G, GB,H,HB,J,JB,K,KB

X

X

TSIO-470-B,C,D

X

GIO-470-A

X

IO-346-A,B

X

LIO-470-A ISSUED

X

X

X

X

X

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

13 of 14 SIL 03-2

B

TABLE 4 SPARK PLUG APPLICATION (Continued) MANUFACTURER

A

H15

PL350

A

A

A

E

X

X

X

X

IO-520-A,B,BA,BB,C,CB,D,E,F, J,K,L,M,MB,N,NB LIO-520-P IO-360-B

SL350

SL300A

632274

A

UNSHLD

E

635148

A

3/4 -20

A

632465

A

3/4 -20

635147 5/8 -24

E

627991

635146 3/4 -20

A

Recommended Electrode Gap

3/4 -20

632467 3/4 -20

PH260

632463 3/4 -20

PH26

632462 5/8 -24

SH150

632461 3/4 -20

SH260

632460

BARREL SIZE

5/8 -24

SH26

627892

SH200A

TCM Part Number

5/8 -24

SH20A

SPARK PLUG MANUFACTURER PART NUMBER

SH15

BENDIX AUTO-LITE CORPORATION

X

L/TSIO-520-B,C,D,DB,E,EB,G, H,J,JB,K,KB,L,LB,M,N,NB,P,R, T,U,UB,VB,WB,AE,BE,CE GTSIO-520-C,D,F,G,H,K,L,M,N TSIO-360-A,B

X X

X

X

X

6-285-B,C,BA,CA 6-320-B & T6-320-A L/TSIO-360-A,AB,B,BB,C,CB, D,DB, E,EB,F,FB,G,GB,H,HB, JB,KB,LB,MB,RB,SB TSIOL-550-A TSIOL-550-B TSIOL-550-C IO-240-A,B; IOF-240-B ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

02

07

2003

10

26

2004

P.O. Box 90 Mobile Alabama • 251-438-3411

14 of 14 SIL 03-2

B

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 5

SERVICE INFORMATION LETTER SIL04-12 Technical Portions FAA APPROVED

Contains Useful Information Pertaining To Your Aircraft Engine SUBJECT:

TCM AUTHORIZED ENGINE ADJUSTMENTS, COMPONENT REPLACEMENT AND REPOSITIONING OF FITTING ORIENTATION

PURPOSE:

To provide authorization to FAA approved TCM OEM and STC Converter customers for performing specific engine adjustments, component replacements and repositioning fitting orientation.

COMPLIANCE:

As required at the time of OEM or STC Converter engine build up, installation or operational adjustment to insure compliance with airworthiness standards

MODELS AFFECTED:

All

Teledyne Continental Motors supplies engines to aircraft Original Equipment Manufacturer’s (OEM) and STC Converters. These engines have been assembled, tested and inspected in accordance with Teledyne Continental Motors FAA approved quality system standards and FAA issued Production Certificate. Normally, only minor adjustments to the engine fuel system will be necessary at engine installation. Reference the latest revision of TCM SID97-3. Occasionally, minor adjustment may be necessary to other engine systems, components and to position fittings for best line and hose routing and fit. Teledyne Continental Motors authorizes those OEM and STC Converter Facilities that meet the requirements of Part A to perform the adjustments and component replacements listed below. PART A: Teledyne Continental Motors hereby authorizes the specified adjustment and component replacements listed in this Service Information Letter to OEM and STC Converters who are approved by the FAA as an aircraft production facility or FAA Approved modification facility. Personnel performing the specified adjustment and component replacements must be a licensed Airframe and Power Plant mechanic or be approved by the OEM or STC Converter facilities quality assurance to be capable of performing the specific task. Work shall be performed in accordance with applicable continued airworthiness instructions including but not limited to the engine Maintenance Manual, Overhaul Manual, Fuel Injection Manual, Service Bulletins, Service Information Letters, Service Information Directives and Special Service Instructions. All work performed in accordance with this Service Information Letter must be documented by the individual performing the task on the OEM or STC Converters FAA approved Quality Inspection Document and traceable by engine and aircraft serial numbers.

ISSUED

REVISED

MO

DAY

YEAR

10

29

2004

MO

DAY

YEAR

© 2004 Teledyne Continental Motors, Inc.

PAGE NO TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama • 251-438-3411

1 of 2 SIL04-12

REVISION

PART B: Adjustments and or replacements accomplished in accordance with this SIL must be documented by the OEM on the aircraft production paper work. Additionally, the OEM must provide Teledyne Continental Motors notification of adjustments and replacements accomplished in accordance with this SIL via Teledyne Continental Motors TCM Link OEM/Converter Services. If a component part is replaced, the OEM must provide the part number and serial number of the component removed and the part number and serial number of the component installed. The removed component is to be returned to Teledyne Continental Motors via the OEM/Converter RGA System. Authorized adjustments and component replacements: Adjustments: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Fuel, oil, reference air fitting orientation Routing of flexible lines Attachment and supporting of fluid lines and hoses Baffles and baffles seal Magneto orientation (positioning) Magneto timing to engine Fuel inspection system adjustment (latest revision of SID97-3-currently SID97-3B) Accessory drive belts Engine control cable attach/support brackets Induction system hose clamps Worm screw clamps

Replacements: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Alternator Baffles Magnetos Magneto harness Magneto sensors Spark plugs Starter motor Starter Adapter Assembly Oil pump Induction system components Exhaust system components Turbochargers and turbocharger system components Fuel pump Throttle body and control assembly Manifold valve Fuel nozzles Fuel nozzle lines Oil filters Oil screens Oil lines and hoses Oil coolers and adapter plates Oil sump and gasket Engine mount legs

ISSUED

REVISED

MO

DAY

YEAR

10

29

2004

MO

DAY

YEAR

PAGE NO TM

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama • 251-438-3411

2 of 2 SIL04-12

REVISION

®

TELEDYNE CONTINENTAL

Category 5

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER CONTAINS USEFUL INFORMATION PERTAINING TO THE CONTINENTAL AIRCRAFT ENGINE

SIL04-1A Technical Portions are FAA Approved

SUBJECT:

Installation of the Optional Altitude-Compensating Fuel Pump on IO240-B Series Engines.

PURPOSE:

To provide instructions for the installation of the altitude compensating fuel pump on IO-240-B series engines.

COMPLIANCE: Optional MODELS AFFECTED: REASON FOR REVISION:

All IO-240-B series engines

Introduction of new assemblies and revised system setup.

GENERAL Teledyne Continental Motors has approved the altitude compensating fuel pump for installation on the IO-240-B-series engines. The altitude compensating fuel pump is compatible with the standard fuel system or with the optional fuel manifold valve scavenge system installation. (Please reference the latest revision of SIL05-5 for information on the manifold valve fuel scavenge system.) The altitude compensating fuel pump installation is at the owner/operators discretion and is not mandatory, however compliance is recommended for aircraft operated at high density altitude airports or in high ambient temperature operations. The following installation and fuel system set-up procedures must be followed when installing the altitude compensating fuel pump. INSTALLATION INSTRUCTIONS (A) PREPARATION: 1. Remove the upper and lower engine cowlings from the aircraft.

WARNING Magnetos must be verified to be grounded and fuel to be selected to the off position when moving the propeller by hand, or personal injury may result. 2. Remove electrical power from the aircraft. 3. Shut off the fuel supply to the engine by closing the fuel shutoff valve. ISSUED

REVISED

MO

DAY

YEAR

MO

DAY

YEAR

02

12

2004

05

31

2005

PAGE NO REVISION TM

Teledyne Continental Motors, Inc.

© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

1 of 3 SIL04-1

A

4. Remove the forward baffle assembly. If a belt driven standby alternator is installed, removal of the alternator will be required to facilitate removal of the baffle assembly. CAUTION . . . Attempting to remove the forward baffle assembly without removing the standby alternator, or attempting to replace the fuel pump assembly without completely removing the forward baffle assembly, may result in damage to the forward baffle assembly. (B) FUEL PUMP INSTALLATION PROCEDURES 1) Remove the standard fuel pump assembly using the instructions contained in the latest revision of the IO-240 Overhaul Manual Form X30622A Section 9. Remove and retain the fuel pump drive shaft for re-installation in step 3, if serviceable. Fuel pump shafts found to be unserviceable must be replaced. 2) Install the altitude compensating pump assembly P/N 649368-49A1 in accordance with the instructions contained in the latest revision of the IO-240 Overhaul Manual Form X30622A section 19-5. (Reference Figure 1) CAUTION . . . The ambient pressure reference fitting must be clear and unobstructed. (Reference Figure 1) 3) Contact the Airframe Manufacturer for the aneroid vent line assembly parts and installation instructions. 4) Contact the airframe manufacturer for rework or replacement instructions for the front baffle assembly. After replacement or rework, reinstall the baffle assembly (and standby alternator, if installed) using the airframe manufacturers maintenance instructions. 5) Contact the airframe manufacturer for replacement mixture control cable or the appropriate mixture control cable rework instructions. After rework or replacement, connect and adjust the mixture control cable in accordance with the airframe manufacturer’s maintenance instructions. (C) SYSTEM TEST 1) Open the fuel shutoff valve and static leak check the fuel system. Correct any defects noted before proceeding to the next step. 2) Restore electrical power to the aircraft. Using the fuel boost pump, leak-check the fuel system. Correct any defects noted before proceeding to the next step.

WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

12

2004

05

31

2005

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

2 of 3 SIL04-1

A

(D) FUEL SYSTEM SETUP 1) Perform the fuel system setup, verification and test flight in accordance with the procedures contained the latest revision of TCM bulletin SID97-3 and the instructions contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. CAUTION . . . You must ensure that the setup and verification procedure selected is appropriate to the type of fuel manifold valve installed on the engine

FIGURE 1 ALTITUDE COMPENSATING (ANEROID) FUEL PUMP

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

02

12

2004

05

31

2005

Teledyne Continental Motors, Inc. P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

3 of 3 SIL04-1

A

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

SERVICE INFORMATION LETTER

CATEGORY 5 SIL04-2 Technical Portions FAA Approved

Contains Useful Information Pertaining To Your Aircraft Engine

SUBJECT:

Cylinder Barrel Ultrasonic Inspection

PURPOSE:

To Clarify the Requirement For Cylinder Barrel Ultrasonic Inspection

COMPLIANCE: At Cylinder Removal MODELS AFFECTED:

All

Several Teledyne Continental Motors maintenance and overhaul manuals indicate a requirement for ultrasonic inspection of the cylinder barrel. TCM would like to clarify the inspection requirement with the following guidelines: 1) Cylinder part numbers specified in TCM Mandatory Service Bulletin M91-7 must have the ultrasonic inspection of the barrel performed in accordance with the instructions contained in the bulletin. 2) Cylinders not specified in Service Bulletin M91-7 do not have a routine ultrasonic inspection requirement at this time. These cylinders should be inspected in accordance with all other inspection requirements contained in the applicable maintenance or overhaul manual and TCM Service Bulletin SB96-12. This bulletin contains Continued Airworthiness Instructions for TCM cylinders. This information will be incorporated in the next revision of the affected manuals.

ISSUED MO 03

DAY 25

REVISED YEAR 2004

MO

DAY

YEAR

© 2004 Teledyne Continental Motors, Inc.

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

1 of 1 SIL 04-2

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL 04-3A

Contains Useful Information Pertaining to the Continental Aircraft Engine

FAA APPROVED

SUBJECT: IO240B Fuel Line Replacement and Rerouting. PURPOSE: Reroute the manifold valve to throttle body fuel line.

COMPLIANCE:

Optional

MODELS AFFECTED: IO240B-Series Engines Reason For Revision: Updated Part Number

GENERAL INFORMATION To improve the line routing, Teledyne Continental Motors has revised the installation of the fuel line running from the engine fuel system throttle body assembly to the manifold valve assembly on current production engines. The owner, at his option, may have the following procedure accomplished.

DETAILED INSTRUCTIONS 1) Secure the aircraft for maintenance and remove the upper cowling in accordance with the airframe manufacturer’s instructions. Remove electrical power from the aircraft and ensure the magneto switch is in the off position. 2) Close the fuel shut-off valve in accordance with the instructions included in the Diamond Aircraft Flight Information Manual. 3) Remove the existing fuel line P/N 646644S4S15.00 and discard. (Figure 1) 4) Remove the 90-degree fitting, P/N MS51521B4, from the throttle body assembly and discard. (Figure 1) 5) Remove the P/N 628436 fitting from the manifold valve fuel inlet, reference Figure 2. Clean the removed fitting in Stoddard Solvent PS-661, or equivalent. Reinstall the fitting in the manifold valve assembly to the position shown in Figure 3 using TCM P/N 646940 fuel injection sealant or equivalent, reference the latest revision of TCM Service Instruction Letter SIL99-2.

CAUTION Never use teflon tape on fluid fittings or fuel nozzles. ISSUED MO 02

DAY 12

REVISED YEAR 2004

MO 06

DAY 18

YEAR 2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc.

1 of 3

PO Box 90 Mobile AL • 251-438-3411

SIL04-3

A Teledyne Technologies Company

© 2004 TELEDYNE TECHNOLOGIES, INC.

A

Detailed Instructions (con’t)

6) Install new P/N 646644S4Y11.50 fuel line, routing the fuel line on top of the intake tubes as shown in Figure 4. Fittings should be torqued in accordance with the instructions contained in the latest revision of bulletin SB96-7.

CAUTION Ensure that the intake tube hose clamp ends are NOT touching the fuel line. 7) Reconnect the aircraft electrical system IAW the aircraft manufacturers instructions. Open the fuel shutoff valve and prime the engine in accordance with the procedures contained in the aircraft manufacturers flight manual. Inspect the fuel line for leakage. If no leakage is noted, test run the engine using the instructions in the aircraft manufacturers flight manual. Inspect the fuel line for leakage. If no leakage is noted, reinstall the engine cowlings.

8) Make an appropriate log entry documenting compliance with SIL04-3A. NOTE Re-routing of the original P/N 646644S4S15.00 fuel line does not constitute compliance with this Service Instruction.

WARRANTY

This is a product improvement installed at the owner’s option; therefore warranty is not applicable for this bulletin.

ISSUED MO 02

DAY 12

REVISED YEAR 2004

MO 06

DAY 18

YEAR 2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc.

2 of 3

PO Box 90 Mobile AL • 251-438-3411

SIL04-3

A Teledyne Technologies Company

© 2004 TELEDYNE TECHNOLOGIES, INC.

A

Current fuel line

45 degree fitting

Remove 90degree fitting

Figure 1

Figure 2

New routing of fuel line

New position of 45-degree fitting

Figure 3

ISSUED MO 02

DAY 12

Figure 4

REVISED YEAR 2004

MO 06

DAY 18

YEAR 2004

PAGE NO REVISION TM

Teledyne Continental Motors, Inc.

3 of 3

PO Box 90 Mobile AL • 251-438-3411

SIL04-3

A Teledyne Technologies Company

© 2004 TELEDYNE TECHNOLOGIES, INC.

A

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 5

SERVICE INFORMATION LETTER

SIL04-8

Contains Useful Information Pertaining To Your Aircraft Engine

Technical Portions FAA Approved

SUBJECT:

OPTIONAL REPLACEMENT STARTER FOR IO-240-Series ENGINES

PURPOSE:

To provide removal and installation instructions for P/N 655957 Starter Assembly

COMPLIANCE:

Optional

MODELS AFFECTED:

IO-240-Series series engines

GENERAL INFORMATION: TCM has production released a new starter assembly for the IO-240–Series engine. Starter assembly P/N 655957 (B & C P/N BC320-1) replaces Starter Assembly P/N 654046, P/N 655551 and P/N 634464 starter motor and P/N 641500 clutch assembly. Engines with B & C starter P/N BC320-1 installed are not affected by this Service Information Letter. This Service Information Letter provides: 1. Instruction for the removal of starter assembly P/N 654046, P/N 655551, and Starter motor and drive clutch assembly P/N 634464 and P/N 641500. 2. Inspection of the crankshaft cluster gear and, if required, replacement of the crankshaft cluster gear. 3. Installation instructions for the new starter assembly P/N 655957, contained in kit part number EQ7371. NOTE: It is recommended that this bulletin be performed in conjunction with the latest revision of SB04-7 “IO-240-Series Crankshaft Cluster Gear inspection and Replacement” and SB03-7 “IO-240Series Magneto Drive Gear”, if applicable.

STARTER SYSTEM OVERVIEW: Lightweight starter assembly P/N 655957 (B & C P/N BC 320-1) is an intermittent mesh unit, which upon energizing extends a pinion gear to engage a driven gear secured to the engine crankshaft (crankshaft cluster gear). Because of the nature of the gear engaging operation, the starter pinion gear and engine crankshaft cluster gear faces will wear slightly until a break-in condition is achieved. Refer to Inspection Overview and Inspection Instructions section on page 3 and 4 of this SIL for additional information and serviceability criteria.

WARRANTY: This bulletin is at the owner / operators option, therefore warranty is not applicable.

ISSUED

REVISED

PAGE NO REVISION TM

MO 06

DAY 18

YEAR 2004

MO

DAY

YEAR

© 2004 Teledyne Continental Motors, Inc.

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

1 of 6 SIL04-8

REMOVAL INSTRUCTION: 1. Remove upper cowling, in accordance with the aircraft manufacturer’s instructions. 2. Remove the electrical connection at starter solenoid terminal stud on the starter drive assembly. 3. Remove fuel injection system manifold valve, in accordance with the aircraft and engine manufacturer’s instructions. 4. Reference Figure1. Remove attaching hardware (3 through 5). Discard items 3 and 4. Loosen and remove bolts, item number 7, from starter drive assembly housing, accessory case and engine lifting eye. It will be necessary to replace bolts P/N 538999 with bolts P/N 630966-4.00 (item number 7, figure 1) if removing the P/N 634464 starter motor and P/N 641500 clutch assembly. Slightly bump the starter by hand to break the gasket adhesion. Carefully remove the starter (2) and clutch if installed. Remove and discard the gasket (1).

FIGURE 1 Typical Starter Drive Assembly Installation (P/N 634464 starter motor and 641500 clutch not shown) FIGURE & INDEX 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8

PART NUMBER 653673 654046/655551 538600 MS35338-45 AN315-5R AN960-516 630966-4.00 653889

ISSUED

DESCRIPTION Gasket, Starter Starter Drive Assembly Washer, Seal: .304 x .625 x .050 Washer, Lock: .3125 Nut, Plain .31-24 Washer, Plain .31 x .063 Thick Bolt: .31-18 x 4.00 Eye-lifting

REVISED

QUANTITY 1 1 3 5 3 6 2 1

PAGE NO REVISION TM

MO 06

DAY 18

YEAR 2004

MO

DAY

YEAR

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

2 of 6 SIL04-8

INSPECTION OVERVIEW: Inspection of the crankshaft cluster gear is recommended whenever the starter drive assembly is removed. The following information and photographs will provide inspection criteria for acceptable and unacceptable wear patterns and conditions of the crankshaft cluster gear.

INSPECTION INSTRUCTIONS - ENGINE CRANKSHAFT CLUSTER GEAR: 1. Ensure that the ignition switch is OFF and the magnetos are properly grounded so that engine ignition cannot occur. 2. With the starter assembly removed, use a flashlight to visually inspect the crankshaft cluster gear through the starter assembly mounting hole in the rear of the accessory case. 3. Inspect the larger of the two gears in accordance with the criteria listed below in items 4 and 5. After inspection of the visible area of the gear tooth surface is complete, slowly rotate the engine so that the next portion of the gear is available for inspection. Repeat the process until a full 360° of rotation is achieved and all gear tooth surfaces have been inspected.

PHOTOGRAPH 1

PHOTOGRAPH 2

4. Photographs 1 and 2 show two examples of normal wear signatures for the crankshaft cluster gear. There will be visible signs of polishing to the contact surfaces of the larger gear teeth that receive initial contact from the pinion gear during start. The wear should be generally even and consistent around the entire circumference of the gear. The IO-240-B3B engine as installed in the Diamond DA20-C1 has a tendency to stop in one of two positions so there may be two areas, 180° apart on the gear face, which show more wear than that of adjacent areas as in Photo 2. This wear pattern is normal and should not be confused with damaged gear teeth as shown in Photographs 3 and 4.

ISSUED

REVISED

PAGE NO REVISION TM

MO 06

DAY 18

YEAR 2004

MO

DAY

YEAR

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

3 of 6 SIL04-8

PHOTOGRAPH 3

PHOTOGRAPH 4

5. Photograph 3 and 4 show abnormal wear on a crankshaft cluster gear. There will be extremely rough areas with damage to the tooth surfaces and the surrounding gear areas. In some circumstances portions of teeth may be broken away from the gear. The most extreme cases may have whole teeth missing. If the damage is considered abnormal without complete teeth missing, replace the cluster gear in accordance with the instructions contained in the applicable sections of the IO-240-B Overhaul Manual (X30622A). Please note in Section 18-6 of the Overhaul Manual that the crankshaft cluster gear must be heated to a temperature of 325° to 350° F (163° C - 177° C) for one hour just prior to installation. If the cluster gear is missing one or more complete teeth, please contact Teledyne Continental Motors Customer Service Department directly at 1-888-826-5465 or 1-251-438-3411. WARNING Do not heat the cluster longer than the time specified. Damage to the gear will result, and possible engine failure may occur.

PARTS REQUIRED FOR CRANKSHAFT CLUSTER GEAR REPLACEMENT: In addition to the parts required for starter replacement, the following parts are required for crankshaft cluster gear replacement. QTY (1)

TCM P/N 656762

DESCRIPTION Cluster Gear

LOCATION Bolted to Crankshaft aft face

(4)

22532

Bolt, Cluster Gear

Bolts cluster gear to crankshaft

(1)

652272

Gasket

Accessory case to crankcase

(1)

652238

Gasket

Alternator mounting

(1)

653673

Gasket

Starter mounting

(2)

10-400613

Gasket

Magneto mounting

.032 MS20995 Condition “A” Lockwire, as required

NEEDLE BEARING REMOVAL AND PLUG INSTALLATION INSTRUCTIONS FOR ENGINES WITH P/N 634464 STARTER MOTOR AND P/N 641500 DRIVE CLUTCH ASSEMBLY: 1. Remove existing needle bearing P/N 633609-8 using a ½ inch expandable bushing/bearing puller and slide hammer. Refer to Figure 2 below. 2. Clean bearing bore with Loctite cleaner P/N 7070. ISSUED

REVISED

PAGE NO REVISION TM

MO 06

DAY 18

YEAR 2004

MO

DAY

YEAR

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

4 of 6 SIL04-8

3. 4. 5. 6. 7.

Screw a .375-16 UNC-2B bolt 3 inches in length into plug P/N 654029. Coat exterior circumference of special plug P/N 654029 with Loctite P/N 222. Tap plug P/N 654029 in bearing cavity. Insure that plug is bottomed in cavity. Remove .375-16 UNC-2B bolt from plug. Proceed to next section to complete installation of P/N 655957 starter assembly.

Remove Needle Bearing P/N 633609-8 Install Plug P/N 654029

Starter Assembly 655957

P/N 401834 studs set to height of 1.33 to 1.37 inches 3 each) FIGURE 2 When replacing the P/N 634464 starter motor and P/N 641500 clutch assembly with the P/N 655957 starter assembly the items listed below in Table 1 will be required. TABLE 1 PART NUMBER DESCRIPTION QUANITY 654029 * Plug 1 401834 * Stud 3 630966-4.00 * Bolt 2 The items listed below in Table 2 are required when installing the P/N 655957 (B & C P/N BC 320-1) starter assembly. TABLE 2 PART NUMBER DESCRIPTION QUANITY 655957 * Starter Assembly 1 653673 * Gasket 1 538600 * Washer, Seal 3 22535 * Spacer 3 MS35338-45 * Washer, Lock 5 AN315-5R Nut, Plain 5

ISSUED

REVISED

PAGE NO REVISION TM

MO 06

DAY 18

YEAR 2004

MO

DAY

YEAR

Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

5 of 6 SIL04-8

*

Items included in EQ 7371

P/N 655957 STARTER ASSEMBLY INSTALLATION INSTRUCTIONS: If no abnormal wear, or other distress to the crankshaft cluster gear is present, install the new starter drive assembly according to the following instructions. Reference Photo 5. 1. Install a new starter gasket P/N 653673 on the accessory case. 2. Align starter assembly P/N 655957 with the accessory case studs. Position the starter assembly so that the 3 o’clock stud (shown in Photo 5) extends through the housing sufficiently to place the P/N 538600 Seal Washer, P/N 22535 Spacer, P/N MS 35338-45 Lock Washer and P/N AN315-5R Plain Nut. Start the nut onto the stud threads and then seat the starter assembly against the gasket. Install hardware on the remaining mount studs in the order listed above. Do not tighten hardware at this time. 3. Secure the upper portion of the starter assembly to the accessory case by installing two P/N 630966-4.00 bolts, lock washers, flat washers and lifting eye. Reference Figure 1, items 4,6,7 and 8. 4. Torque nuts to 180-220 inch pounds of torque. Torque bolts to 180-220 inch pounds of torque. 5. Install the electrical connection at starter terminal on the starter assembly and torque to 65 to 75 inch pounds. A new starter lead may be required. If a new starter lead is required, contact the airframe manufacturer for the replacement lead.

P/N 653673 GASKET

P/N 538600 WASHER, SEAL P/N AN315-5R NUT, PLAIN

P/N 22535 SPACER P/N MS35338-45 LOCK WASHER

PHOTO 5 PN 655957 STARTER ASSEMBLY

LOG BOOK ENTRY: Make a logbook entry indicating removal of existing starter assembly and installation of P/N 655957 starter assembly in accordance with this bulletin SIL04-8. ISSUED

REVISED

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Teledyne Continental Motors, Inc. A Teledyne Technologies Company

PO Box 90 Mobile AL • 251-438-3411

6 of 6 SIL04-8

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SIL 04-9 Technical Portions FAA Approved Supercedes SIL04-3A

SUBJECT:

IO240B13B Manifold Valve Replacement, Heat Isolation Modifications and Throttle Body Modification.

PURPOSE:

To reduce heat on the engine fuel system components and enhance idle stability

COMPLIANCE: MODELS AFFECTED:

Optional All IO240B13B Engines and any IO240B-Series engine which has previously complied with SIL04-1 “Installation of the Altitude Compensating Pump”.

PART 1 MANIFOLD VALVE REPLACEMENT AND HEAT ISOLATION MODIFICATIONS Teledyne Continental Motors has introduced fuel system product enhancements in order to reduce the possibility of heat build up in the engine fuel system components. The changes include a new manifold valve assembly installed on a heat-insulating manifold valve mount assembly. The existing Diamond Aircraft® fuel pressure transducer will be relocated. In order to enhance idle stability, a modification to drill an air bleed hole in the throttle plate has been introduced. REQUIRED PARTS (1) TCM has issued kit EQ 7462 in support of this bulletin. Contents of the kit are as follows: Part Number Nomenclature Quantity 656832-1A1 Manifold Valve assembly 1 656849 Bracket Assembly – Fuel Manifold Valve 1 656839 Plate – Isolator 1 656840 Spacer 3 AN500-8-12 Screw- Isolator to Mount Assembly 2 AN500-8-18 Screw- Manifold Valve to Isolator Assembly 3 AN960-8 Washer 8 MS21044N08 Nut, Self Locking 3 646644R4S13.00 Hose- Throttle Body Outlet to “Tee” Fitting 1 MS51513B4 “Tee” Fitting- Pressure Transducer 1 646644S4S8.50 Hose- “Tee” Fitting to Manifold Valve 1 MS21919WF27 Clamp, Cushioned 1 MS21919WCF10 Clamp, Cushioned 1 AN3-4A Bolt 1 AN960-10 Washer, Flat 1 MS21044N3 Nut, Self Locking 1 653900 Gasket, Throttle Body 1 656842 Twist Drill, .161 Dia. 1 ISSUED

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© 2004 Teledyne Continental Motors, Inc.

Part Number 656837 (2) (a) (b) (c) (d) (e) (f) (g) (h)

Nomenclature Template, Throttle Plate

Quantity 1

Additional Parts Required for Aft Baffle Assembly Repair: 22-2441-62-01 Blanking Plate 1 Each (Procure from Diamond Aircraft) BSPQ-50-02 Cherry Q Rivets 2 Each (Local Procure) AN960-8 Washer 2 Each (Local Procure) MS21919WDG12 Clamp 1 Each (Local Procure) MS21919WDG2 Clamp 1 Each (Local Procure) AN526-832R8 Screw 1 Each (Local Procure) AN960-8 Washers 2 Each (Local Procure) AN365-832 Self Locking Nut 1 Each (Local Procure)

PART 1 MANIFOLD VALVE REPLACEMENT AND HEAT ISOLATION MODIFICATIONS (1) Referring to the airframe manufacturers maintenance instructions: WARNING Magnetos must be verified to be in the off position and grounded and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. (a) Remove electrical power from the aircraft. (a) Remove the upper engine cowling from the aircraft. (b) Shut off the fuel supply from the engine by closing the fuel shutoff valve. (2) Remove the fuel pressure transducer and retain for re-installation. Remove the existing fuel pressure transducer hose and discard. Remove and retain the grommet from the aft baffle installation and retain for re-installation. (3) Using one blanking plate P/N 22-2441-62-01, two Cherry Q rivets P/N BSPQ-05-02 and two AN960-8 washers, plug the existing hole in the RH aft baffle assembly. (The washers are to be placed under the shop head of the cherry rivets prior to pulling the rivets) (4) Referring to the latest revision of the X30622 IO240 Series Overhaul Manual, Section 9, remove the existing fuel system manifold valve assembly, the manifold valve bracket assembly, and the fuel injector lines. Retain the manifold valve assembly and mounting bracket for core return to TCM. Retain the fuel injector lines for reinstallation. (5) Remove the existing fuel line from the throttle and control unit to the manifold valve assembly (P/N 646644S4S15.00 pre SIL04-3 or 646644S4Y11.50 post SIL04-3) and discard. (6) Measure 4 inches horizontally from the outboard edge of the LH aft baffle and place a vertical mark at this location. Measure vertically down 1.250 inches from the top of the aft baffle at the previously marked 4inch location and place a horizontal mark. Inspect the marked location for interference with the oil cooler duct or baffle rivets. If location is satisfactory, drill a 7/8 inch hole at this location. A Uni-bit® is recommended for the drilling operation. (7) Install the previously retained fuel pressure switch transducer rubber grommet into the new hole in the LH aft baffle. (8) Install the new 656849 manifold valve bracket on the engine using the previously retained AN4-14A bolts, 20522 washers and 646605 plain nuts. The bolt threads must be lubricated with 50 weight motor oil and the nuts torqued to 100-125 In-Lbs. (9) Install the new 656839 isolator assembly to the 656849 bracket assembly using 2 each P/N AN500-8-12 screws and AN960-8 washers. Torque the screws to 17.5 – 22.5 In-Lbs. (10) Install the new 656832-1A1 manifold valve assembly to the isolator plate using 3 each 656840 spacers, AN500-8-18 screw, AN960-8 washers and MS21044N08 self locking nuts. Torque the nuts to 17.5 – 22.5 In-Lbs. (11) Install the retained fuel pressure transducer from the aft side of the LH aft baffle through the rubber grommet into the MS51513B4 “T” fitting center port. Reference the airframe manufacturer’s manual for proper torque. ISSUED

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(12) Reroute the two fuel pressure transducer electrical wires from their existing routing on the RH side of the engine mount to their new position on the aft side of the LH baffle. Cut tywraps holding transducer wires in place on wire bundle across firewall. Open up adel clamps on wire bundle as required to free up transducer wires for rerouting under adel clamps on the RH side of the bundle with sufficient length to reach the new location of the transducer. Secure any excess wire to the wire bundle using tywraps. Secure the wires to the upper LH engine mount strut with one MS21919WDG12 clamp on the engine mount strut and one MS21919WDG2 clamp around the fuel pressure transducer wires, secured with one AN526832R8 screw, two AN960-8 washers and one AN365-832 lock nut. (13) Reinstall the previously removed fuel injector lines. Torque the fitting at the manifold valve to 55-60 In-Lbs. Torque the fitting at the fuel injector nozzle to 40-45 In-Lbs. (14) Install the 646644R4S13.00 hose assembly from the throttle and control assembly to the outboard connection of the fuel pressure transducer “Tee” fitting. Install the 646644S4S7.00 hose assembly from the fuel pressure transducer “Tee” fitting to the manifold valve inlet fitting. Torque newly installed hose connections to 100-140 In-Lbs. (15) Position the “Tee” fitting snug against the rubber grommet in the baffle assembly. Clamp the 646644R4S13.00 line to the #2 intake tube using one MS21919WF27 clamp, one MS21919WCF10 clamp, one AN3-4A bolt, one AN960-10 washer and one MS21044N3 nut. Position the clamp so that the “Tee” fitting retains it’s position snug against the rubber grommet. (16)

Proceed to Part 2 of this bulletin.

FIGURE 1 AN500-8-18 Screw AN960-8 Washer MS21044N08 Nut 3 places 656839 Isolator 656840 Spacer 3 Places

AN500-8-12 Screw AN960-8 Washer

656849 Bracket

Manifold Valve and Heat Isolator Assembly

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646644S4S7.00 Hose

MS51513B4 “Tee”

646644R4S13.00 Hose

PHOTO 1

Pressure Transducer Clamp Installation

PHOTO 2

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PART 2 THROTTLE PLATE MODIFICATION In order to further enhance engine idle characteristics, Teledyne Continental Motors has introduced a modification to the throttle plate located in the fuel injection system Throttle and Control Assembly. This modification utilizes a drill guide template to allow precise placement of a hole in the throttle plate. MODIFICATION INSTRUCTIONS (1) Referring to the airframe manufacturers maintenance instructions: WARNING Magnetos must be verified to be in the off position and grounded and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. (a) Remove electrical power from the aircraft. (b) Remove the upper engine cowling from the aircraft. (c) Shut off the fuel supply from the engine by closing the fuel shutoff valve. (2) Remove the Throttle and Control Unit using the instructions contained in the latest revision of the IO240Series Overhaul Manual X30622. Retain the removed hardware for re-installation, discard the gasket. (Reference Figure 1) (3) Support the Throttle and Control Assembly with the flange on a suitable flat work surface. CAUTION Do not clamp the Throttle and Control assembly in a vise. Damage to the Throttle and Control Assembly may result. (4) With the throttle lever in the closed position, insert the P/N 656837 drill guide template into the induction end of the Throttle and Control Assembly, matching the angle of the template to the angle of the throttle plate. (Reference Figure 2) (5) Use drill guide hole as shown in Figure 2 to drill through the throttle plate using the P/N 656742 twist drill. A slight downward pressure on the drill template will keep the template properly seated against the throttle plate during the drilling operation. After the drilling procedure is completed remove all burrs, metal shavings and contaminants. (6) Reinstall the throttle and control assembly using a new P/N 653900 gasket in accordance with the procedures contained in the overhaul manual. Torque the retaining nuts to 90-100 In-LBS, using 50 weight engine oil as thread lubricant. (7) Restore electrical power to the aircraft and open the fuel supply valve. Using the boost pump, leak check the fuel system. Correct any discrepancies before the engine is operated. WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage of failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinder prior to engine start. (8) Perform the fuel system setup in accordance with the procedures contained in the latest revisions of SID97-3 and the IO240 Engine Maintenance Manual. (9) Restore the aircraft to it’s original configuration by reinstalling all airframe parts removed in step 1 using the airframe manufacturers maintenance manual. (10) Make appropriate log entries for compliance with this bulletin.

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FIGURE 2 INDUCTION SYSTEM ON IOF-240-B3B, B9B & B13B SERIES ENGINES 1. Gasket 2. Plenum Assembly 3. Plug 3A. Plug 4. Stud 5. Screw 6. Washer

ISSUED

7. Washer 8. Spacer 9. Sleeve 10. Plenum Bracket 11. Lock Washer 12. Plain Nut 13. Intake Gasket

14. Clamp 15. Intake Hose 16. Induction Tube 17. Induction Flange 18. Washer 19. Lock Washer 20. Nut

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FIGURE 3 THROTTLE PLATE MODIFICATION

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine SUBJECT:

Engine Specification Numbers

PURPOSE:

To clarify the meaning of engine specification numbers.

MODELS AFFECTED:

SIL05-3 Technical Portions FAA Approved

All current production engines.

Teledyne Continental Motors has received questions from the field concerning the meaning of the engine specification numbers that are stamped on the engine data plate following the engine model letter. One example of an Engine Model Code is as follows: Example Code: TSIO-550-B(1)B TS: I: O: 550: B: (1): B:

Turbo-Super Charged Fuel Injected Horizontally Opposed Displacement in Cubic Inches Model Number Specification Number (NOTE: Some engine spec numbers may not be enclosed in parenthesis.) Shipping Designation (A= Cardboard Crate B= Wood Crate F= Factory Packaging)

Additional Codes:

G: Geared {Example GTSIO-520-N(1)B } L: (Before the pre-fix) Left-Hand Rotation {Example LTSIO-360-RB(1)B } L: (After the pre-fix) Liquid Cooled {Example TSIOL-550-C(1)B } F: FADEC equipped engine {Example IOF-550-N(1)B }

In this example the Specification Number (1), following the Model Number only designates the accessory configuration for this engine. The Specification Number does not in any way alter the model designation for this engine. As a further example, a TSIO-550-B(1)B and a TSIO-550-B2B are both TSIO-550-B model engines and both would meet the requirements for an installation specifying a TSIO-550-B. The letter following the Specification Number is normally a shipping designation code assigned by TCM. The shipping code does not affect the model of the engine. In some rare cases a different letter may be present in the shipping designation position. This indicates a customer requested deviation from the designated engine specification number.

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama • 251-438-3411

SIL05-3

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

Category 5

SERVICE INFORMATION LETTER

SIL05-4A

Contains Useful Information Pertaining To The Continental Aircraft Engine SUBJECT:

PURPOSE:

IO240-SERIES ENGINES P/N 656859 INLINE FUEL FILTER INSTALLATION AND INSPECTION PROCEDURES

Technical Portions FAA Approved Supersedes SIL05-4

To provide installation instructions for an additional fuel system filter and provide Instructions For Continued Airworthiness for the filter once it is placed in service.

COMPLIANCE: Optional, recommended to be performed in conjunction with SIL04-9 or SIL05-5 MODELS AFFECTED:

IO240-B Series Engines

GENERAL INFORMATION Teledyne Continental Motors has received approval for the installation of an additional fuel system filter, to be installed in-line between the engine driven fuel pump and the throttle and control assembly. The P/N 656859 filter assembly incorporates a 32-micron screen and a built-in bypass valve that opens at approximately 3.5 PSID.

NOTE: The P/N 656143-1 fuel pump inlet filter is to be installed in addition to the P/N 656859 Inline Fuel Filter Installation, reference the latest revision of SIL05-6. NOTE: Modifications found in this bulletin are specific to the IO-240-B as installed in the Diamond DA-20. Owners wishing to incorporate engine upgrades in other applications should contact TCM Technical Customer Service at 888-826-5465 or 1-251-438-3411. PARTS TCM has issued a kit in support of the fuel filter installation EQ7463 (A) 656859A1

Fuel Filter Assembly with Fittings

1 Each

(B) 646644S4Y6.50 Hose Assembly

2 Each

(C) AN500-10-8

Screw #10-24

2 Each

(D) AN960-10

Washer, Plain

2 Each

(E) MS35338-43

Washer – Lock

2 Each

(F) 656892-1

Sleeve – Heat 6 Inches Long

1 Each

(G) 10-620013

Cable Tie

2 Each

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INSTALLATION INSTRUCTIONS: (1) Referring to the airframe manufacturers maintenance instructions: WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. (a) Remove electrical power from the aircraft. (b) Remove upper and lower engine cowlings from the aircraft (c) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. (2) Remove the existing P/N 646644S4Y13.00 fuel line running from the engine driven fuel pump to the throttle and control assembly and discard this line. Cap both the fuel pump outlet fitting and the throttle and control assembly inlet fitting to protect them from contamination during the engine cooling baffle modification. (3) Drill and deburr two .198” (#10 drill) holes in the engine cooling baffle, 0.80” apart, in the position shown in Figure 1 and Photo 1. (4) Trim the lower edge of the engine cooling baffle assembly as required, reference photo 1, to allow the fuel line to be routed to the front of the cooling baffle assembly. (5) Install the P/N 656859A1 filter assembly onto the cooling baffle assembly using two AN500-10-8 screws, two MS35338-43 lock washers and two AN960-10 plain washers. Torque the screws to 21-25 In-Lbs. CAUTION: Ensure that the arrow on the filter assembly housing is pointing in the direction of fuel system flow from the fuel pump to the throttle and control assembly. (6) Install the P/N 656892-1 fire-sleeve on one P/N 646644S4Y6.50 hose assembly and secure on both ends with the P/N 10-620013 cable ties. Install the P/N 646644S4Y6.50 hose assembly protected with firesleeve from the pump to the filter and the other P/N 646644S4Y6.50 hose assembly from the filter to the throttle and control assembly. Torque the fittings to 135-190 In-Lbs. using the following procedures: (a) Select the proper size open-end wrenches that will fit the fitting body and hose or tubing end fitting. (b) Torque the hose or tubing end fitting to the specified torque using a properly certified calibrated torque wrench while maintaining sufficient force on the component fitting to prevent twisting and shear loads. (c) Support the last fitting in the assembly on components that contain multiple fittings coupled in one location. DO NOT over torque fittings. (7) Open the fuel shutoff valve and static leak check the fuel filter assembly. Correct any discrepancies noted before proceeding to the next step. (8) Restore electrical power to the aircraft. Using the fuel boost pump, leak-check the fuel system. Correct any defects noted before proceeding to the next step.

WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start.

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Outlet to Throttle and Control Assembly

Inlet from fuel pump

Arrow on filter body must point in direction of fuel flow

Trim existing baffle to allow clearance for fuel line routing. Ensure sufficient clearance exists to prevent chafing.

PHOTO 1

Washer-Flat (If required)

Airframe Baffle assembly

AN500-10-8 Screw No. 10 MS35338-43 Washer – Lock AN960-10 Washer -Flat

FIGURE 1

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(9) Perform the fuel system verification in accordance with the procedures contained in the latest revision of TCM bulletin SID97-3 and the procedures contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A.

(10)

Reinstall the cowlings in accordance with the airframe manufacturer’s maintenance instructions.

FILTER INSTALLATION

Metering Cover Fuel Inlet Fitting

646644S4Y6.50 Hose Assembly Filter Outlet to metering Cover Inlet

10-620013 Cable Tie

656892-1 Sleeve-Radiant Heat 656859A1 Filter Assembly

646644S4Y6.50 Hose Pump Outlet to Filter Inlet

10-620013 Cable Tie Fuel Pump Outlet Fitting

FIGURE 2 ISSUED

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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Teledyne Continental Motors requires the P/N 656859A1 filter assembly to be inspected after each 200 hours in service using the following instructions and referencing Figure 2.

(1) Referring to the airframe manufacturers maintenance instructions: WARNING Magnetos must be verified to be in the off position and grounded, and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result.

(a) Remove electrical power from the aircraft. (b) Remove the upper engine cowling from the aircraft (c) Shutoff the fuel supply to the engine by closing the fuel shutoff valve. (2) Remove the P/N 656859A1 filter assembly. Cut the safety wire on the four screws holding the P/N 656855 cover on the inlet side of the fuel filter assembly. Remove the four screws and remove the cover. Remove the P/N MS9021-020 o-ring from the cover and discard. (3) Remove the P/N 656858 filter spring from the filter housing, then remove the P/N 656856 filter disc from the housing. (4) Clean the filter disc by soaking in lacquer thinner or acetone for several hours. Blow the filter disc dry with clean, filtered dry compressed air. If any physical damage is noted to the filter disc, it must be replaced. (5) Install the filter disc and then the spring into the filter housing assembly. Install a new P/N MS9021-020 oring onto the cover. Lubricate the o-ring with clean engine oil and install the cover onto the filter housing assembly. Secure the cover using the four P/N AN500-A8-7 screws and AN960-8 washers. Torque the cover retaining screws to 17.5 to 22.5 In-Lbs. Lockwire the screws in pairs using 0.032” stainless steel lockwire conforming to MS20995 Condition A. (6) Install the P/N 656859A1 filter assembly onto the cooling baffle assembly using two AN500-10-8 screws, two new MS35338-43 lock washers and two AN960-10 plain washers. Torque the screws to 21-25 In-Lbs. (7) Reconnect the hose fittings to the filter assembly. Torque the fittings to 135-190 In-Lbs. using the following procedures: (a) Select the proper size open end wrenches that will fit the fitting body and hose or tubing end fitting. (b) Torque the hose or tubing end fitting to the specified torque while maintaining sufficient force on the component fitting to prevent twisting and shear loads. (c) Support the last fitting in the assembly on components that contain multiple fittings coupled in one location. DO NOT over torque fittings. (8) Open the fuel shutoff valve and static leak check the fuel filter assembly. Correct any discrepancies noted before proceeding to the next step. (9) Restore electrical power to the aircraft. Using the fuel boost pump, leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step.

WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. ISSUED

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(10) Perform the fuel system verification in accordance with the procedures contained in the latest revision of TCM bulletin SID97-3 and the procedures contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A.

(11)

Reinstall the cowlings in accordance with the airframe manufacturer’s maintenance instructions.

MS9021-020 O-Ring

656855 Cover

Install P/N 524816 Pipe Plugs (Two Places) 656858 Filter Spring 656854 Housing

656856 Filter Disk

AN500-8-7 Screw 4 Each AN960-8 Washer 4Each

PHOTO 2 FUEL FILTER ASSEMBLY

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SIL 05-5 Technical Portions FAA Approved

SUBJECT:

IO240B-SERIES MANIFOLD VALVE FUEL SCAVENGE SYSTEM INSTALLATION

PURPOSE:

To reduce the effects of heat on the engine fuel system components and enhance idle stability

COMPLIANCE: MODELS AFFECTED:

Optional

Any IO240B-Series engine which has previously complied with SIL04-1 “Installation of the Altitude Compensating Pump”.

GENERAL

Teledyne Continental Motors has introduced fuel system product enhancements in order to reduce the effects of heat build up in the engine fuel system components. The changes include a newly released vapor scavenging type of manifold valve assembly installed on a heat-insulating mount assembly. The existing Diamond Aircraft® fuel pressure transducer will be relocated. Also included in the kit is a replacement throttle and control assembly that utilizes a bleed hole in the throttle plate to enhance idle stability. The manifold valve fuel scavenge system has been designed to allow a constant bypass of fuel through the manifold valve then back to the airframe fuel system vapor return line during system operation. The manifold valve body has been machined with a high annulus chamber to collect potential vapor at the high points in the chamber. The vapor is then routed through an orifice fitting in the manifold valve back to the airframe fuel system vapor return line. REQUIRED PARTS (1) TCM has issued kit EQ 7464 in support of this bulletin. Contents of the kit are as follows: Part Number Nomenclature Quantity 656863-1A1 Manifold Valve Assy. With Fittings 1 653898-3A1 Throttle and Control Assembly 1 656836A1 Tuned Nozzle Kit 1 653900 Gasket – Throttle Body 1 MS35338-44 Washer, Lock .25” Diameter 4 646644R4S13.0 Hose Assy. Throttle Body Out To Tee 1 MS51513B4 Tee, Pipe To Tube 1 629518-1 Plug, Install In Tee 1 646644S4S8.50 Hose Assy. Tee To Manifold Valve Inlet 1 MS21919WF27 Clamp 1 MS21919WCF10 Clamp 1 AN3-4A Bolt 1 AN960-10 Washer 1 MS21044N3 Nut – Self Locking 1 646644S4S26.75 Hose Assembly Manifold Valve Vapor Return To Tee 1 MS51523B4 Tee – Vapor Return 1 MS35489-20 Grommet 1 ISSUED

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama • 251-438-3411

SIL 05-5

MANIFOLD VALVE REPLACEMENT (1) Referring to the airframe manufacturers maintenance instructions: WARNING Magnetos must be verified to be in the off position and grounded and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. (a) Remove electrical power from the aircraft. (b) Remove the upper engine cowling from the aircraft. (c) Shut off the fuel supply from the engine by closing the fuel shutoff valve. (2) Remove the fuel pressure transducer and retain for re-installation. Remove the existing fuel pressure transducer hose and discard. Remove the grommet from the aft baffle installation and retain for reinstallation. (3) Referring to the latest revision of the X30622 IO240 Series Overhaul Manual, Section 9, remove the existing fuel system manifold valve assembly and the manifold valve bracket assembly. Disconnect the four fuel injection lines from both ends and remove. Remove the fuel injector from each cylinder. Retain the fuel injector lines for reinstallation. Retain the manifold valve assembly, mounting bracket and fuel injectors for core return to TCM. CAUTION Protective closures must be installed on all open lines and fittings to prevent contamination. (4) Remove the existing fuel line from the throttle and control unit to the manifold valve assembly (P/N 646644S4S15.00 pre SIL04-3 or 646644S4Y11.50 post SIL04-3) and discard. (5) Disconnect the throttle control cable from the throttle body lever, retaining all hardware for reinstallation. Disconnect the hose assembly from the fuel pump to the throttle and control assembly. Cap the open line to prevent contamination. (6) Remove the existing throttle and control assembly from the induction manifold, retaining the .25” nuts and flat washers for re-installation. Retain the throttle and control assembly for core return to TCM. Discard the lock washers and base gasket. {If provision already exists in the aft LH baffle assembly for mounting of the fuel pressure transducer, proceed to step 9} (7) Measure 4 inches horizontally from the outboard edge of the LH aft baffle and place a vertical mark at this location. (Reference Figure 2 and Photo 1 & 2) Measure vertically down 1.250 inches from the top of the aft baffle at the previously marked 4-inch location and place a horizontal mark. Inspect the marked location for interference with the oil cooler duct or baffle rivets. If location is satisfactory, drill a 7/8 inch hole at this location. A Uni-bit® is recommended for the drilling operation. (8) Install the previously retained fuel pressure transducer rubber grommet into the new hole in the LH aft baffle. (9) Install the P/N 656863-1A1 manifold valve assembly on the engine using the previously retained AN414A bolts, 20522 washers and 646605 plain nuts. The bolt threads must be lubricated with 50 weight motor oil and the nuts torqued to 100-125 In-Lbs. (10) Install the P/N 653893-3A1 Throttle and Control assembly on the induction manifold using the previously retained nuts and flat washers, new P/N MS35338-44 lock washers and a new P/N 653900 gasket. (Reference Figure 3) Torque the 4 each throttle body retaining nuts to 90-110 In-Lbs. Reinstall the throttle cable using the airframe manufacturer’s approved procedures. ISSUED

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(11) Remove the protective caps from the P/N 646644R4S13.0 and P/N 646644S4S8.50 hose assemblies. Flush the lines prior to installation to remove any possible contaminants. Referencing Figure 2 for routing information, connect the P/N 646644R4S13.0 line from the throttle body to the “tee.” Connect the P/N 646644S4S8.50 hose from the “tee” to the manifold valve inlet fitting. Reconnect the hose from the pump to the throttle body. Torque all fittings to 135-190 In-Lbs. (12) Install the retained fuel pressure transducer from the aft side of the LH aft baffle through the rubber grommet into the MS51513B4 “T” fitting center port. Reference the airframe manufacturer’s manual for proper torque. [If the aircraft is not equipped with a pressure transducer, install the 629518-1 pipe plug into the “tee” fitting, coating the threads of the plug with Loctite 569 prior to installation. Torque the plug to 60-80 in-lbs, then proceed to step 14] (13) Reroute the two fuel pressure transducer electrical wires from their existing routing on the RH side of the engine mount to their new position on the aft side of the LH baffle. Cut tywraps holding transducer wires in place on wire bundle across firewall. Open up adel clamps on wire bundle as required to free up transducer wires for rerouting under adel clamps on the RH side of the bundle with sufficient length to reach the new location of the transducer. Secure any excess wire to the wire bundle using tywraps. Secure the wires to the upper LH engine mount strut with one MS21919WDG12 clamp on the engine mount strut and one MS21919WDG2 clamp around the fuel pressure transducer wires, secured with one AN526832R8 screw, two AN960-8 washers and one AN365-832 lock nut. (14) Apply P/N 646943 anti-seize lubricant to the threads of each fuel injector assembly. (Alternate P/N Loctite 76732) Reference Figure 1 for proper anti-seize compound application to the fuel nozzle. (15) Install the new tuned fuel injectors into the following positions: P/N 656836-110B into #1 cylinder, P/N 656836-210B into #2 cylinder, P/N 656836-310B into #3 cylinder and P/N 656836-410b into #4 cylinder. Torque the fuel injector nozzle to 55-65 In-Lbs. (16) Reinstall the previously removed fuel injector lines. Torque the fitting at the manifold valve to 55-60 InLbs. Torque the fitting at the fuel injector nozzle to 40-45 In-Lbs. (17) Position the “Tee” fitting snug against the rubber grommet in the baffle assembly. Clamp the 646644R4S13.00 line to the #2 intake tube using one MS21919WF27 clamp, one MS21919WCF10 clamp, one AN3-4A bolt, one AN960-10 washer and one MS21044N3 nut. Position the clamp so that the “Tee” fitting retains it’s position snug against the rubber grommet. (18) Remove the airframe splash shield from the firewall. Retain the splash shield and hardware for reinstallation. (19) Disconnect the fuel pump vapor return hose from the 90° elbow. Place a protective closure to the open hose end fitting. (20) Install new P/N MS51523B4 swivel “T” fitting to the airframe 90° elbow fitting. Position “Tee” fitting as required for best hose installation. Torque the swivel “Tee” fitting to 135-190 In-Lbs. (Ref. Figure 2) (21) Connect the fuel pump vapor return hose to the newly installed swivel “Tee” fitting. Torque to 135-190 In-Lbs. (22) Position the splash shield in place and mark the centerline of the hose entry. (Manifold valve to “Tee”). Drill a 1.062” diameter hole in the marked location on the splash shield and install P/N MS35489-20 grommet. (Ref. Figure 2 and Figure 3) (23) Remove the protective covers from the P/N 646644S4S26.75 hose assembly and flush the hose to remove any contamination. Insert the hose through the grommet in the splash shield and connect to the swivel “Tee” fitting. Torque to 135-190 In-Lbs. Reinstall the splash shield to the firewall using the airframe manufacturer’s procedures.

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(24) Route the vapor return hose through the RH aft baffle opening through the pre-existing grommet where the pressure transducer was originally installed and connect it to the manifold valve assembly vapor return fitting. Torque to 100-140 In-Lbs.

SYSTEM SET-UP AND TEST 1) Open the fuel shutoff valve and static leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step. 2) Restore electrical power to the aircraft. Using the fuel boost pump, leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step. WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. 3) Perform the fuel system setup and verification in accordance with the instructions and specifications contained in TCM bulletin SID97-3, revision C or later and the instructions contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. NOTE Pressure altitude must be used when determining fuel system set-up values. To determine pressure altitude prior to take-off, set your altimeter to 29.92 in hg, and the altimeter will indicate your pressure altitude.

FIGURE 1 Fuel Nozzle sealant Application ISSUED

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FIGURE 2

Fuel Scavenge System Installation and Operation

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Fuel Pressure Transducer

Clamp Installation

PHOTO 1

MS51513B4 “TEE” Fitting

646644S4S8.50 Hose assembly

646644R4S13.00 Hose Assembly

PHOTO 2

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Hose Assembly Fuel Pump Supply (No. 6 Line)

Hose Assembly Fuel Pump Vapor Return (No. 4 Line)

646644S4S26.75 Hose Assembly

MS51523B4 Swivel “TEE”

Elbow 90° (No. 4)

FIGURE 3 Bypass Vapor Return Line Installation

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Splash Shield MS51523B4 swivel “TEE” MS35489-20 Grommet

646644S4S26.75 Hose Assembly Drill 1.062” Diameter Hole in the Airframe Splash Shield

FIGURE 4 Airframe Splash Shield Modification

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FIGURE 2 INDUCTION SYSTEM ON IO-240-B3B, B9B & B13B SERIES ENGINES 1. Gasket 2. Plenum Assembly 3. Plug 3A. Plug 4. Stud 5. Screw 6. Washer

ISSUED

7. Washer 8. Spacer 9. Sleeve 10. Plenum Bracket 11. Lock Washer 12. Plain Nut 13. Intake Gasket

14. Clamp 15. Intake Hose 16. Induction Tube 17. Induction Flange 18. Washer 19. Lock Washer 20. Nut

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

Category 5

SERVICE INFORMATION LETTER

SIL05-6A

Contains Useful Information Pertaining To Your Aircraft Engine

Technical Portions FAA Approved Supersedes SIL05-6

SUBJECT:

IO-240-B SERIES PRODUCT UPGRADES

PURPOSE:

To provide an overview of product upgrades necessary to upgrade IO-240-series engines to current production configuration.

COMPLIANCE: MODELS AFFECTED: REASON FOR REVISION:

At next scheduled engine inspection. IO-240-B Series Engines To provide FAA required Instructions for Continued Airworthiness for the fuel pump inlet filter.

GENERAL INFORMATION Teledyne Continental Motors has incorporated several product upgrades available for the IO-240-B Series. This bulletin contains a synopsis of the available TCM bulletins and information required for updates to the IO240-Series engines. Refer to each individual bulletin to determine if the upgrades are required or optional.

NOTE: Modifications found in this bulletin may be specific to the IO-240-B as installed in the Diamond DA-20C. Owners wising to incorporate engine upgrades in other applications should contact TCM Technical Customer Service at 888-826-5465 or 251-438-3411. NOTE: This Service Information Letter includes a Product Upgrade Compliance Form so TCM may track progress of the product upgrade program. Compliance with this SIL should be accomplished and the compliance form returned to TCM no later than the next scheduled inspection. PRODUCT UPGRADE BULLETINS (1) SB03-7 IO-240 Series Magneto Drive Gear Purpose:

To notify owners, operators, maintenance facilities and distributors of inspection, repair and/or replacement of magneto drive gear P/N 36066.

NOTE: Magneto timing must be reset after compliance with SB03-7 using the instructions contained in the latest revision of MSB94-8 and the engine Maintenance Manual. ISSUED MO 02

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REVISED YEAR 2005

MO 10

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

1 of 6 SIL 05-6

A

(2) SIL04-8 Replacement Starter For IO-240-Series Engines Purpose:

To provide removal and installation instructions for P/N 655957 starter assembly on engines equipped with earlier P/N starter assemblies.

(3) SIL04-7 IO-240-Series Crankshaft Cluster Gear Inspection and Replacement Purpose:

To announce the availability of an improved crankshaft cluster gear P/N 656752 for IO-240 series engines and provide inspection criteria for currently installed crankshaft cluster gears.

(4) Start Vibrator Battery In order to ensure proper start voltage to the start vibrator during engine start, Diamond Aircraft has installed a backup battery utilized during the start process. This battery should be inspected at the airframe manufacturers recommended interval, using procedures contained in the latest revision of the Airframe Maintenance Manual. In addition, the start vibrator backup battery must be replaced at least every 12 months. The start vibrator battery is available through Diamond Aircraft as P/N LCR12V1.3P.

CAUTION: Low voltage to the start vibrator (below 8 volts) will cause loss of start vibrator boost voltage output and possible reversion of the magneto to the advanced timing mode. Engine damage may result from improper start vibrator operation. (5) SB04-4A Replacement Of Manifold Valve Spring P/N 630184 Purpose:

To provide instructions for the replacement of manifold valve spring P/N 630184 with spring P/N 627378.

(6) SIL04-9 IO240B13B Manifold Valve replacement, Heat Isolation Modifications and Throttle Body Modification Purpose:

To reduce heat on the engine fuel system components and enhance idle stability.

(7) SIL05-4 IO240B-Series Engines P/N 656859 Inline Fuel Filter Installation and Inspection Procedures Purpose:

To provide installation instructions for an additional fuel system filter and to provide Instructions For Continued Airworthiness for the filter once it is placed in service.

(8) SIL04-1 Installation of the Optional Altitude-Compensating Fuel Pump on IO-240-B Series Engines Purpose:

To provide instructions for the installation of the altitude compensating fuel pump on IO240-B series engines.

(10) SIL05-5 IO-240-Series Manifold Valve Fuel Scavenge System Installation Purpose:

To reduce the effects of heat on the engine fuel system components and enhance idle stability.

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MO 10

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

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(11)

Installation of Fuel Pump Inlet Filter: In order to enhance the aircraft fuel filtration system, DIAMOND AIRCRAFT has requested the optional installation of an additional fuel line filter screen at the engine driven fuel pump inlet fitting. Installation of the fuel pump inlet filter is recommended by Teledyne Continental Motors. Screen P/N 656143-1 is available from Diamond Aircraft or a TCM Authorized Distributor.

NOTE: The P/N 656143-1 fuel pump inlet filter is to be installed in addition to the P/N 656859 Inline Fuel Filter Installation, reference SIL05-4. (a) Insure that the aircraft Master Switch is in the OFF position. (b) Turn the aircraft fuel selector valve to the OFF position. (c) In accordance with the aircraft manufacturers instructions, remove the engine cowling to gain access to the engine driven fuel pump. (d) Select the proper size open end wrenches to fit the fuel inlet fitting body and the fuel inlet hose “B” nut.

WARNING FAILURE TO PROPERLY SUPPORT COMPONENT FITTINGS DURING REMOVAL/INSTALLATION CAN RESULT IN FITTING AND/OR COMPONENT DAMAGE, POSSIBLE FAILURE OF THE FITTING OR COMPONENT, LOSS OF SYSTEM PRESSURE, ENGINE FIRE, LOSS OF POWER AND FORCED LANDING. (e) Loosen the fuel inlet hose fitting while maintaining sufficient force on the fuel pump inlet fitting to prevent twisting or shear loads. (f) Remove the fuel inlet hose from the fuel pump inlet fitting. (g) Insert the P/N 656143-1 fuel filter element into the fuel inlet fitting. Ensure that the fuel filter flange seats against the fitting flare. Reference Figure 1. (h) Install the fuel inlet hose on to the fuel pump fuel inlet fitting. (i) Torque the fuel inlet hose “B” nut to 150 to 195 inch pounds while maintaining sufficient force on the fuel pump inlet fitting to prevent twisting or shear loads. (j) Turn the aircraft fuel selector to the ON position. (k) In accordance with the aircraft manufacturers instructions perform a fuel system leak test. Correct any discrepancies before proceeding. (l) Check the fuel system for proper adjustment in accordance with the latest revision to TCM service bulletin SID 97-3. Make adjustments as necessary to meet specifications published in the latest revision of SID 97-3. (m) Re-installed any aircraft or engine mounted equipment removed to facilitate compliance with this Special Service Instruction. (n) In accordance with the aircraft manufacturers instructions re-install the aircraft cowling. (o) Make appropriate log book entries for the installation of the P/N 656143-1 Fuel filter screen.

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

3 of 6 SIL 05-6

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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS P/N 656143-1 FUEL FILTER SCREEN: The following procedure must be performed at intervals not to exceed every 100 hours. (a) Insure that the aircraft Master Switch is in the OFF position. (b) Turn the aircraft fuel selector valve to the OFF position. (c) In accordance with the aircraft manufacturer's instructions, remove the engine cowling to gain access to the engine driven fuel pump. (d) Select the proper size open end wrenches to fit the fuel inlet fitting body and the fuel inlet hose “B” nut.

WARNING

FAILURE TO PROPERLY SUPPORT COMPONENT FITTINGS DURING REMOVAL/INSTALLATION CAN RESULT IN FITTING AND/OR COMPONENT DAMAGE, POSSIBLE FAILURE OF THE FITTING OR COMPONENT, LOSS OF SYSTEM PRESSURE, ENGINE FIRE, LOSS OF POWER AND FORCED LANDING. (e) Loosen the fuel inlet hose fitting while maintaining sufficient force on the fuel pump inlet fitting to prevent twisting or shear loads. (f) Remove the fuel inlet hose from the fuel pump inlet fitting. Install a protective cover on the fuel supply line to prevent contamination. (g) Remove the P/N 656143-1 inlet screen from the fuel pump inlet fitting. Install a protective cover on the fuel pump inlet fitting to prevent contamination. (h) Clean the filter cone by soaking in lacquer thinner or acetone for several hours. Blow the filter cone dry with clean, filtered dry compressed air. If any physical damage is noted to the filter, it must be replaced. (i) Remove the protective cover from the fuel pump inlet fitting and insert the P/N 656143-1 fuel filter element into the fuel inlet fitting. Ensure that the fuel filter flange seats against the fitting flare. (Reference Figure 1.) (j) Remove the protective cover from the fuel supply hose. Temporarily restore power to the aircraft and open the fuel selector valve. Placing the end of the fuel supply hose into a proper container, use the aircraft boost pump to flush the hose to remove any contaminants. Turn the fuel selector valve back to the off position and remove power from the aircraft. (k) Install the fuel inlet hose on to the fuel pump inlet fitting. (l) Torque the fuel inlet hose “B” nuts to 150 to 195 inch pounds while maintaining sufficient force on the fuel pump inlet fitting to prevent twisting or shear loads. (m) Restore electrical power to the aircraft. Turn the aircraft fuel selector to the ON position. (n) In accordance with the aircraft manufacturers instructions perform a complete fuel system leak test. Correct any discrepancies before proceeding. (o) Re-install any aircraft or engine mounted equipment removed to facilitate compliance with this Special Service Instruction. (p) In accordance with the aircraft manufacturers instructions re-install the aircraft cowling. (q) Make appropriate log book entries for the required 100-hour inspection and cleaning of the P/N 656143-1 fuel inlet filter screen.

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P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

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CAUTION: After any fuel system modifications in accordance with the latest revisions of bulletins SIL04-1, SB04-4, SIL04-9, SIL04-10, SIL05-4, SIL05-5 or installation of the fuel pump inlet filter the fuel system must be set up using the instructions contained in the latest revision of SID97-3 and the latest revision of the engine Maintenance Manual Form X30621.

P/N 656143-1 Fuel Filter Assembly

Fuel Inlet

FIGURE 1 P/N 656143-1 FUEL PUMP INLET FILTER INSTALLATION

NOTE: The P/N 656143-1 fuel pump inlet filter is to be installed in addition to the P/N 656859 Inline Fuel Filter Installation, reference SIL05-4. (12)

SIL00-11 Cylinder Drain Port Connectors In order to enhance cold starting, modified cylinder induction port drain connectors P/N 655472 are now available. The P/N 655742 Cylinder Induction Port Drain Connector may be installed using the instructions contained in the latest revision of TCM Service Information Letter SIL00-11.

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© 2005 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama 36601 • 251-438-3411

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IO-240-B Series Product Upgrade Compliance Form Return Form to: Teledyne Continental Motors Technical Customer Service PO Box 90 Mobile, AL 36601 Attn: Joe Barton FAX: 251-432-7352 Date:

Owner Name: Address: City:

State/Country/ZIP

PH#

City:

State/Country/ZIP

PH#

Aircraft Registration #:

Make/Model:

S/N:

Bulletin:

Facility:

Date of Compliance:

Serial Number:

Date Installed:

FBO Name: Address:

SB03-7: IO240-Series Magneto Drive Gear (SSI2001-1 constitutes previous compliance) SIL04-8 Replacement Starter (SSI2002-5 constitutes previous compliance) SB04-7 Cluster Gear Inspection / Replacement Start Vibrator Battery Inspection/Replacement SB04-4A Replacement of Manifold Valve Spring (SSI2002-1 Constitutes Previous Compliance) SIL04-1A Altitude Compensating Pump Fuel Pump Inlet Filter Installation SIL04-9 IO240B13B Manifold Valve Replacement, Heat Isolation Mods and Throttle Body Modifications SIL05-4A IO240-Series P/N 656859A1 Fuel Filter Installation SIL05-5 IO-240-Series Manifold Valve Fuel Scavenge System Installation SILO0-11B Cylinder Drain Port Connectors Engine Model: Engine Total Time (Hours):

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© 2005 Teledyne Continental Motors, Inc.

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SIL06-2 Technical Portions FAA Approved

SUBJECT:

UNAPPROVED PARTS NOTIFICATION NO. 2004-00053

PURPOSE:

To announce the issuance of Unapproved Parts Notification No. 2004-00053 issued by the Federal Aviation Administration

COMPLIANCE: MODELS AFFECTED:

Recommended

E-Series Engines, O-470- 2, 4, 7, 11, 13, 13A and 15

Teledyne Continental Motors recommends that any owner or operator of one of the above listed engines comply with the attached Unapproved Parts Notification No. 2004-00053 issued by the Federal Aviation Administration (FAA) on February 13, 2006. Further information concerning this notification can be obtained from the FAA at: Federal Aviation Administration Suspected Unapproved Parts Program Office AVS-20 13873 Park Center Rd., Suite 165 Herndon, VA 20171 (703) 668-3720 http://www.faa.gov/aircraft/safety/programs/sups/upn/ OR Federal Aviation Administration Oklahoma City FSDO 1300 S. Meridian Suite 601 Oklahoma City, OK 73108 (405) 951-4200

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SIL06-2

UNAPPROVED PARTS NOTIFICATION SUSPECTED UNAPPROVED PARTS PROGRAM OFFICE, AVS-20 13873 PARK CENTER ROAD, SUITE 165 HERNDON, VA 20171

U.S. Department of Transportation

Federal Aviation Administration No. 2004-00053 February 13, 2006

http://www.faa.gov/aircraft/safety/programs/sups/upn/ Mailed by FAA AIR-140, P O Box 26460, Oklahoma City OK 73125

AFFECTED PARTS Thompson fuel pumps.

PURPOSE The purpose of this notification is to advise all aircraft owners, operators, maintenance organizations, manufacturers, and parts distributors regarding improper maintenance performed on Thompson fuel pumps (part no. TF-1900).

BACKGROUND Information received during a Federal Aviation Administration (FAA) suspected unapproved parts investigation revealed that prior to April 26, 2005,Thunderbird Aircraft Parts, Inc. (Thunderbird), located at 5406 N. Rockwell Avenue, Bethany, OK 73008, improperly maintained and approved for return to service Thompson fuel pumps applicable to various types of aircraft. Thunderbird holds Air Agency Certificate No. IC2R893K, with limited accessory ratings. Discrepancies noted in Thunderbird’s practices included: • •

Approving for return to service fuel pumps that were not properly tested using methods, techniques, and practices acceptable to FAA. Approving for return to service fuel pumps that were not maintained in accordance with the current manufacturer’s maintenance manual or methods otherwise acceptable to FAA.

RECOMMENDATIONS Regulations require that type-certificated products conform to their type design. Aircraft owners, operators, maintenance organizations, and parts suppliers and distributors should inspect their aircraft, aircraft records, and/or parts inventories for Thompson fuel pumps approved for return to service by Thunderbird. Suspect parts installed on aircraft should be inspected for conformity to type design. If any are found in existing stock, it is recommended that the parts be quarantined to prevent installation until a determination can be made regarding each part’s eligibility for installation.

page 2

2004-00053

FURTHER INFORMATION Further information concerning this investigation, and guidance regarding the above-referenced parts, can be obtained from the FAA Flight Standards District Office (FSDO) given below. The FAA would appreciate any information concerning the discovery of the above-referenced part from any source, the means used to identify the source, and the actions taken to remove the part from aircraft and/or stock. This notice originated from the FAA Oklahoma City FSDO, 1300 S. Meridian, Suite 601, Oklahoma City, OK 73108, telephone (405) 951-4200, fax (405) 951-4282; and was published through the FAA Suspected Unapproved Parts Program Office, AVS-20, telephone (703) 668-3720, fax (703) 4813002.

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SIL06-3 Technical Portions FAA Approved

SUBJECT:

CRANKSHAFT GEAR RETAINING SCREW

PURPOSE:

To announce the supersedure of P/N 536379 crankshaft gear retaining screw by P/N 656990 retaining screw.

MODELS AFFECTED:

O-470-Series; IO-346-A; IO-470-Series; IO-520-Series; LIO-520-P; IO-550-Series IOF-550-Series; TSIO-470-B, C and D; L&TSIO-520-Series; TSIO-550-A, B, C and E; TSIOL-550-A, B and C; GTSIO-520-Series

Teledyne Continental Motors (TCM) has announced the release of a new crankshaft gear retaining screw (bolt) P/N 656990 for the above listed engines. Retaining screw P/N 536379 is no longer available. The new P/N 656990 retaining screw may be obtained through any TCM authorized distributor. To locate your nearest TCM authorized distributor you may go on-line to: www.tcmlink.com/distributor/distributorLocator.cfm. OR Call TCM Customer Service at 1-888-826-5465 or 1-251-438-3411 Extension 8292.

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P.O. Box 90 Mobile Alabama • 251-438-3411

SIL06-3

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL06-4

Contains Useful Information Pertaining To Your Aircraft Engine

SUBJECT:

Technical Portions FAA Approved

FADEC SYSTEM HEALTH STATUS ANNUNCIATOR INDICATIONS

PURPOSE: To provide guidelines for the correct interpretation of momentary condition indications on the Health Status Annunciator (HSA) MODELS AFFECTED:

IOF-240-SERIES

Teledyne Continental Motors (TCM) has received reports from the field of momentary Light Emitting Diode (LED) indications on the FADEC System Health Status Annunciator panel. These occasional, flickering indications most commonly occur on the FADEC CAUTION, FADEC WARNING, or PPWR FAIL LEDs. (Reference Figure 1) FADEC CAUTION (YELLOW)

FADEC WARN

FADEC CAUTION

FADEC WARNING (RED)

PPWR FAIL

EBAT FAIL

FUEL PUMP

PRIMARY POWER FAIL (RED)

FIGURE 1 HEALTH STATUS ANNUNCIATOR PANEL

TCM has reviewed this issue and found that noted momentary indications (flicker) of the FADEC WARN, FADEC CAUTION or PPWR FAIL LEDs are not safety issues and do not require pilot actions. TCM is currently working on software enhancements to address this issue.

WARNING Persistent and steady LED indications of over 10 seconds or any other indications of abnormal engine operation may indicate potential propulsion system issues and must not be ignored. For any LED indication of over 10 seconds the specified Pilots Operating Handbook procedures must be followed. ISSUED

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SIL06-4

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SUBJECT:

SIL07-7A Technical Portions FAA Approved

IO-240-B17B CONVERSION TO IO-240-B3B

PURPOSE: To provide instructions for the conversion of IO-240-B17B engines to the IO-240-B3B configuration. COMPLIANCE:

Optional

MODELS AFFECTED:

IO-240-B17B

CONVERSION INSTRUCTIONS (1) Referring to the airframe manufacturers maintenance instructions: (a) Remove the upper and lower engine cowlings from the aircraft. (b) Remove electrical power from the aircraft. (c) Shut off the fuel supply from the engine by closing the fuel shutoff valve. WARNING Magnetos must be verified to be in the off position and grounded and fuel must be selected to the off position when moving the propeller by hand, or personal injury may result. (2) Disconnect the air inlet duct assembly from the throttle and control unit and the front baffle assembly. (3) Remove the P/N 646644S4Y6.50 hose assembly from the fuel filter assembly to the throttle and control assembly and discard. Cap the fuel filter fitting to preclude contamination (4) Disconnect the P/N 646644S4Y6.50 hose assembly from the fuel pump outlet fitting to the P/N 656859A1 filter assembly and discard. Cap the fuel filter fitting and throttle /control inlet fitting to preclude contamination. (5) Remove the P/N 656859A1 filter assembly and retain for core return to TCM. (6) Remove the retention hardware from the left forward baffle area and cylinder lower baffle retaining screw.

Caution: Take care not to over flex the front baffle assembly during fuel pump replacement. Bending action in the center of the baffle can cause damage to the baffle assembly.

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(7) Remove the fuel pressure transducer and retain for re-installation. Remove the existing fuel pressure transducer hoses P/N 646644S4S8.50 and P/N 646644R4S13.00 and discard. Cap the outlet fitting of the throttle/control and manifold valve inlet fitting. Remove the MS51513B4 “TEE” Fitting and discard. Remove the installed P/N MS21919WF27 and P/N MS21919WCF10 clamps and discard. Remove the grommet from the aft baffle installation and retain for re-installation. (Reference Figure 1A and 1B)

Fuel Pressure Transducer (RETAIN)

FIGURE 1A By-Pass Fuel System Component Removal

646644S4S8.50 Hose Remove and Discard

Clamp Assembly Remove and Discard

646644R4S13.00 Hose Remove and Discard

FIGURE 1B By-Pass Fuel System Component Removal

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(8)

Using the airframe manufacturers instructions remove the airframe splash shield from the firewall. Remove and discard the P/N 646644S4S26.75 by-pass fuel hose assembly installed from the manifold valve to the firewall “TEE” fitting. Cap the tee fitting to preclude contamination. For disposition of the manifold valve by-pass “TEE” fitting and repair of the airframe splash shield refer to Diamond Aircraft Industries, Inc bulletin DAC1-73-04 (reference Figure 2)

Fuel Pump Vapor Return Hose Assembly (Reference Only) Grommet (Discard)

P/N 646644S4S26.75 Hose Assembly (Discard)

For Disposition of Swivel “TEE” P/N MS51523B4 See Diamond Bulletin DAC1-73-04

Airframe Splash Shield Repair per Diamond Bulletin DAC1-73-04

FIGURE 2 Manifold Valve By-Pass Hose “TEE” Fitting Rework (9)

Referring to the latest revision of the X30622A IO240 Series Overhaul Manual, Section 9, remove the existing fuel system manifold distributor valve assembly, the phenolic heat sink assembly and the manifold distributor valve bracket assembly. Cap or plug all fittings to preclude contamination. Disconnect the four fuel injection lines from both ends and remove. Plug the injector line bosses to preclude contamination. Remove the fuel injector from each cylinder. Retain the manifold valve assembly, fuel injector lines, mounting bracket and fuel injectors for core return to TCM. (10) Disconnect the throttle control cable from the throttle body lever, retaining all hardware for reinstallation.

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(11) Remove the throttle and control assembly from the induction manifold. Retain the .25” nuts and flat washers for re-installation. Retain the throttle and control assembly for core return to TCM. Discard the lock washers and base gasket. Cap all fittings to preclude contamination. (12) Remove the P/N 646644S4Y6.50 hose assembly from the fuel pump outlet fitting to the P/N 656859A1 filter assembly and discard. Install cap on the pump outlet fitting. (13) Disconnect the mixture control cable from the fuel pump assembly. Retain all hardware for reinstallation. (14) Remove the altitude compensating fuel pump assembly using the instructions contained in the latest revision of the IO-240 Overhaul Manual form X30622A Section 9. Remove and retain the P/N 656143-1 inlet filter assembly for reinstallation. Plug both the fuel inlet hose and vapor return hose to preclude contamination. Install caps on the fuel pump fittings. Remove and retain the fuel pump drive shaft for reinstallation. The removed fuel pump shaft must be inspected in accordance with the IO-240 Maintenance Manual X30621A Chapter 13. Fuel pump shafts inspected and found to be unserviceable must be replaced. Remove and discard the P/N 653747 fuel pump gasket. (15) Rework the existing mixture control cable installation, fuel pump drain line assembly, and baffle assemblies in accordance with Diamond Aircraft Industries, Inc. bulletin DAC1-73-04. (16) Install the P/N 653351-3A5 fuel pump assembly using the retained fuel pump drive shaft, new P/N 653747 gasket and the retained mounting hardware. Torque fuel pump mounting bolts to 180-220 InchLbs. NOTE: All caution must be exercised during reassembly of the fuel system to NOT allow any contaminants to enter the components, lines and fittings during installation. All surfaces surrounding the area where components are to be installed must be clean and free of all forms of contaminant before and during installation. (17) Restore electrical power to the aircraft and open the fuel shutoff valve. Utilizing the airframe boost pump, flush a minimum of 1 quart of fuel from the fuel pump inlet hose into a clean, dry container. Inspect the flushed fuel. If free from contamination, proceed to step (18). If contamination is found, locate the source and correct the issue before proceeding further. CAUTION: All hose assemblies must be flushed and verified to be free of contamination prior to installation. All fittings must be capped and lines plugged until flushed and ready for installation. NOTE: When torquing hose fittings the following procedures must be followed: (a) Select the proper size open-end wrenches that will fit the fitting body and hose or tubing end fitting. (b) Torque the hose or tubing end fitting to the specified torque using a properly certified calibrated torque wrench while maintaining sufficient force on the component fitting to prevent twisting and shear loads. (c) Support the last fitting in the assembly on components that contain multiple fittings coupled in one location. DO NOT over torque fittings (18) Remove the fuel pump inlet fitting cap, install the inlet fuel line and the retained P/N 656143-1 inlet filter assembly to the engine driven fuel pump in accordance with the following procedure: (a) Insert the P/N 656143-1 fuel filter element into the fuel inlet fitting. Ensure that the fuel filter flange seats against the fitting flare. Reference Figure 6. (b) Install the fuel inlet hose after flushing, onto the fuel pump fuel inlet fitting. (c) Torque the fuel inlet hose “B” nut to 150 to 195 inch pounds while maintaining sufficient force on the fuel pump inlet fitting to prevent twisting or shear loads. (d) Install mixture control lever using airframe manufacturer’s instruction. ISSUED

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CAUTION: The mixture control lever must be supported during installation to prevent side or torsion loads to the mixture control shaft and stop pin. (19) Install the P/N 653898-1A19 Throttle and Control assembly on the induction manifold using the previously retained nuts and flat washers, new P/N MS35338-44 lock washers and a new P/N 653900 gasket. (Reference Figure 3) Torque the 4ea throttle body retaining nuts to 90-110 In-Lbs. Using the airframe manufacturers maintenance instructions install the throttle control lever and throttle control. CAUTION: The throttle control lever must be supported during installation to prevent side or torsion loads to the throttle shaft. (20) Install the P/N 656863-1A1 manifold valve assembly on the engine using the previously retained AN4-14A bolts, 20522 washers and 646605 plain nuts. The bolt threads must be lubricated with 50 weight motor oil and the nuts torqued to 100-125 In-Lbs. Remove all fitting caps and line plugs. (21) Install P/N 646644S4Y13.00 hose to the fuel pump outlet fitting (remove hose plugs and fitting cap). Connect the mixture control cable to the mixture control lever. Using the airframe boost pump, flush a minimum of 1 quart of fuel through the engine driven fuel pump into a clean, dry container while working the mixture control through it’s full range of operation. Inspect the flushed fuel. If free from contamination, proceed to step (22). If contamination is found, correct the issue before proceeding further. (22) Install P/N 646644S4Y13.00 hose assembly to the throttle and control unit inlet fitting. Install the P/N 646644S4S11.50 hose assembly to the throttle and control unit outlet fitting. Torque to 135-190 Inch-Lbs. Using the airframe boost pump, flush a minimum of 1 quart of fuel through the throttle and control unit into a clean, dry container while working the throttle control through it’s full range of operation. Inspect the flushed fuel. If free from contamination, proceed to step (23). If contamination is found, correct the issue before proceeding further. (23) Install the P/N 646644S4S11.50 hose assembly from the throttle and control unit to the manifold valve assembly. Torque to 135-190 Inch-Lbs. Remove hose plugs and fitting caps. (24) Install the fuel pressure transducer hose per Diamond Bulletin DAC1-73-04. Assure the hose from manifold valve to fuel transducer is connected to the RED, orifice equipped fitting on the manifold valve. (25) Using the airframe boost pump, flush a minimum of 1 quart of fuel through the fuel transducer hose into a clean dry container. Inspect the flushed fuel. If free from contamination, proceed to step (26). If contamination is found, correct the issue before proceeding further. Install the fuel transducer in accordance with Diamond Bulletin DAC1-73-04. (26) Install the 4 each fuel injector lines. Torque the fitting at the manifold valve to 55-60 In-Lbs. (27) Using the airframe boost pump, flush the 4 fuel injector lines into 4 appropriate, clean, dry containers. If the flushed fuel is free from contamination, proceed to step (28). If contamination is found, correct the issue before proceeding further. (28) Assure fuel injection nozzles to be clean and free of contamination by soaking in cleaning solution and drying with dry compressed air. (29) Apply P/N 646943 anti-seize lubricant to the threads of each fuel injector assembly. (Alternate P/N Loctite 76732) Reference Figure 3 for proper anti-seize compound application to the fuel nozzle. (30) Install the new tuned fuel injectors into the following positions: P/N 632147-110J into #1 cylinder, P/N 632147-210J into #2 cylinder, P/N 632147-310J into #3 cylinder and P/N 632147-410J into #4 cylinder. Torque the fuel injector nozzles to 55-65 In-Lbs. (31) Install 4 ea fuel injector lines to their respective fuel nozzles. Torque the fitting at each fuel injector nozzle to 40-45 In-Lbs.

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FIGURE 3 Fuel Nozzle Anti-Seize Application

SYSTEM SETUP AND TEST 1) Static leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step. 2) Using the fuel boost pump, leak check the complete engine fuel system. Correct any defects noted before proceeding to the next step.

WARNING Over priming can cause a flooded intake resulting in a hydraulic lock condition and subsequent engine damage or failure. If the engine is over primed, or flooded, make sure that all fuel has drained from the intake and cylinders prior to attempting engine start. 3) Perform the fuel system setup and verification in accordance with the instructions and specifications contained in the latest revision of TCM bulletin SID97-3 (except as noted in 4 and 5 following) and the instructions contained in the latest revision of the IO-240 Maintenance Manual TCM Form X30621A. 4) During setup, assure that idle mixture rise at idle (1000 rpm) is 50-75 rpm. 5) Assure that low boost pump is the on position during all setup procedures. 6) After conversion and test procedures are complete make a log book entry in accordance with 14 CFR Part 43 section 43.9(a). In addition to the minimum requirements of the Federal Aviation Regulations the log entry must: (a) Note compliance with the appropriate revision of SIL07-7. (b) Note the conversion of the engine from model/specification IO-240-B17B to model/specification IO-240-B3B.

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Fuel Injection Service Kit

18

“M” Cap Flare Tube

29

Hose Assembly

2

Pump Assembly W/Fittings

19

Swivel Elbow

30

Tube Bend Assembly

3

Mixture Control Lever

19A

Radiant Heat Sleeve

31

Tube Bend Assembly

5

Self Locking Nut

19B

Cable Tie

32

Tube Bend Assembly

6

Elbow Fitting

20

Clamp Assembly

33

Dust Shield

7

Elbow Fitting NPTF

21

Hose Assembly

34

Screen

8

Fuel Pump Drive Shaft

22

Hose Assembly

35

Gasket

9

Plug

23

Manifold Valve Assembly

36

Nozzle

10

Washer

24

Elbow Fitting NPTF

144

Tee Fitting

11

Lock Washer

25

Fitting NPTF

145

Grommet

12

Nut

26

Filter

146

Clamp

13

Throttle And Control Assembly

27

Tube Bend Assembly

147

Clamp

14

Throttle And Mix Control Lever

28

90 Degree Elbow W/Orifice Fitting

148

Bolt

15

Nozzles (A-D)

28A

Tee Fitting

149

Washer

FIGURE 4 IO-240-B17B Fuel System Installation

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FIGURE 5 IO-240-B3B Fuel System Installation

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P/N 656143-1 Fuel Filter

Fuel Inlet Fitting

FIGURE 6 Fuel Pump Inlet Screen Installation

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®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engine

SIL08-10 Technical Portions FAA Approved

SUBJECT: Precision Airmotive, LLC SIL RS-88. RSA5, RSA10 Servo inspections of Hex Plug Gasket PURPOSE: To alert all operators of potential service issues with regulator plugs used on RSA5 and RSA10 Fuel Injection Servo Units. MODELS AFFECTED: All RSA5 and RSA10 NOT inspected and identified as set forth in prior bulletin PRS107 Revision’s 1-3, TCM Bulletin MSB08-2, AD 2006-06-51

Precision Airmotive, LLC has issued Service Information Letter SIL RS-88 expanding the inspection of regulator hex plugs as set forth in prior bulletin PRS-107 Rev1 through 3. SIL RS-88 includes additional RSA5 and RSA10 Fuel Injection Servo Units to be inspected. Information from the field has reported that RSA5 and RSA10 Servo units outside the prior reported dates of manufacture, appear to have contained “loose” regulator plugs. The attached Service Information Letter contains detailed instructions outlining actions to be completed on your aircraft engine. All questions concerning this bulletin should be directed to Precision Airmotive LLC through their website: www.precisionairmotive.com or via telephone at 361-651-8282, Product Support.

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SIL 08-10

Original

SIL RS-88

Service Information Letter - Fuel Systems

SMALL RECIPROCATING ENGINES RSA-5 and RSA-10 Issued: 6/16/08 Page 1 of 2

SUBJECT: Inspection of Regulator Hex Plug on RSA-5 and RSA-10 Fuel Injection Servos. PURPOSE:

To alert operators to potential service issues with regulator hex plugs on RSA-5 and RSA-10 Fuel Injection Servos.

A.

EFFECTIVITY: This Service Information Letter is applicable to all RSA-5 and RSA-10 servos which do NOT have a “G” marked on the regulator hex plug (see photograph page 2.).

B.

DESCRIPTION: Precision Airmotive LLC has received information from the FAA relating to our Service Bulletin PRS-107. In response to PRS-107, operators have reported to the FAA finding “loose” regulator hex plugs on fuel injection servos that do not appear to fall within the date range specified on that bulletin. Quantification of “loose” has been anecdotal in nature and it is therefore unknown how that determination was made. Nonetheless, to ensure safety, Precision recommends that the servos on all aircraft be inspected at each periodic inspection as set forth below.

C.

DETAILED INSTRUCTIONS: If your aircraft has an RSA-5 or RSA-10 fuel injection servo that is NOT marked with a “G” on the regulator hex plug, during each annual or other periodic inspection (but at least annually) the regulator hex plug on the fuel injection servo should be inspected to verify that it is not loose. The regulator hex plug is a 1” brass hex plug on the large round cover on the side of the fuel injection servo. (See photograph page 2.) Determining if the plug is loose requires more than just a visual inspection. The inspection should be accomplished by attempting to move the plug with a single finger. Do not use a wrench, grip the plug, or in any other way apply significant torque to the plug. If the plug does not move, it is acceptable. If the plug does move, one of the two following steps must be taken: (1) The servo can be removed and sent to a qualified repair station for repair, or (2) the servo can be repaired on the aircraft as follows: 1. Carefully cut and remove the safety wire that spans between the regulator hex plug and regulator cover only. 2. Remove hex plug. 3. Examine the threads on the hex plug and regulator cover for damage. Threads should not show signs of excessive wear. The hex plug outer diameter threads should also measure within .740-.750 inches. If the condition of the threads is suspect in any way, please contact Precision Airmotive Product Support. 4. If the threads on either the hex plug or regulator cover are excessively worn or don’t measure within the aforementioned dimensions the servo must be removed and sent to a qualified repair station for repair. 5. If the threads on both the hex plug and the regulator cover are acceptable, obtain a new gasket, Precision Airmotive part number 2577258. Discard the old gasket.

S.I.L. RS-88

Page 2 of 2

6. Stamp or scribe the letter “G” onto the face of the hex plug as shown in the sample photos. This shall be done with the plug removed from the servo. DO NOT stamp the plug with it installed in the servo. 7. With an acceptable hex plug and an acceptable regulator cover and the new 2577258 gasket, install the gasket over the hex plug and install plug into the regulator cover. Torque the hex plug to 90-100 in-lbs. 8. The hex plug must be safety wired with .015 thru .025 inch diameter wire to the regulator cover as shown in the photos below. The wire shall pass thru the plug such that it pulls the plug in the tightened direction and does not rest on the corners of the hex on the plug (it is acceptable to wrap under the corners of the hex plug). These photos are just two examples of acceptable safety methods. Other safety wire methods such as those described in FAA AC 43-13-1B (or latest revision) are also acceptable. 9. Ensure that any other safety wire on the servo that may have been damaged when removing the hex plug safety wire is replaced. 10. Enter in the engine log book the date the 2577258 gasket was installed and a “G” was marked on the regulator hex plug per this Service Information Letter, SIL RS-88. Further inspections per this SIL are no longer required.

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Ignition System’s Service Documents MODELS AFFECTED: SUBJECT: REASON FOR LETTER:

CATEGORY 5

SIL640

FAA APPROVED

All

NEW SERVICE DOCUMENT FORMAT To advise and explain the use of a new format.

TCM has adopted a new service document format which will provide the user with an explanation of the compliance criticality of the document. This format was developed by the General Aviation Manufacturers Association (GAMA) to standardize service documents used by aviation manufacturers. The documents will be presented in five categories which are defined below. Each revision to the document will be noted in the information block located at the bottom of each page. This information will include the date of original issuance, revision date, page number and revision number. The most recent revisions to the document will be identified by a solid bold vertical line on the left hand side of the page, adjacent to the revised sentence, paragraph, drawing, etc. SERVICE DOCUMENT CATEGORY 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 an Airworthiness Directive (AD) issued by the FAA or have been issued, at the direction of FAA, by the manufacturer, in order to allow compliance with an already issued AD (or an equivalent issued by another country's airworthiness authority). CATEGORY 2: "CRITICAL SERVICE BULLETIN" (CSB) - Service documents (not included in Category 1) that have been determined by the product manufacturer to constitute a threat to continued safe operation of an aircraft or to persons or property on the ground unless some specific action (inspection, repair, replacement, etc.) is taken by the product owner or operator. Documents in this category are candidates for incorporation in an Airworthiness Directive issued by 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 improvement to the inherent safety of an aircraft or component of an aircraft. This "Service Bulletin" category also includes the most recent updates of instructions for continued airworthiness. CATEGORY 4: "SERVICE INFORMATION DIRECTIVE" (SID) – Serviced documents (not included in Categories 1, 2 or 3) that have been determined by the manufacturer to be of value to an owner/operator 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 Category 1-4) that may be of use to the owner, operator or maintainer of the aircraft.

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IGNITION SYSTEMS

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B

FAA APPROVED

NOTES A. DOCUMENT NAME B. CATEGORY EXPLANATION C. DOCUMENT CATEGORY D. DOCUMENT NUMBER – REGARDLESS OF CATEGORY, NUMBERS WILL RUN CONSECUTIVELY. Fore Example: SB639 SIL640 CSB641 etc. ALERT BORDER SOLID RED FOR CATEGORY 1: ALTERNATING RED AND WHITE FOR CATEGORY 2: NO BORDER FOR OTHER CATEGORIES

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TELEDYNE CONTINENTAL ® IGNITION SYSTEMS

CATEGORY 5

SERVICE INFORMATION LETTER

SIL642B

Contains Useful Information Pertaining To Your Ignition System

SUPERSEDES SERVICE BULLETINS 633, 642, and 642A FAA APPROVED

SUBJECT:

MANUFACTURING NUMBER (SERIAL NUMBER) INTERPRETATION

REASON FOR LETTER: EQUIPMENT AFFECTED:

To Clarify The Meaning Of Manufacturing Numbers Found on TCM Ignition Systems Data Plates.

All TCM S-20, S-200, S-1200 and D-3000 Series Magnetos, New or Factory Rebuilt, Gold Seal Harnesses, Ignition Switches and Starting Vibrators.

GENERAL INFORMATION: Field Reports indicate occasional difficulty when determining Service Bulletin applicability based on Serial Numbers. Manufacturing numbers, commonly referred to as serial numbers, are currently used to identify ignition system equipment built by TCM. These manufacturing numbers employ a coding system shown below. The build date derived from this code, rather than the magnitude of the numbers, determines the time of manufacture. Therefore, for Service Bulletin compliance purposes, all magnetos manufactured or rebuilt by TCM may be considered to have a "higher" serial number than magnetos manufactured or "Remanufactured" by Bendix in Sidney, New York, or in Jacksonville, FL. Corporate identification and factory location is found on the Unit's Data Plate. Current serial numbers, since late 1999, may be read as follows:

01= sequential number for unit ( begins each day, magnetos only)

Example: D02EA005R

F= Component Identification code

D= Component Identification Code (S20 Series Magneto)

R= Rebuilt (No letter for new unit)

with 01

Component Identification Codes: 02= Year of Manufacture (2002) E= Month (May) A005= Unit Serial Number (5th unit in sequence, begin with A001 each month, after A999 go to B001, etc.) R= Rebuilt (No letter for new unit)

D - S20 Series Magneto E - S200 Series Magneto F - S1200 Series Magneto G - D3000 Series H – Switches, Ignition J – Vibrators, Ignition K – Harness, Ignition

Serial numbers for components manufactured prior to late 1999 may be read as follows:

Month Codes A – Jan

E- May

I – Sep

Example: B159801FR

B – Feb

F – Jun

J – Oct

B= Month (February)

C – Mar

G – Jul

K – Nov

15= Day of Month

D – Apr

H – Aug

L – Dec

98= Year of Manufacture (1998)

Note: Switches, harness and vibrators require only year and month codes for component identification.

MO 02

ISSUED DAY YEAR 01

94

MO 03

REVISED DAY YEAR 09

2005

© 2005 Teledyne Continental Motors, Inc.

PAGE NO REVISION TM

Teledyne Continental Motors, Inc. PO Box 90 Mobile Alabama 36601 • 251-438-3411

1 of 1

B

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 5

SERVICE INFORMATION LETTER SIL646 Contains Useful Information Pertaining To Your Aircraft SUBJECT:

FAA APPROVED

HISTORY OF THE REQUIREMENT TO REPLACE MAGNETO COILS AND ROTATING MAGNETS.

This March, the Federal Aviation Administration issued Airworthiness Directive 94-01-03 that applies to Teledyne Continental Motors Ignition Systems Service Bulletin 637. The issuance of this A.D. has caused some confusion as to which magneto models and serial numbers are affected. To help understand which magnetos are affected and/or require inspection, some background history is required. In August of 1972, Bendix Corporation issued Service Bulletin 560 that required the replacement of certain part number coils and rotating magnets at overhaul in all new and remanufactured S-20, S-200, S-600 and S-1200 Series magnetos within specific serial number ranges. This requirement applies to each Type magneto included in each magneto Series designation. Reference the following table for magneto Series and their associated Type numbers. S-20 SERIES

S-200 SERIES

S-1200 SERIES

*S-600

S-20 SERIES

S-200 SERIES

S-1200 SERIES

*S-600

S4LN-20

S4LN-200

S4LN-1208

*S6RN-600

S6LN-25P

S6LN-201

S6LN-1227

----

S4RN-20

S4LSC-200

S4LN-1209

*S6RN-604

S6RN-25P

S6RN-201

S6RN-1227

----

S4LN-21

S4RN-201

S4RN-1209

----

S6LSC-25

S6LSC-201

S6LN-1251

----

S4RN-21

S4RSC-201

S4LN-1227

----

S4LN-204

S4RN-1227

----

S6RSC-25

S6RSC-201

S6RN-1251

----

S4LSC-21 S4RSC-21

S4LSC-204

S6LN-1201

----

S6LSC-25P

S6LN-204

S6LN-1255

----

S4LSC-21T

S4RSC-204

S6RN-1201

----

S6RSC-25P

S6RN-204

S6RN-1255

----

S6LN-20

S4LSC-204T

S6LN-1205

----

S6LSC-25T

S6LSC-204

S6LN-1258

----

S6LN-21

S4RN-205

S6RN-1205

----

* S6LN-22

S6RSC-204

S6RN-1258

----

S6RN-21

S4RSC-205

S6LN-1208

----

* S6RN-23

S6LSC-204P

S6LN-1259

----

S6LSC-21

S6LN-200

S6RN-1208

----

----

S6LSC-204T

S6RN-1259

----

S6RSC-21

S6RN-200

S6LN-1209

----

----

S6LN-205

S8LN-1208

----

S6LN-23

S6LSC-200

S6RN-1209

----

----

S6RN-205

S8LN-1209

----

----

S6LSC-205

S8LN-1258

----

----

S6RSC-205

S8LN-1259

----

S6LN-25

S6RSC-200

S6LN-1225

----

S6RN-25

S6LSC-200P

S6RN-1225

----

* - No Longer Produced

Additional Type numbers may be added as new magneto models are developed. For a detailed explanation of Type numbers, reference the applicable magneto System Support Manual.

MO 09

ISSUED DAY YEAR 14

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

1 of 2

Soon thereafter, the F.A.A. issued A.D. 73-07-04 that required that the affected parts listed in Service Bulletin 560 be replaced upon the accumulation of 2000 hours on magnetos that had less than 1800 hours total time in service and within the next 200 hours on those with 1800 hours or more. Those with unknown time in service were considered to fall within the category of those that had accumulated 1800 hours or more. Compliance with A.D. 73-07-04 will be indicated by the letter "A" stamped on the magneto housing between the timing plug hole and harness outlet plate. Bendix Service Bulletin 560 was later revised to 560A. This revision included the addition of changes that did not affect the applicability or compliance times of the original Service Bulletin 560 issuance. Six years after the purchase of the Bendix Corporation light aircraft ignition systems product line, Teledyne Continental Motors issued Service Bulletin 637 which superseded 560A. This bulletin included three major changes: (1) Magneto serial number affectivity, (2) compliance at the next 100 hour, annual or progressive maintenance inspection, whichever comes first, and (3) the deletion of certain previously approved S-20, S-200 and S-1200 Series coils. In March of this year, the F.A.A. superseded A.D. 73-07-04 with A.D. 94-01-03 to remain consistent with the changes and requirements of Service Bulletin 637. An important detail to remember is that magnetos that have complied with A.D. 73-07-04 may be in compliance with A.D. 94-01-03, as long as the latest part number coil, (as listed in Service Bulletin 637) was installed at the time of compliance. The types of rotating magnets that were required to be replaced under the instructions listed in A.D. 73-07-04 and A.D. 94-01-03 are the same and therefore, did not change. None of the affected coils and rotating magnets that were required to be replaced by Service Bulletin 637 were available from Bendix or TCM after 1974. Also, any magneto with a TCM data plate would not be affected by A.D. 94-01-03. TCM Ignition Systems service bulletin MSB644 supersedes 637. This supersedure is intended to clarify magneto affectivity and reduce the number of "new" magnetos affected. This month, the F.A.A. issued A.D. 94-01-03 R1 to reflect the changes included in Service Bulletin MSB644. The latest "new" S-20, S-200 or S-600 series magneto affected by A.D. 94-01-03 R1 was built January 4, 1971. The latest "new" S-1200 series magneto was built December 31, 1974. The latest "remanufactured" magneto of any series was built December 31, 1978. All of these magnetos were built by Bendix Corporation, not TCM Ignition Systems. The need for releasing a service bulletin and A.D. with reduced compliance time stems from the lack of adherence to the required preventive maintenance to be performed on magnetos. In 1992, the National Transportation Safety Board recommended that the F.A.A. issue airworthiness directives requiring inspection and maintenance on all brands of magnetos, due to the number of accidents caused by magneto neglect. Teledyne Continental Ignition Systems Service Bulletin SB643 (which superseded 632A) provides the required maintenance intervals for all TCM and Bendix aircraft magnetos and related equipment. Ignition systems must be maintained in accordance with the manufacturer's instructions.

MO 09

ISSUED DAY YEAR 14

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

2 of 2

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 5

SERVICE INFORMATION LETTER SIL647 Contains Useful Information Pertaining To Your Aircraft

FAA APPROVED

Ignition System

SUBJECT:

SC-20 AND SC-200 SERIES MAGNETO PRODUCT LINE

REASON FOR LETTER:

To announce superseding product information and to specify revised installation instructions.

EQUIPMENT AFFECTED:

All S-20 and S-200 Series Magnetos (Refer to Table 1 and Table 2).

COMPLIANCE:

For information when replacing affected magnetos.

GENERAL INFORMATION: 1. Teledyne Continental Motors is now supplying new SC-20 and SC-200 Series Magnetos in place of new S-20 and S-200 Series Magnetos and will be phasing-in rebuilt SC-20 and SC-200 Series Magnetos to fill orders for rebuilt S-20 and S-200 Series Magnetos in the coming year. Refer to Table 1 and Table 2 for a detailed listing of superseding part numbers and superseding type numbers. 2. SC-20 and SC-200 Series Magnetos have the following features: •

Feed-thru capacitor on all specifications. This technology eliminates the need for aftermarket in-line P-lead filters.

•

Capacitor interchangeable with S-1200 Series Magnetos.

•

Simplified stud-type switch connections. This technology eliminates the need for special "Plead" terminal kits. This also facilitates interchangeability with S-1200 Series Magnetos as well as Slick 400, 600, 4000, 4100, 4200, 4300, 6000, 6100, 6200, and 6300 Series Magnetos.

•

Low profile short cover allows maximum installation flexibility.

•

Consolidated parts usage.

•

Familiar, rugged and versatile S-20 and S-200 technology.

3. SC-20 and SC-200 Series Magnetos may be serviced by referring to the latest revision of the S-20 / S-200 Series Service Support Manual, Form X42002-1, dated November, 1993. Engine applications for SC-20 and SC-200 Series Magnetos may be determined by referring to the latest revision of TCM Ignition Application Data, form X44001-2, dated May, 1994. Both of these publications are included in TCM Ignition Systems Master Service Manual, form X40000.

MO 10

ISSUED DAY YEAR 03

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

1 of 4

4. Short Cover SC-20 and SC-200 Series Magnetos are fully interchangeable with S-20 and S-200 Series Magnetos previously supplied. Although installing the SC-20 and SC-200 in matching sets is preferred, pairing an SC magneto with one of the old type magnetos on an engine installation is permissible. All SC magnetos listed in Tables 1 and 2 are FAA-PMA approved. Also note that engines fitted with a single impulse coupled magneto (example: Type S4LSC-21, Part Number 10500514-2) are typically also fitted with an SC-200 Series "straight drive" Magneto (example: Type S4LSC-204, Part Number 10-600644-1) on the right side of the engine. INSTALLATION INSTRUCTIONS: Installation of SC-20 and SC-200 Series Magnetos is accomplished in the same manner as with old style S-20 and S-200 Series Magnetos, except for the connection to the wire (also known as the Plead) that goes to the cockpit-mounted ignition switch. WARNING If the propeller is moved during maintenance procedures and a functional ("hot") magneto condition exists, the engine may fire and cause damage to property, injury, or death. WARNING Upon installation SC-20 or SC-200 Series Magnetos, externally mounted P-lead filter capacitors, including but not limited to part numbers MF-3A, NFT-403, or 94B016-01, are no longer required, can have a detrimental effect on magneto operation, and must not be installed. NOTE...P-lead terminal kits, part numbers 10-52305, 10-52305-1, 10-52306, 10-157208, 10-157209, and 10-382814, are no longer required to attach the P-lead to the magneto. 1. Install an MS25171-1S Boot over the P-lead wire. Crimp an appropriate No. 10 eyelet terminal onto the P-lead conductor. Secure the eyelet to the Magneto's capacitor stud (marked "SWITCH") using a locknut or nut and lockwasher appropriate for 10-32 UNF-2A threads. Apply 15-17 in-lbs torque to P-lead securing nut. NOTE...Retard lead connections are made in the identical manner as P-lead connections, except the retard stud (marked "RETARD") is used. 2. Where shielded P-lead wire is used, the shielding pigtail must be crimped into an appropriate Number 6 eyelet terminal and secured to airframe ground at the magneto's capacitor mounting screw. Apply 8 to 12 in-lbs torque to the capacitor mounting screw. 3. Ensure that the P-lead conductor and its associated eyelet and nut cannot inadvertently be grounded. To complete the installation, move the MS25171-1S boot into position to cover the stud connection. 4. Check the integrity of the connection by performing the "Magneto RPM Drop" preflight test, as detailed in the Aircraft's Pilot's Operating Handbook. Make a logbook entry indicating magneto is installed in accordance with this Service Information Letter.

MO 10

ISSUED DAY YEAR 03

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

2 of 4

TABLE 1 SUPERSEDURE OF TCM (BENDIX) S-20 AND S-200 SERIES MAGNETOS OLD P/N TO NEW P/N CROSS REFERENCE Old Style Magneto P/N

Old Style Magneto P/N

Replaced By SC Magneto P/N

New SC Type Number

Old Style Magneto P/N

Old Style Magneto P/N

Replaced By SC Magneto P/N

New SC Type Number

10-51360-25

S4LN-21

10-500514-1

S4LSC-21

10-79020-6

S6LN-25

10-500556-3

S6LSC-25

10-51360-26

S4LN-21

10-500514-1

S4LSC-21

10-79020-10

S6RN-25

10-500556-1

S6RSC-25

10-51360-27

S4RN-20

10-600644-3

S4RSC-204

10-79020-11

S6LN-25

10-500556-203

S6LSC-25T

10-51360-28

S4RN-21

10-500514-3

S4RSC-21

10-79020-16

S6LN-25

10-500556-3

S6LSC-25

10-51360-29

S4LN-20

10-600644-1

S4LSC-204

10-79020-17

S6LN-25

10-500556-203

S6LSC-25T

10-51360-37

S4LN-21

10-500514-1

S4LSC-21

10-79020-18

S6LN-25

10-500556-3

S6LSC-25

10-51360-40

S4RN-20

10-600644-5

S4RSC-204

10-79020-19

S6RN-25

10-500556-1

S6RSC-25

10-51360-41

S4RN-21

10-500514-5

S4RSC-21

10-79020-118

S6LN-25P

10-500556-103

S6LSC-25P

10-51360-45

S4LN-21

10-500514-1

S4LSC-21

10-79020-119

S6RN-25P

10-500556-101

S6RSC-25P

10-51360-46

S4RN-21

10-500514-4

S4RSC-21

10-163005-2

S4LN-200

10-600614-1

S4LSC-200

10-51360-47

S4LN-21

10-500514-201

S4LSC-21T

10-163005-3

S4LN-200

10-600614-3

S4LSC-200

10-51360-54

S4LN-21

10-500514-2

S4LSC-21

10-163005-11

S4LN-200

10-600614-2

S4LSC-200

10-51360-55

S4LN-21

10-500514-2

S4LSC-21

10-163010-1

S6RN-200

10-600616-4

S6RSC-200

10-51360-58

S4LN-21

10-500514-2

S4LSC-21

10-163010-2

S6LN-200

10-600616-5

S6LSC-200

10-51365-9

S6LN-21

10-500516-10

S6LSC-21

10-163010-10

S6LN-200

10-600616-3

S6LSC-200

10-51365-32

S6LN-21

10-500516-3

S6LSC-21

10-163010-11

S6LN-200

10-600616-6

S6LSC-200

10-51365-33

S6LN-20

10-600646-2

S6LSC-204

10-163010-15

S6RN-200

10-600616-7

S6RSC-200

10-51365-34

S6RN-21

10-500516-5

S6RSC-21

10-163015-3

S4RN-201

10-600604-1

S4RSC-201

10-51365-35

S6RN-21

10-500516-6

S6RSC-21

10-163020-3

S6RN-201

10-600606-1

S6RSC-201

10-51365-39

S6LN-21

10-500516-4

S6LSC-21

10-163020-4

S6LN-201

10-600606-3

S6LSC-201

10-51365-40

S6RN-21

10-500516-7

S6RSC-21

10-163045-1

S4LN-204

10-600644-4

S4LSC-204

10-51365-43

S6LN-21

10-500516-3

S6LSC-21

10-163045-3

S4LN-204

10-600644-1

S4LSC-204

10-51365-46

S6LN-20

10-600646-1

S6LSC-204

10-163045-6

S4LN-204

10-600644-201

S4LSC-204T

10-51365-47

S6LN-21

10-500516-2

S6LSC-21

10-163050-1

S6LN-204

10-600646-2

S6LSC-204

10-51365-48

S6RN-21

10-500516-9

S6RSC-21

10-163050-2

S6LN-204

10-600646-3

S6LSC-204

10-51365-54

S6RN-21

10-500516-7

S6RSC-21

10-163050-7

S6RN-204

10-600646-4

S6RSC-204

10-51365-57

S6LN-21

10-500516-2

S6LSC-21

10-163050-9

S6LN-204

10-600646-1

S6LSC-204

10-52350-19

S6RN-23

10-500516-9

S6RSC-21

10-163050-12

S6LN-204

10-600646-201

S6LSC-204T

10-52350-20

S6LN-23

10-500516-3

S6LSC-21

10-163055-1

S4RN-205

10-600654-1

S4RSC-205

10-52350-22

S6LN-22

10-600646-2

S6LSC-204

10-163060-1

S6RN-205

10-600656-1

S6RSC-205

10-52350-23

S6RN-23

10-500516-5

S6RSC-21

10-163060-2

S6LN-205

10-600656-3

S6LSC-205

TABLE 2 SUPERSEDURE OF TCM (BENDIX) S-20 AND S-200 SERIES MAGNETOS: NEW P/N TO OLD P/N CROSS REFERENCE NEW SC PART NUMBER

MO 10

NEW TYPE NUMBER

ISSUED DAY YEAR 03

94

MO

REPLACES OLD P/N

OLD TYPE NUMBER

REVISED DAY YEAR

NEW SC PART NUMBER

NEW TYPE NUMBER

REPLACES OLD P/N

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

OLD TYPE NUMBER

PAGE NO REVISION

3 of 4

NEW SC PART NUMBER 10-500514-1

NEW TYPE NUMBER S4LSC-21

10-500514-2

S4LSC-21

REPLACES OLD P/N

OLD TYPE NUMBER

NEW SC PART NUMBER

10-51360-25

S4LN-21

10-500556-203

10-51360-26

S4LN-21

10-51360-37

S4LN-21

10-600604-1

10-51360-45

S4LN-21

10-51360-54

NEW TYPE NUMBER S6LSC-25T

REPLACES OLD P/N

OLD TYPE NUMBER

10-79020-11

S6LN-25

10-79020-17

S6LN-25

S4RSC-201

10-163015-3

S4RN-201

10-600606-1

S6RSC-201

10-163020-3

S6RN-201

S4LN-21

10-600606-3

S6LSC-201

10-163020-4

S6LN-201

10-51360-55

S4LN-21

10-600614-1

S4LSC-201

10-163005-2

S4LN-200

10-51360-58

S4LN-21

10-600614-2

S4LSC-200

10-163005-11

S4LN-200

10-500514-3

S4RSC-21

10-51360-28

S4RN-21

10-600614-3

S4LSC-200

10-163005-3

S4LN-200

10-500514-4

S4RSC-21

10-51360-46

S4RN-21

10-600616-3

S6LSC-200

10-163010-10

S6LN-200

10-500514-5

S4RSC-21

10-51360-41

S4RN-21

10-600616-4

S6RSC-200

10-163010-1

S6RN-200

10-500514-201

S4LSC-21T

10-51630-47

S4LN-21

10-600616-5

S6LSC-200

10-163010-2

S6LN-200

10-500516-2

S6LSC-21

10-51365-47

S6LN-21

10-600616-6

S6LSC-200

10-163010-11

S6LN-200

10-51365-57

S6LN-21

10-600616-7

S6RSC-200

10-163010-15

S6RN-200

10-51365-32

S6LN-21

10-600644-1

S4LSC-204

10-51360-29

S4LN-20

10-51365-43

S6LN-21

10-163045-3

S4LN-204

10-52350-20

S6LN-23

10-600644-3

S4RSC-204

10-51360-27

S4RN-20

10-51365-39

S6LN-21

10-600644-4

S4LSC-204

10-163045-1

S4LN-204

10-500516-3

S6LSC-21

10-500516-4

S6LSC-21

10-500516-5

S6RSC-21

10-51365-34

S6RN-21

10-600644-5

S4RSC-204

10-51360-40

S4RN-20

10-52350-23

S6RN-23

10-600644-201

S4LSC-204T

10-163045-6

S4LN-204

10-600646-1

S6LSC-204

10-51360-46

S6LN-20

10-163050-9

S6LN-204

10-51365-33

S6LN-20

10-500516-6

S6RSC-21

10-51365-35

S6RN-21

10-500516-7

S6RSC-21

10-51365-40

S6RN-21

10-51365-54

S6RN-21

10-51365-48

S6RN-21

10-52350-22

S6LN-22

10-52350-19

S6RN-23

10-163050-1

S6LN-204

10-500516-9

S6RSC-21

10-600646-2

S6LSC-204

10-500516-10

S6LSC-21

10-51365-9

S6LN-21

10-600646-3

S6LSC-204

10-163050-2

S6LN-204

10-500556-1

S6RSC-25

10-79020-10

S6RN-25

10-600646-4

S6RSC-204

10-163050-7

S6RN-204

10-79020-19

S6RN-25

10-600646-201

S6LSC-204T

10-163050-12

S6LN-204

10-79020-6

S6LN-25

10-600654-1

S4RSC-205

10-163055-1

S4RN-205

10-79020-16

S6LN-25

10-600656-1

S6RSC-205

10-163060-1

S6RN-205

10-79020-18

S6LN-25

10-600656-3

S6LSC-205

10-163060-2

S6LN-205

10-500556-3

S6LSC-25

10-500556-101

S6RSC-25P

10-79020-119

S6RN-25P

10-500556-103

S6LSC-25P

10-79020-118

S6LN-25P

MO 10

ISSUED DAY YEAR 03

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

4 of 4

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 5

SERVICE INFORMATION LETTER SIL648 Contains Useful Information Pertaining To Your Aircraft Ignition System SUBJECT: REASON FOR LETTER:

OPTIONAL CONVERSION TO "SHOWER-OF-SPARKS" IGNITION To provide installation data regarding "Shower-Of Sparks" ignition systems.

EQUIPMENT AFFECTED:

COMPLIANCE:

FAA APPROVED

MAGNETO TYPE NUMBER S4LN-21 S4LN-21 S4LN-21 S4LN-21 S4LN-21 S4LN-21 S4LSC-21 S4LSC-21 S6LN-21 S6LN-21 S6LN-21 S6LSC-21 S6LSC-21 S6LN-25 S6RN-25 S6LN-25 S6LN-25

MAGNETO PART NUMBER 10-51360-26 10-51360-37 10-51360-45 10-51360-54 10-51360-55 10-51360-58 10-500514-1 10-500514-2 10-51365-39 10-51365-47 10-51360-57 10-500516-2 10-500516-4 10-79020-6 10-79020-10 10-79020-16 10-79020-18

MAGNETO TYPE NUMBER S6RN-25 S6RSC-25 S6LSC-25 S4LN-1227 S4LN-1227 S6RN-1225 S6RN-1225 S6LN-1225 S6LN-1225 S6LN-1227 D6LN-2031 D6LN-2031 D6LN-3000 D6LN-3000 D6LN-3000 D6LN-3000 D6LN-3000

MAGNETO PART NUMBER 10-79020-19 10-500556-1 10-500556-3 10-349365-3 10-349365-9 10-349350-4 10-349350-5 10-349350-6 10-349350-7 10-349370-4 10-385126-105 10-385126-107 10-685126-105 10-685126-107 10-685126-108 10-785126-105 10-785126-107

At user’s discretion.

GENERAL INFORMATION: Since the 1940's, the vast majority of four and six cylinder aircraft engines have been manufactured to include one of two systems to assist magneto ignition during engine start: either the impulse coupling or the "Shower-of-Sparks" booster technology. An impulse coupling is a mechanical device attached to the drive shaft of the magneto. Impulse couplings contain moving parts which are subject to wear. In order to avoid periodic inspections for impulse coupling wear, operators may convert their ignition equipment from impulse coupling to Shower-of-Sparks.

MO 10

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A typical Shower-of-Sparks ignition system includes a special ignition switching arrangement, a "boosted" left mounted magneto fitted with a retard breaker, a "non-boosted" right mounted magneto which is grounded during starting, and a starting vibrator. The function of the special ignition switching arrangement is to ground the right mounted magneto during the start cycle, to energize the starter relay and the starting vibrator, and to direct the starting vibrator output voltage to both the main and retard breakers in the left mounted magneto for boosted starting. Many engine applications can be converted from impulse coupled to Shower-of-Sparks starting. See Table 1for a complete listing of eligible engines. All engines listed in Table 1 may be converted by removing the impulse coupled magneto(s) and replacing them with Shower-of Sparks magnetos as detailed in Table 1. Follow Detailed Instructions, paragraph A for complete installation instructions. In a few cases, impulse coupled magnetos themselves may be converted to Shower-of-Sparks configurations. See Detailed Instructions, paragraph B, for conversion instructions, then install reconfigured magnetos in accordance with paragraph A. DETAILED INSTRUCTIONS A. "Shower-of-Sparks" Conversion 1. Remove impulse coupled magneto(s). If possible, magneto(s) may be converted to Shower-ofSparks configuration in accordance with paragraph B. Install Shower-of-Sparks replacement magneto(s) and associated mounting and drive parts in accordance with applicable engine parts list (see NOTE, below). Adjust magneto-to-engine timing in accordance with engine manufacturer's instructions. See Table 1 for application data. NOTE...For many Lycoming installations, some additional engine parts, such as gears, standoffs, drive plates, studs and clamps may be necessary for conversion. Consult engine parts list. Also for many Lycoming installations, only the left magneto was originally equipped with an impulse coupling. Therefore, these engines can be converted to Shower-of-Sparks without affecting the right magneto in any way. 2. Using suitable mounting hardware and acceptable standard shop practice, install starting vibrator unit on airframe. Refer to Table 4 for a list of typical installation materials. Vibrator unit is to be mounted in a location which will provide minimum wire lengths, freedom from excessive heat or exposure to the elements, freedom from interference with other parts of the aircraft, and accessibility for inspection. Vibrator unit part number selection is based on electrical system voltage and magneto type. See Table 2 for vibrator applications. Complete the Shower-ofSparks wiring using standard 18 gage (or larger) aircraft wire as necessary. See Figure 1 or Figure 2 for typical wiring diagrams. WARNING Only aircraft grade materials must be used. Selection of materials, installation positioning, routing of wires, and installation workmanship must be performed in accordance with all applicable Federal Aviation Regulations, including but not limited to: Section 23.1301, 23.1309, 23.1351, 23.1357, 23.1365, 23.1367 and 43.13.

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3. Complete an FAA Form 337 with all pertinent information regarding conversion, referencing this Service Information Letter and detailing specific parts added and deleted as well as specific new wiring configuration. B. Magneto Conversion Certain impulse coupled magnetos may be economically converted to magneto specifications with retard breaker (boosted) or with no start assist mechanism (non-boosted). Such magnetos are listed in Table 3. Following the latest revision of the appropriate service manual and parts catalog (included in TCM Ignition Systems Master Service Manual, Form X40000): 1. Remove impulse coupling and replace with P/N 10-163003 drive plate and associated attaching parts. 2. Stop pins in S-20 Series magnetos being converted may be left in place. Stop pins in S-1200 Series magnetos being converted MUST be left in place, unless flange is replaced with P/N 10349392-1 flange with sealed stop pin holes. If converting to non-boosted magneto, proceed to step 4. 3. When converting to boosted (with retard breaker) magnetos, mark and adjust distributor gear as specified for boosted magnetos, then install and adjust retard breaker. Install retard lead and associated parts. a. For S6LN-25 and S6RN-25 magnetos, remove and discard cap nut P/N 10-163177 and disk P/N 10-163384 from retard terminal. b. For all other magnetos, remove magneto cover from magneto housing and drill hole .290 inch diameter through cover at retard countersink position. Remove all debris and burrs from cover prior to assembly of retard stud terminal and associated parts. 4. Assemble new data plate onto magneto to indicate new magneto part number and type number. Data plate P/N 10-400012 is to be used for S-200 Series magnetos. Data plate P/N 10-400009 is to be used for S-1200 Series magnetos. PARTS REQUIRED: As determined by application. MAN HOURS REQUIRED: Approximately 2 hours per engine. WEIGHT CHANGE: As determined by application. WARRANTY CONSIDERATION: None. Compliance with this Service Information Letter is optional. New or Rebuilt parts installed in accordance with this Service Information Letter are covered under the terms and conditions of the standard TCM Ignition Systems Warranty Policy.

MO 10

ISSUED DAY YEAR 18

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

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TABLE 1 SHOWER-OF-SPARKS CONVERSION INFORMATION MAGNETO TO ENGINE APPLICATION CHART

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ISSUED DAY YEAR 18

94

MO

REVISED DAY YEAR

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PAGE NO REVISION

4 of 10

TABLE 1 SHOWER-OF-SPARKS CONVERSION INFORMATION MAGNETO TO ENGINE APPLICATION CHART

MO 10

ISSUED DAY YEAR 18

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

5 of 10

TABLE 1 SHOWER-OF-SPARKS CONVERSION INFORMATION MAGNETO TO ENGINE APPLICATION CHART

MO 10

ISSUED DAY YEAR 18

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

PAGE NO REVISION

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TABLE 2 – STARTING VIBRATOR APPLICATIONS Vibrator Part Number

Description

Use With Ignition System

10-176487-121

12VDC, 2.5A

S-200 Series

10-357487-241

24VDC, 2.5A

S-200 Series

10-176487-122

12VDC, 2.0A

S-1200 Series

10-357487-242

24VDC, 2.0A

S-1200 Series

10-382775-12

12VDC, 2.0A

D-3200 Series

10-382808-24

24VDC, 2.0A

D-3200 Series

TABLE 3 CONVERSION OF IMPULSE COUPLED MAGNETOS TO SHOWER-OF-SPARKS CONFIGURATIONS

MO 10

Impulse Coupled Magneto P/N (Type Number)

May be Converted to Boosted Magneto P/N (Type Number) Left Mount

May be Converted to Non-Boosted Magneto P/N (Type Number) Right Mount

10-79020-18 (S6LN-25)

10-163020-4 (S6LN-201)

10-163060-2 (S6LN-205)

10-79020-19 (S6RN-25)

10-163020-3 (S6RN-201)

10-163060-1 (S6RN-205)

10-500556-1 (S6RSC-25)

10-600606-1 (S6RSC-201)

10-600656-1 (S6RSC-205)

10-500556-3 (S6LSC-25)

10-600606-3 (S6LSC-201)

10-600656-3 (S6LSC-205)

10-349350-4 (S6RN-1225)

10-349220-5 (S6RN-1201)

--------------------

10-349350-5 (S6RN-1225)

--------------------

10-349260-6 (S6RN-1205)

10-349350-6 (S6LN-1225)

10-349220-4 (S6LN-1201)

--------------------

10-349350-7 (S6LN-1225)

--------------------

10-349260-7 (S6LN-1205)

ISSUED DAY YEAR 18

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TABLE 4 TYPICAL INSTALLATION MATERIALS LIST Description Magneto Vibrator Terminal, Jumper Screw, Switch Cable Tie #10 Eyelet #10 Nut #10 Screw #10 Washer Wire, 18 Gage Boot Gasket, Magneto

Retard Terminal Kit * Switch Terminal Kit **

Part Number See Table 1 See Table 2 10-126656 10-126648 10-620013 10-400039 10-13799 10-35937-10 10-78655 Aircraft Grade MS25171-1S 62224 535324 534750 10-157209 10-157209

Quantity, 1 Engine 1 1 1 3 15 4 3 2 4 25 ft. 1 1 2 2 1 2

Quantity, 2 Engines 2 1 2 6 25 8 4 2 4 50 ft. 2 2 4 2 4

Vendor TCM TCM TCM TCM TCM TCM TCM TCM TCM Local Purchase Local Purchase LYCOMING TCM TCM TCM TCM

Notes: * For use with D6LN-3200 type magnetos or old style S-200 Series (P/N 10163XXX-X Series) magnetos only. ** For use with old style S-200 Series (P/N 10-163XXX-X Series) magnetos only, if not previously installed.

MO 10

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MO

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TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

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A

&

B

For twin engine installations, starting vibrator may be shared by interconnecting ignition/start circuits at points shown.

FIGURE 1: WIRING DIAGRAM – SHOWER-OF-SPARKS IGNITION SYSTEM WITH TWIST-TO-START OR PUSH-TO-START MAGNETO SWITCH

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PAGE NO REVISION

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A

&

B

For twin engine installations, starting vibrator may be shared by interconnecting ignition/start circuits at points shown.

FIGURE 2: WIRING DIAGRAM – SHOWER-OF-SPARKS IGNITION SYSTEM WITH INDIVIDUAL TOGGLE MAGNETO SWITCHES OR “GM TYPE” MAGNETO SWITCH

MO 10

ISSUED DAY YEAR 18

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MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS

PAGE NO REVISION

P.O. Box 90 MOBILE ALABAMA 36601 (205) 438-3411

10 of 10

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Ignition System SUBJECT: REASON FOR LETTER: EQUIPMENT AFFECTED: COMPLIANCE:

CATEGORY 5

SIL649

FAA APPROVED

10-400405 AND 10-400406 DISTRIBUTOR GEAR KITS FOR S-1200 SERIES MAGNETOS.

To announce availability of the subject distributor gear kits for product standardization. All S-1200 Series Magnetos. Any time distributor gear is replaced.

GENERAL INFORMATION: The 10-400405 and 10-400406 Distributor Gear Kits for S-1200 Series Magnetos are being provided as a standardization change for TCM Magnetos. The gear kits include all parts (except distributor block) as identified in Figure 1. The 10-400405 gear kit for four or eight cylinder magnetos will supersede the 10-349234 distributor gear, and the 10-400406 gear kit for six cylinder magnetos will supersede the 10349237 distributor gear. Assembly sequence of the gear kit to the distributor block is shown in Figure 1. WARNING When timing magneto on bench or when reinstalling magneto on engine, do not use a gear holding timing device. Hidden distributor gear tooth damage and subsequent magneto failure may result.

FIGURE 1.

MO 02

ISSUED DAY YEAR 06

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (334)-438-3411

PAGE NO REVISION

1 of 1 SIL649

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 5

SERVICE INFORMATION LETTER SIL655 Contains Useful Information Pertaining To Your Aircraft Ignition System SUBJECT:

REASON FOR LETTER:

FAA APPROVED

IMPROVED BALL BEARING, P/N 10-400605, FOR PRESSURIZED S-1200, D-2000, AND D-3000 MAGNETOS FORMERLY USING STANDARD BEARING P/N 10-353056. To announce availability of improved bearing and to require its use in affected magnetos at time of bearing replacement.

EQUIPMENT AFFECTED:

COMPLIANCE:

MAGNETO TYPE NUMBER

MAGNETO PART NUMBER

MAGNETO TYPE NUMBER

MAGNETO PART NUMBER

S6RN-1251

10-349420-1

S6RN-1259

10-349510-1

S6LN-1251

10-349420-2

S6LN-1259

10-349510-2

S6RN-1255

10-349460-1

S6RN-1259

10-349510-3

S6LN-1255

10-349460-2

D6LN-2230

10-382910-13

S6LN-1258

10-349490-1

D6RN-2230

10-382910-18

S6LN-1259

10-349490-2

D6LN-3200

10-682910-13

S6RN-1258

10-349490-3

D6RN-3200

10-682910-18

Any time ball bearing is replaced, not later than next magneto overhaul.

GENERAL INFORMATION: Ball bearing P/N 10-400605 with improved air sealing characteristics, is now available as a replacement for ball bearing P/N 10-353056 for use in affected equipment. Do not install 10-353056 bearing in affected equipment after receipt of this letter. 10-353056 bearings may continue in service if already installed, and may be installed in unpressurized magnetos. Disassembly, assembly, and testing procedures are unchanged from those specified in the latest S-1200 Series and D-3000 Series Service Support Manuals.

MO 12

ISSUED DAY YEAR 11

MO

REVISED DAY YEAR

95

 1996, TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 1 SIL656

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 5

SERVICE INFORMATION LETTER SIL656 Contains Useful Information Pertaining To Your Aircraft Ignition System SUBJECT: REASON FOR LETTER: EQUIPMENT AFFECTED:

FAA APPROVED

RELAY VIBRATOR SUPERSEDURE To announce product and part number revision. Starting Vibrators equipped with an internally mounted relay, identifiable by five electrical terminals located on the face plate. Part Numbers: 10-176485-121 10-176485-122 10-176485-241

10-176485-242 10-382780-12 10-382780-24

GENERAL INFORMATION: Due to a product improvement design change, all above listed starting vibrators, which incorporate open relays, will be superseded on a use stock basis by starting vibrators incorporating sealed relays. Superseding parts are detailed in Table 1. The sealed relay simplifies the design while affording greater protection of the relay contacts from mechanical damage and contamination. The new vibrators are FAA-PMA approved for all applications where the old units were approved, and are fully interchangeable without modification to engine, airframe or wiring. Weight change is negligible. The new relay-type starting vibrators incorporate a revised internal schematic diagram as shown in Figure 1. The new relay-type starting vibrators may be inspected and maintained in accordance with TCM Ignition Systems Starting Vibrator Support Manual, Form X43003 or later revision. All specifications, procedures, and service parts are identical to those specified for the superseded units. TABLE 1 Old Relay Vibrator P/N

Superseded By Sealed Relay Vibrator P/N

System Voltage

Use With Magneto Series

10-176485-121

10-400608-121

12V

S-200, S-600

10-176485-122

10-400608-122

12V

S-1200

10-176485-241

10-400608-241

24V

S-200, S-600

10-176485-242

10-400608-242

24V

S-1200

10-382780-12

10-400608-123

12V

D-2200, D-3200

10-382780-24

10-400608-243

24V

D-2200, D-3200

MO 05

ISSUED DAY YEAR 17

MO

REVISED DAY YEAR

96

 1996, TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 2 SIL656

AFFECTED PUBLICATIONS:

MO 05

ISSUED DAY YEAR 17

Insert a copy of this Service Information Letter into the appropriate sections of the TCM Ignition Systems Master Service Manual, Form # X40000.

MO

REVISED DAY YEAR

96

 1996, TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 2 SIL656

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

CATEGORY 5

SIL657A

SERVICE INFORMATION LETTER

Contains Useful Information Pertaining To Your Aircraft Ignition System

FAA APPROVED

SUBJECT:

SUPERSEDURE OF P/N 10-163136 AND 10-361638 COVERS AND OF 10-361637 COVER KIT

PURPOSE:

To announce availability of Short Cover Conversion Service Kits to replace superseded covers.

COMPLIANCE:

Any time replacement of 10-163136 or 10-361638 cover, or 10-361637 cover kit is required.

EQUIPMENT AFFECTED:

All S-20 and S-200 Series Bendix and TCM Magnetos that use P/N 10-163136 or P/N 10-361638 cover assemblies. This includes Magneto Part Numbers:

10-51360-45 10-51360-47 10-51360-58 10-51365-57 10-79020-11 10-79020-17 10-79020-18 10-79020-19

10-79020-118 10-79020-119 10-163005-2 10-163005-3 10-163005-11 10-163010-1 10-163010-2 10-163010-10

10-163010-11 10-163010-15 10-163015-3 10-163020-3 10-163020-4 10-163045-1 10-163045-3 10-163045-6

10-163050-1 10-163050-2 10-163050-7 10-163050-9 10-163050-12 10-163055-1 10-163060-1 10-163060-2

GENERAL INFORMATION 1. P/N 10-163136 and 10-361638 covers and 10361637 cover kit are no longer available as service spares. In their place, TCM is offering Short Cover Conversion Service Kits to convert magnetos that use the discontinued covers to the Short Cover configuration. 2. By installing the Service Kit, the magneto part number and type number change, so a replacement data plate is included with each kit. Table 1 lists affected magnetos, applicable Service Kit, and new Magneto Part Number and Type Number.

ISSUED MO 05

DAY 17

REVISED YEAR 96

MO 10

DAY 09

YEAR 97

 1997 TELEDYNE INDUSTRIES INC.

3. Service Kits must be assembled and installed in accordance with the latest revision of the TCM S-20/S-200 Service Support Manual, form X42002-1. 4. Each kit contains a cover, a capacitor, attaching hardware, and any applicable retard or tachometer lead parts. Kit contents are detailed in Table 2. 5. Weight change is negligible.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

1 of 3 SIL657A

A

TABLE 1 KIT APPLICABILITY Original Magneto P/N

Original Magneto Type

Cover Service Kit P/N

New Magneto P/N

New Magneto Type

10-51360-45

S4LN-21

10-400409

10-500514-1

S4LSC-21

10-51360-47

S4LN-21

10-400412

10-500514-201

S4LSC-21T

10-51360-58

S4LN-21

10-400409

10-500514-2

S4LSC-21

10-51365-57

S6LN-21

10-400409

10-500516-2

S6LSC-21

10-79020-11

S6LN-25

10-400412

10-500556-203

S6LSC-25T

10-79020-17

S6LN-25

10-400412

10-500556-203

S6LSC-25T

10-79020-18

S6LN-25

10-400415

10-500556-3

S6LSC-25

10-79020-19

S6RN-25

10-400415

10-500556-1

S6RSC-25

10-79020-118

S6LN-25P

10-400413

10-500556-103

S6LSC-25P

10-79020-119

S6RN-25P

10-400413

10-500556-101

S6RSC-25P

10-163005-2

S4LN-200

10-400410

10-600614-1

S4LSC-200

10-163005-3

S4LN-200

10-400410

10-600614-3

S4LSC-200

10-163005-11

S4LN-200

10-400410

10-600614-2

S4LSC-200

10-163010-1

S6RN-200

10-400410

10-600616-4

S6RSC-200

10-163010-2

S6LN-200

10-400410

10-600616-5

S6LSC-200

10-163010-10

S6LN-200

10-400410

10-600616-3

S6LSC-200

10-163010-11

S6LN-200

10-400410

10-600616-6

S6LSC-200

10-163010-15

S6RN-200

10-400410

10-600616-7

S6RSC-200

10-163015-3

S4RN-201

10-400410

10-600604-1

S4RSC-201

10-163020-3

S6RN-201

10-400417

10-600606-1

S6RSC-201

10-163020-4

S6LN-201

10-400417

10-600606-3

S6LSC-201

10-163045-1

S4LN-204

10-400409

10-600644-4

S4LSC-204

10-163045-3

S4LN-204

10-400409

10-600644-1

S4LSC-204

10-163045-6

S4LN-204

10-400412

10-600644-201

S4LSC-204T

10-163050-1

S6LN-204

10-400409

10-600646-1

S6LSC-204

10-163050-2

S6LN-204

10-400409

10-600646-3

S6LSC-204

10-163050-7

S6RN-204

10-400409

10-600646-4

S6RSC-204

10-163050-9

S6LN-204

10-400409

10-600646-1

S6LSC-204

10-163050-12

S6LN-204

10-400412

10-600646-201

S6LSC-204T

10-163055-1

S4LN-205

10-400409

10-600654-1

S4LSC-205

10-163060-1

S6RN-205

10-400415

10-600656-1

S6RSC-205

10-163060-2

S6LN-205

10-400415

10-600656-3

S6RSC-205

ISSUED

REVISED

MO 05

DAY 17

YEAR 96

MO 10

DAY 09

YEAR 97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

2 of 3 SIL657A

A

TABLE 2 KIT CONTENTS KIT PART NUMBER

PART NUMBER

PART

10-400160-3Y

COVER

10-400160-1Y

COVER

10-400160-4Y

COVER

10-400160-7Y

COVER

10-349276

CAPACITOR

10-400604

CAPACITOR

10-35935-6

SCREW

2

2

10-349263

PACKING

1

10-157160

SCREW

10-400012

PLATE

10-35937-12

SCREW

1

1

10-400050

LEAD

1

1

10-16092

WASHER

1

1

10-125996

BUSHING

1

1

10-92873-302

NUT

1

1

10-357532

GASKET

10-400103

GROMMET

1

10-400141

LEAD

2

10-180128-1

TUBING

AR

10-400409

10-400410

10-400412

10-400413

1

10-400415

10-400417

1 1

1 1 1

1

1

1 1

1

1

2

2

2

2

1

1

1

1

1

4

4

4

4

4

4

1

1

1

1

1

1

1

AFFECTED PUBLICATIONS: Insert a copy of this Service Information Letter into the appropriate sections of the TCM Ignition Systems Master Service Manual, Form # X40000.

ISSUED MO 05

DAY 17

REVISED YEAR 96

MO 10

DAY 09

YEAR 97

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

3 of 3 SIL657A

A

TELEDYNE CONTINENTAL

®

IGNITION SYSTEMS

SERVICE INFORMATION LETTER Contains useful information pertaining to your aircraft ignition system

CATEGORY 5

SIL661

SUBJECT:

BL- PREFIX MARKING ON REBUILT MAGNETOS AND REBUILT D-3000 IGNITION SYSTEMS

PURPOSE:

To inform customers of procedure change.

COMPLIANCE: At time of magneto or ignition system installation and at all subsequent maintenance events. MODELS AFFECTED:

All factory rebuilt S-20, S-200, S-1200 and D-3000 magnetos, and all factory rebuilt D-3000 ignition systems beginning with manufacturing number (serial number) E289901DR, E289901ER, E289901FR, E289901GR. (May 28,1999. Refer to SIL642 to interpret manufacturing numbers.)

GENERAL INFORMATION On and after May 28, 1999, all TCM factory rebuilt magnetos and rebuilt D-3000 Ignition Systems (harness and rebuilt magneto supplied assembled) will be marked with part numbers beginning with BL- (“Blue Label”) instead of 10- prefix. For example, the data plate for a factory rebuilt magneto formerly marked “10349350-4” will now read “BL-349350-4.” Data plates for rebuilt units will continue to be blue in color and include the word “REBUILT.” Except for data plate markings, the BL- prefix has been used for many years to designate factory rebuilt magnetos, and to distinguish rebuilt magnetos from new magnetos. The action described in this letter will reconcile the

ISSUED MO

DAY

09

15

REVISED YEAR 99

MO

DAY

YEAR

part number marked on the magneto data plate with the part number found on the package, invoice, shipper, price list, and other documents. Magnetos and Ignition systems marked with a BL- prefix part number are FAA/PMA for all applications that are approved for the corresponding 10- prefix units. Units marked with a BL- prefix are fully interchangeable with the corresponding units marked with a 10prefix. To maintain BL- prefix magnetos and ignition systems, use the corresponding 10- prefix service and parts list data. When ordering rebuilt units, specify BL- prefix part numbers. 10- prefix applies to new units only.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company P.O. Box 90 Mobile AL 36601

334-438-3411

PAGE NO REVISION

1 of 1 SIL661

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL93-11A

Contains Useful Information Pertaining To Your Aircraft Engine

Technical Portions FAA Approved

SUBJECT:

SERVICE DOCUMENT FORMAT

PURPOSE:

To advise and explain the use of the Teledyne Continental Motors Service Bulletin format and the use of service bulletins to disseminate updates to the manufacturer's Instructions for Continued Airworthiness. (ICA)

MODELS AFFECTED:

ALL MODELS / ALL MANUALS / ALL ICA'S

GENERAL TCM has adopted a service document format which will provide the user with an explanation of the compliance criticality of the document. This format was developed by the General Aviation Manufacturers Association (GAMA) to standardize service documents used by aviation manufacturers. The documents will be presented in six categories, which are defined in Table 1. Each revision to the document will be noted in the information block located at the bottom of each page. This information will include the date of original issuance, revision date, page number and revision number. The most recent revisions to the document will be identified by a solid bold vertical line on the left-and side of the page, adjacent to the revised sentence, paragraph, drawing, etc.

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS In accordance with FAR 33.4, Teledyne Continental Motors issues Instructions for Continued Airworthiness (ICA) for the engines and components for which it holds the Type Certificate or Parts Manufacturing Authorization (PMA) authority. The ICA's are primarily published in the form of Operator's Manuals, Maintenance Manuals and Overhaul Manuals. These manuals may be supplemented by Service Documents, which may contain updates to the ICA's until such time that the updated ICA's are incorporated into the appropriate manual. Additionally, Service Documents may address a specific issue and modify the published ICA's for a limited purpose, which may not be incorporated into the general manuals.

WARNING New or updated Instructions for Continued Airworthiness may be contained in TCM Service Documents. Service Documents applicable to the engine or accessories on which work is being performed must be consulted and complied with prior to performing any installation, maintenance, or overhaul function. ISSUED

REVISED

PAGE NO REVISION TM

MO 05

DAY 12

YEAR 1993

MO 09

DAY 20

YEAR 2006

© 2006 Teledyne Continental Motors, Inc.

Teledyne Continental Motors, Inc. P.O. BOX 90 MOBILE, AL 36601 251-438-3411

1 of 3 SIL93-11

A

NOTE: Service Documents which contain updates to the Instructions for Continued Airworthiness must be inserted into the affected manual until such time the manual is revised or the Service Document is cancelled or superseded. The affected manuals will be referenced in all Service Documents containing updates to the manufacturer's Instruction for Continued Airworthiness.

TABLE 1 SERVICE DOCUMENT CATEGORY 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 an Airworthiness Directive (AD) issued by the FAA or have been issued, at the direction of FAA, by the manufacturer, in order to allow compliance with an already issued AD (or an equivalent issued by another country's airworthiness authority). May contain updates to TCM's Instructions for Continued Airworthiness to address a safety issue. CATEGORY 2: "CRITICAL SERVICE BULLETIN" (CSB)- Service documents (not included in Category 1) that have been determined by the product manufacturer to constitute a threat to continued safe operation of an aircraft or to persons or property on the ground unless some specific action (inspection, repair, replacement, etc.) is taken by the product owner or operator. Documents in this category are candidates for incorporation in an Airworthiness Directive issued by the FAA (but may not be). May contain updates to TCM's Instructions for Continued Airworthiness to address a safety issue. CATEGORY 3: " SERVICE BULLETIN" (SB)- Service documents (not included in Categories 1 and 2) considered by the product manufacturer to constitute a substantial improvement to the inherent safety of an aircraft or component of an aircraft. This "Service Bulletin" category also includes the most recent updates of instructions for continued airworthiness. CATEGORY 4: "SERVICE INFORMATION DIRECTIVE" (SID)- Service documents (not included in Categories 1, 2 or 3) that have been determined by the manufacturer to be of value to an owner/operator in the use of a product by enhancing safety, maintenance or economy. May contain updates to TCM's Instructions for Continued Airworthiness in the form of maintenance procedures or specifications. CATEGORY 5: "SERVICE INFORMATION LETTER" (SIL)- This category includes all information (not included in Category 1-4) that may be of use to the owner, operator or maintainer of the aircraft. May contain updates to TCM's Instructions for Continued Airworthiness for optional component installations, which are not covered in the applicable Operator, Maintenance or Overhaul manuals. CATEGORY 6: "SPECIAL SERVICE INSTRUCTION" (SSI)- This category is used to address an issue on specific model and/or serial number engines. TCM will distribute SSI notification directly to the owners of the affected engines. SSI's will not be included in the general service bulletin set but will be made available through TCM Customer Service to owners of the affected engines only. An SSI may contain updates to the Instructions for Continued Airworthiness applicable only to the listed engines.

IMPORTANT NOTE: All inspection procedures, maintenance, preventative maintenance, repairs and component replacement must be performed using the latest revision of the TCM manuals and current Service Documents.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

05

12

1993

09

20

2006

P.O. BOX 90 MOBILE, AL 36601 251-438-3411

2 of 3 SIL93-11

A

TELEDYNE CONTINENTAL ® AIRCRAFT ENGINE

Category 3

SERVICE BULLETIN

SB06-XX{|

Compliance Will Enhance Safety

SUBJECT:

Technical Portions FAA Approved

SAMPLE DOCUMENT HEADING

PURPOSE: MODELS AFFECTED

REVISION BAR MSB ALERT BAR: CSB

SAMPLE DOCUMENT { Bulletin numbers will run consecutively regardless of category. Example: SB06-1, SID06-2, SIL06-3, etc.

| When bulletins originally issued in the old (M-) format are revised they will be superseded in the new format.

ISSUED

REVISED

PAGE NO REVISION TM

MO

DAY

YEAR

MO

DAY

YEAR

Teledyne Continental Motors, Inc.

05

12

1993

09

20

2006

P.O. BOX 90 MOBILE, AL 36601 251-438-3411

3 of 3 SIL93-11

A

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER SIL93-14 Contains Useful Information Pertaining To Your Aircraft Engine

FAA APPROVED

SUBJECT:

CFC WARNING STATEMENT

PURPOSE:

Compliance with United States Environmental Protection Agency Regulations

COMPLIANCE: MODELS AFFECTED:

Not applicable

All

The United States Environmental Protection Agency recently adopted regulations under the Clean Air Act which require that warning statements accompany all products which are "manufactured with" or contain a Class I ozone depleting substance, as defined in EPA regulations 58 Fed. Reg. 8136 (February 11, 1993). In order to satisfy Teledyne Continental Motors' obligations under the EPA labeling regulations, Teledyne product catalogs, manuals and service bulletin sets will contain the following statements: 1.

WARNING... Manufactured with 1,1,1 trichloroethane, CFC-12 and/or CFC-113, substances which harm public health and environment by destroying ozone in the upper atmosphere. This warning applies to all Teledyne Continental Motors new and rebuilt aircraft engines.

2.

WARNING... Manufactured with 1,1,1 trichloroethane and/or CFC-113, substances which harm public health and environment by destroying ozone in the upper atmosphere. This warning applies to all Teledyne Continental Motors fuel injection assemblies, manifold valve assemblies, regulator assemblies, magneto assemblies, starter adapters, oil pumps, oil coolers, accessory cases, crankcases, cylinder and valve assemblies, stud assemblies, cylinder kits, bearings, turbochargers, turbocharger bearings and thrust collars, tubes, hoses and exhaust systems and components.

In addition, all Teledyne products which are "manufactured with" ozone depleting substances will be appropriately marked on Teledyne shippers. Teledyne Continental Motors is currently pursuing alternatives to these substances and plans to eliminate their use as soon as possible.

ISSUED MO

DAY

08

24

REVISED YEAR 93

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 1

NONE

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER SIL93-15 Contains Useful Information Pertaining To Your Aircraft Engine

FAA APPROVED

SUBJECT:

GENERAL PRACTICES FOR USE OF LOCK WIRE, TAB WASHERS AND COTTER PINS.

PURPOSE:

To provide the required locking practices for various hardware used in TCM engines.

COMPLIANCE:

When the use of these devices is required.

MODELS AFFECTED:

All

LOCK WIRE PROCEDURES Lock wiring is the securing together of two or more parts with safety wire which shall be installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the wire. All lock wire utilized on TCM engines must conform to MS20995 Condition A. Most bolts utilized in TCM engines that require lock wiring will use .032 lock wire and require twisting at a rate of 7 to 10 twists per inch. Smaller wire (when specified or required) will require twisting at a rate of 9 to 12 twists per inch. Lock wire shall be new upon each application. Wire shall be pulled taut while being twisted and caution must be exercised during the twisting operation to keep the wire tight without overstressing. See Figure 1 for steps in applying safety wire.

MO 09

ISSUED DAY YEAR 13

93

MO -

REVISED DAY YEAR -

-

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 4

NONE

Various examples of lock wiring are shown in Figure 2. 1. Check the units to be lock wired to make sure that they have been correctly torqued. Applying torque that is above or below specified limits to obtain alignment of the holes is not permitted. 2. It is desirable to have the holes parallel, but this is not a necessity. For right-hand threads, the lock wire shall be installed in such a manner that the strand through the hole will have a tendency to pull the unit clockwise. 3. Insert half of the required length of wire through the first unit and bend around the head of the unit. The direction of wrap and twist of strands shall be such that the loop around the unit comes under the strand protruding from the hole so that the loop will stay down and will not tend to slip up and leave a slack loop. 4. Twist the strands while taut until the twisted part is just short of a hole in the next unit. The twisted portion should be within one-eighth (1/8) inch from the hole in either unit. 5. Insert the uppermost strand through the hole in the second unit and follow the rules in paragraph 3. 6. After wiring the last unit, continue twisting the wire to form a pigtail, providing sufficient twists (four minimum) to assure that the pigtail will not unravel. Cut off the excess wire and bend the pigtail toward the part and against the bolt head flats. DO NOT ALLOW THE PIGTAIL TO EXTEND ABOVE THE BOLT HEAD.

FIGURE 2. TYPICAL SAFETY WIRE PATTERNS

MO 09

ISSUED DAY YEAR 13

93

MO -

REVISED DAY YEAR -

-

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

2 of 4

NONE

TAB WASHER PROCEDURES Tab washers are used to restrain relative motion between two parts by fitting a tab in a tab slot and bending the remaining tabs firmly against the bolt or nut flat. Tab washers are used in various locations in TCM engines and must not be reused after removal. The tabs that are provided to be bent up against the head flats must be seated firmly, with no scaring of the tabs. This provides proper locking of the unit and prevents tabs from breaking off. 1. Make certain that the holding tab is located in the tab hole or slot. 2. Check the units to be secured and verify that they have been correctly torqued per the applicable overhaul manual. 3. Bend tabs against the head flats firmly by tapping them into place with a soft drift. See Figure 3. 4. Inspect tabs for any signs of damage. Remove and replace any tabs that exhibit damage.

FIGURE 3. TAB WASHER INSTALLATION PROCEDURE

COTTER PIN PROCEDURE Cotter pins are used to restrain relative motion between two parts by inserting the cotter pin through a hole in one part and slots in the other part and spreading the exposed ends. Cotter pins are not reusable and must be replaced with a new cotter pin after removal. 1. Tighten the nut to the lower limit of the torque specification. If the slots in the nut do not line up with one of the holes in the bolt, continue tightening until one does, but do not exceed the upper limit of the torque specification. Change the nut if necessary.

MO 09

ISSUED DAY YEAR 13

93

MO -

REVISED DAY YEAR -

-

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

3 of 4

NONE

2. Insert the cotter pin with the head seated firmly in the slot of the nut. Bend the ends over the flat on the nut and the end of the bolt, trimming the prong lengths as necessary. 3. Seat the prongs firmly against the bolt and nut. See Figure 4. CAUTION... Do not use side-cutting type pliers to bend the ends over, since the resulting nick could weaken the pin and allow a portion to become detached.

FIGURE 4. TYPICAL COTTER PIN INSTALLTION SPECIAL NOTE... When cotter pinning the IO360 and L/TSIO360 model engines' connecting rod bolts, use the following procedure upon completion of the steps listed above. 1. Use a hammer and soft drift to tap the head of the cotter pin firmly into the nut slot and bolt hole, deforming the head until it is flush with or no more than .030 inches above both the flat on the nut and the end of the bolt. See Figure 5.

FIGURE 5. CONNECTING ROD COTTER PIN INSTALLATION

MO 09

ISSUED DAY YEAR 13

93

MO -

REVISED DAY YEAR -

-

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

4 of 4

NONE

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining To Your Aircraft Engines’ Operational Maintenance REPLACEMENT OF INTAKE VALVE ROTOCOILS

PURPOSE:

To improve intake valve seating performance.

MODELS AFFECTED:

SIL94-10 FAA APPROVED

SUBJECT:

COMPLIANCE:

CATEGORY 5

Next engine overhaul, cylinder overhaul or cylinder replacement.

All E-185, E-225, O-470, TSIOL-550 and GTSIO-520.

IO-470,

IO-520/550,

TSIO-520/550,

At the next engine overhaul, cylinder overhaul or cylinder replacement, install solid valve retainer, TCM P/N 35971 on all intake valves. Rotocoils continue to be required on the exhaust valves and must be replaced 100% at overhaul. Overhaul manuals and parts catalogs affected by this change will be revised to include this requirement at the next revision.

MO 11

ISSUED DAY YEAR 14

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE BULLETIN

Contains Useful Information Pertaining To Your Aircraft Engines’ Service Documents

CATEGORY 5

SIL94-5

FAA APPROVED

SUBJECT:

MOBIL AV1 OIL

PURPOSE:

Removal of Mobil AV1 Oil from the approved TCM Oil Grade Listing

COMPLIANCE: MODELS AFFECTED:

Affects engines presently using Mobil AV 1 Oil within the next 25 hours

All

Teledyne Continental Motors approved the use of Mobil AV1 under MHS25 in 1987. Since that time we have monitored the service experience associated with the use of this oil in our liquid cooled and air cooled engines. Service history has been generally good except for certain reported instances of higher than normal lead deposits throughout the engine and stuck oil control rings. As a result of these reports into TCM's corrective action system, an analysis program was implemented with Mobil Oil to review the lead deposit and stuck ring issues. Following this review and a marketing analysis by Mobil a decision has been made by Mobil Oil Company to remove the Mobil AV1 oil from the market. TCM concurs with the decision and will remove the oil from our Service Bulletin M87-12 Rev 1 which lists approved oils for use in TCM engines. Within the next 25 hours, TCM requires that the oil be changed on any engine presently using Mobil AV1 oil and replaced with an oil approved under MHS24 as listed in Service Bulletin M8712 Rev 1. Based on reported field experiences and instructions from Mobil there should be no problem when changing from Mobil AV1 to another approved oil. As a precaution, operate the first oil change for 25 hours and then return to specified oil change intervals.

MO 06

ISSUED DAY YEAR 14

94

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 (205)-438-3411

PAGE NO REVISION

1 of 1

NONE

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER SIL95-5 Contains Useful Information Pertaining To Your Aircraft Engines’ Operational Maintenance

FAA APPROVED

SUBJECT:

HOSE AND TUBING INSTALLATION.

PURPOSE:

To emphasize the importance of supporting component fittings when removing, attaching and torquing hoses and tubing.

COMPLIANCE:

Whenever engine component hose and/or tubing removal, installation or torquing is required.

MODELS AFFECTED:

All.

It is required that the following procedure be followed when hoses and tubing are removed, attached and torqued to fittings contained on components such as fuel, induction, lubrication and turbocharger systems. WARNING FAILURE TO PROPERLY SUPPORT COMPONENT FITTINGS CAN RESULT IN FITTING AND/OR COMPONENT DAMAGE AND A RESULTING LOSS OF SYSTEM PRESSURE. INSTRUCTIONS: See Figures 1 and 2. 1. Select the proper size open end wrenches that will fit the fitting body and hose or tubing end fitting. 2. Torque or loosen (as the case may be) the hose or tubing end fitting while maintaining sufficient force on the component fitting to prevent twisting and shear loads. 3. Components that contain multiple fittings coupled in one location, must have the last fitting in the assembly properly supported as indicated in the preceding paragraphs. 4. DO NOT over torque fittings. Consult the appropriate manufacturer's manual for specific installation procedures and torque values.

MO 08

ISSUED DAY YEAR 30

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 2 SIL95-5

FIGURE 1

FIGURE 2

MO 08

ISSUED DAY YEAR 30

95

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 2 SIL95-5

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER SIL96-9 Contains Useful Information Pertaining To Your Aircraft Engines’ Operational Maintenance

FAA APPROVED

SUBJECT:

OIL PRESSURE RELIEF VALVE SPRING.

PURPOSE:

To provide optional oil pressure relief valve springs for improved pressure adjustment capabilities.

COMPLIANCE: MODELS AFFECTED:

As required to improve oil pump pressure relief valve adjustment capabilities.

All TSIO-470, TSIO-520, LTSIO-520, TSIO-550 and TSIOL-550 model engines.

In 1993, Teledyne Continental Motors replaced P/N 634150 oil pressure relief valve spring with P/N 632652 in oil pumps of the affected engine models. Part number 632652 spring has a free length (1.88") that improves the adjustment range of the relief valve. The free length of P/N 634150 spring is 1.64". We have received reports of high oil pressure that cannot be effectively reduced by relief valve adjustment with oil pumps using the P/N 632652 spring. In these circumstances it is permissible to replace P/N 632652 spring with P/N 634150. Installation of either of these springs in oil pumps of the affected engine models at overhaul is permissible. Select the spring that will maintain operational oil pressure within the specified limits. AFFECTED PUBLICATIONS: Insert a copy of this Service Information Letter into the appropriate section of all affected engine model parts catalogs.

MO 08

ISSUED DAY YEAR 12

MO

REVISED DAY YEAR

96

 1996 TELEDYNE INDUSTRIES, Inc.

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

1 of 1 SIL96-9

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER SIL97-1 Contains Useful Information Pertaining To Your Aircraft Engines’ Operational Maintenance

FAA APPROVED

SUBJECT:

AIRWORTHINESS LIMITATIONS.

PURPOSE:

To provide airworthiness limitations information for all Teledyne Continental Motors (TCM) engines.

COMPLIANCE:

Upon receipt of this Service Information Letter, remove the "Airworthiness Limitations" chapter currently contained in the "AFFECTED PUBLICATIONS" listed below and replace with page two (2) of this Service Information Letter. For those manuals listed below that do not contain a airworthiness limitations chapter, attach page 2 to the first page of the manual.

MODELS AFFECTED:

All.

AFFECTED PUBLICATIONS: FORM #

MANUAL TITLE

X30008 X30010 X30622A X30027 X30013 X30019 X30594A X30596A X30016 X30586A X30588A X30039A X30033 X30574A X30575A X30568A X30607A X30600A X30045A X30144 X30009

A65, A75 Maintenance, Overhaul & Parts Manual C75, C85, C90, O-200 Overhaul Manual IO-240-A Overhaul Manual IO-346 Overhaul Manual C125, C145, O-300 Overhaul Manual GO-300 Overhaul Manual IO-360 Overhaul Manual L/TSIO-360 Overhaul Manual E165, E185 & E225 Overhaul Manual O-470 Overhaul Manual IO-470 Overhaul Manual IO-520 Overhaul Manual TSIO-470 Overhaul Manual TSIO-520 Permold Overhaul Manual L/TSIO-520 Sandcast Overhaul Manual IO-550 Permold Overhaul Manual IO-550 Sandcast Overhaul Manual TSIOL-550 Overhaul Manual GTSIO-520 Overhaul Manual Tiara Overhaul Manual W670 Overhaul & Parts Manual

MO 01

ISSUED DAY YEAR 03

97

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

REVISION DATE 8/77 1/84 11/93 7/80 6/82 8/81 6/92 12/92 10/78 10/92 8/92 1/92 5/69 7/85 11/87 3/85 9/92 2/90 8/78 3/79 12/56

PAGE NO REVISION

1 of 2 SIL97-1

AIRWORTHINESS LIMITATIONS The Airworthiness Limitations section has been FAA approved and specifies maintenance required under §§43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. Federal Aviation Regulations §§43.16 and 91.403 require owner/operator compliance with all maintenance limitations in this section concerning mandatory replacement times, inspection intervals and other related procedures that are specific to this engine. Any such limitations listed below are part of the design limits of the engine and the engine was type certificated based upon required owner/operator compliance with the limitations.

1. Mandatory Replacement Times. Subject to additional information contained in FAA Airworthiness Directives (AD) issued after the date of certification, the engines covered in this manual do not contain any components having mandatory replacement times required by type certification.

2. Mandatory Inspection Intervals. Subject to additional information contained in FAA Airworthiness Directives (AD) issued after the date of certification, the engine does not require specific intervals of inspection pursuant to type certification.

3. Other Related Procedures. Subject to additional information contained in the Airworthiness Directives (AD) issued after the date of certification, there are no other related procedures required pursuant to the type certification for this engine.

4. Distribution of Changes to Airworthiness Limitations. Changes to the Airworthiness Limitations section constitute changes to the type design of this engine and require FAA approval. Such changes will be published in FAA Airworthiness Directives (AD).

NOTE The limitations in this section apply only to specific limitations which are part of the engine design. Under the Federal Aviation Regulations numerous other additional limitations are applicable to this engine and its accessories. For example Federal Aviation Regulation Parts 91 and 43, among other parts, define inspection criteria, maintenance requirements and procedures that are applicable to this engine. It is the responsibility of the owner/operator to maintain the engine in an airworthy condition by complying with all applicable Federal Aviation Regulations and by performing maintenance in accordance with TCM Instructions for Continued Airworthiness, which consist of TCM publications and service documents.

MO 01

ISSUED DAY YEAR 03

97

MO

REVISED DAY YEAR

TELEDYNE CONTINENTAL MOTORS P.O. Box 90 MOBILE ALABAMA 36601 334-438-3411

PAGE NO REVISION

2 of 2 SIL97-1

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER

Contains Useful Information Pertaining to Your Aircraft Engine’s Operational Maintenance

CATEGORY 5

SIL97-12

FAA APPROVED Supersedes M91-11

SUBJECT:

INSTALLATION OF STARTER ADAPTER SHAFT SEAL AND ASSOCIATED PARTS.

PURPOSE:

ANNOUNCES NEW STARTER ADAPTER SHAFT SEAL SLEEVE P/N 654229 AND PROVIDES INSTRUCTIONS FOR REMOVAL AND INSTALLATION OF THE STARTER ADAPTER SHAFT SEAL AND SLEEVE.

COMPLIANCE:

AT STARTER ADAPTER OVERHAUL OR ANYTIME THE STARTER ADAPTER SHAFT SEAL REQUIRES REPLACEMENT.

MODELS AFFECTED:

IO-520-BA, BB. TSIO-520-BE, L, LB, UB and WB. IO-550-B. TSIO-550-A,B,C and E.

REMOVAL INSTRUCTIONS Caution: Stand clear of the propeller at all times.

applicable engine overhaul manual or aircraft maintenance manual.

2. Remove the engine cowling in accordance with the aircraft manufacturers instructions, to gain access to the starter and starter adapter.

6. Reference Figure 1. Using a 12 point deep socket loosen and remove nut (4) and spacer (5) or air-conditioning compressor drive sheeve and shims and sleeve (6). Do not misplace or discard shims as they will need to be reinstalled to assure correct alignment of the air-conditioning compressor drive sheeve, idle sheeve and compressor sheeve.

3. Disconnect the electrical lead to the engine starter motor in accordance with the aircraft manufacturers instructions.

7. Following the instructions provided in the applicable engine overhaul manual, remove the starter adapter from the engine.

4. Remove any accessories, lines, hoses and wire bundles that restrict access to the starter motor and starter adapter in accordance with the instructions provided in the appropriate engine overhaul manual and the aircraft manufacturers maintenance manual.

8. Position the starter adapter to allow access to body (7).

1. Disconnect the battery in accordance with the aircraft manufacturers instructions.

5. Remove the starter motor in accordance with the instructions provided in the ISSUED MO

DAY

10

14

REVISED YEAR

MO

DAY

97

 1997 Teledyne Industries, Inc.

YEAR

9. Remove five sets of hardware (1 & 3) and seal retaining clip (2). 10. Remove body (7) from the starter adapter. Note: On turbocharged engines scavenge pump idler gear (not shown in Figure 1)

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

1 of 5 SIL97-12

will need to be removed from the body (7). 11. Remove oil seal (8) from body (7). 12. Remove bearing (9) and spacer (10) from body (7). Do not discard these items, they will be reinstalled. 13. Clean all parts as required in accordance with the instructions provided in the applicable engine overhaul manual. 14. Dimensionally inspect sleeve (6). A. Sleeve P/N 654229 has an outside diameter of .812 inches to .814 inches. The outside diameter is unplated. B. Earlier sleeve P/N 640733 has an outside diameter of .808 inches to .810 inches. The outside diameter is cadmium plated. 15. Replace sleeve P/N 640733, regardless of condition, with sleeve P/N 654229. 16. Replace any worn or damaged sleeve with new P/N 654229. 17. Inspect bearing (9) and spacer (10) for wear and damage. Replace if wear or damage is indicated. INSTALLATION AND ASSEMBLY 1. Using clean engine oil, lubricate sleeve (6). 2. Using clean engine oil, lubricate the inside diameter of seal P/N 653171. 3. Carefully install sleeve P/N 654229 into seal P/N 653171. Insure that the seal garter spring has not been dislodged from the seal lip recess. 4. Using Aviation Permatex, P/N646942, lightly coat the parting surface of body (7). Allow the Permatex to set for a few minutes until slightly tacky. See figure 2. 5. Using Grade 3 Silk Thread, P/N 641543, apply a single line of thread over the Permatex surface of body (7). See Figure 2.

ISSUED MO

DAY

10

14

REVISED YEAR 97

MO

DAY

YEAR

6. Insure that gear (12) is correctly positioned. 7. Carefully install body (7) onto starter adapter. 8. Install five sets of hardware (3) and (1). Do not install any hardware on the stud adjacent to the oil seal bore. This hardware and seal retainer (2) will be installed after seal (8) and sleeve (6) are installed. Torque nuts (1) to 180 - 220 inch pounds. 9. Install spacer (10) into body (7). 10. Install bearing (9) into body (7). Note: Bearing (9) has a closed cage on one side and an open cage on the other. The bearing must be installed with the closed or "Thrust" side toward the front of the engine. The word "Thrust" is stamped on the cage. 11. Position the assembled oil seal (8) and sleeve (6) over the starter adapter shaft and into the seal bore in body (7). Lightly tap or press the seal and sleeve (8 and 6) as an assembly into its recess in body (7). The seal must be positioned flush with or within .030 inches below the surface of its recess. See Figure 3. 12. Install washer (3), seal retaining clip (2) and nut (1) on stud adjacent to oil seal (8). Torque nut to 180 - 220 inch pounds. 13. Lubricate starter adapter shaft gear with clean engine oil. Using a new gasket and following the instructions provided in the applicable engine overhaul manual reinstall the starter adapter. Torque attaching hardware as specified in the applicable engine overhaul manual. 14. Reinstall spacer (5) or air-conditioning drive sheeve and shims onto starter adapter shaft. 15. Lubricate shaft threads with clean engine oil and install 12 point nut (4). Torque nut to 450-500 inch pounds.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

2 of 5 SIL97-12

16. If the optional freon compressor drive sheeve is installed it will be necessary to insure correct sheeve alignment. Refer to the applicable engine overhaul manual for this information.

the aircraft manufacturer’s maintenance manual, aircraft flight manual/pilots operating handbook. Operate the engine for five minutes at 900 to 1100 R.P.M. to cool the engine, then perform a normal shut down in accordance with the Aircraft Flight Manual.

17. Following the instructions provided in the applicable engine overhaul manual and aircraft manufacturers maintenance manual reinstall any accessories, lines, hoses and wire bundles removed to gain access to the starter adapter.

23. After completing the engine ground run up, remove the engine cowling in accordance with the aircraft manufacturers maintenance manual.

18. Following the instruction provided in the applicable engine overhaul manual, reinstall the starter motor.

24. Visually inspect the starter motor and starter adapter area for leaks and loose or missing hardware. Correct any discrepancies noted.

19. Following the instructions provided in the aircraft manufacturers maintenance manual, connect the electrical lead to the starter motor.

25. Following the instructions provided in the aircraft manufacturers maintenance manual, re-install the engine cowling.

20. Following the instructions provided in the aircraft manufacturers maintenance manual, re-install the engine cowling. 21. Following the instructions provided in the aircraft manufacturers maintenance manual, re-connect the aircraft battery. 22. Perform an engine ground run up in accordance with the instructions provided in

ISSUED MO

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26. Complete all log book and maintenance record entries prior to returning the engine and aircraft to service. Note compliance with this service bulletin in the appropriate section of the engine logbook. WARRANTY: The actions required by this bulletin are covered by TCM's Gold Medallion Warranty, subject to its terms and conditions.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

3 of 5 SIL97-12

FIGURE 1.

ISSUED MO

DAY

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14

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MO

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TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

4 of 5 SIL97-12

FIGURE 2.

FIGURE 3.

ISSUED MO

DAY

10

14

REVISED YEAR 97

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

5 of 5 SIL97-12

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining to Your Aircraft Engine

CATEGORY 5

SIL97-14

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

REPLACEMENT CYLINDER ASSEMBLY

PURPOSE:

To notify owners, operators, maintenance facilities and distributors of new cylinder

COMPLIANCE: MODELS AFFECTED:

At next cylinder replacement or engine overhaul

C-75, C-85, C-90, O-200, O-300, GO-300

Teledyne Continental Motors announces the production release of a new cylinder assembly for use on the above listed engine models. These cylinders incorporate a pinned rocker shaft boss structure, removable push rod housings, new intake and exhaust valve springs, intake valve guide seal, new material for intake and exhaust valve seats and exhaust valve guide, revised cylinder bore hone finish.

cylinders being installed on an engine for the first time. Refer to the applicable engine overhaul manual for cylinder removal and installation instructions. First time installations will require replacement of the existing push rod housing adapter with the adapter provided in the EQ Kit for the specific engine. Figure 1 provides cylinder and illustration and parts break down.

component

This service bulletin provides cylinder application by engine model and EQ kit applicability for CYLINDER APPLICATION BY ENGINE MODEL Engine Model C-75, C-85

Cylinder P/N 653816 653816A2 ➀

Description New Stud Assy

653816A6 ➁

New Valve Assy- Kit

653816

New Stud Assy

653816A2 ➀ 653816A3 ➁

New Valve Assy

New Valve Assy

➀ Requires one each EQ6955 ➁ Requires one each EQ6956 C-90, O-200-A, B

653816A3BP ➂

New Valve Assy-Kit New Kit -Engine Set

➀ Requires one each EQ6955 ➁ Requires one each EQ6956 ➂ Requires one each EQ6957

ISSUED MO

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30

REVISED YEAR

MO

DAY

YEAR

97

 1997, TELEDYNE INDUSTRIES, INC.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

1 of 5 SIL97-14

Engine Model O-300-A, C, D

Cylinder P/N 653816

Description New Stud Assy

653816A2 ➀ 653816A3 ➁ 653816A4BP ➂

New Valve Assy New Valve Assy-Kit New Kit-Engine Set

653816 653816A2 ➀ 653816A5 ➁

New Stud Assy New Valve Assy New Valve Assy-Kit

➀ Requires one each EQ6955 ➁ Requires one each EQ6956 ➂ Requires one each EQ6958 GO-300

➀ Requires one each EQ6955 ➁ Requires one each EQ6956

FIGURE 1

ISSUED MO

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30

REVISED YEAR 97

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TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

2 of 5 SIL97-14

FIGURE & INDEX

PART NUMBER

DESCRIPTION

QUANTITY

1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 35 36 37 38 39 40 41 41 42 43 44

653816A2 652421 652422 653426 653786 653791 520112 653802 653726 643804-1 401870 653817 629518-1 653783 654004 24026 MS51963-64 646678 625957 625958 653793 627731 639614 639615 24122 21007 654375 653728 40762 534471 MS35338-44 649353-.50 632837 653796 21477 653847 646846 637268 530940 653851 537870 537870P030 AN315-4R 653818 649952

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CYLINDER & VALVE ASSY ............................................... 1 NUT-.375-24 FLANGED.................................................... 2 NUT .4375-20 UNF-3B FLGD ........................................... 4 CYLINDER ASSY-MACH (ref. only) ............................... 1 INSERT-INTAKE VALVE SEAT...................................... 1 INSERT-EXH. VALVE SEAT ........................................... 1 INSERT-HELICOIL .33LG ................................................ 2 GUIDE-INTAKE VALVE .................................................. 1 GUIDE-EXHAUST VALVE .............................................. 1 STUD RING LOCKED....................................................... 2 STUD.25-20-28X1.12#639302 ........................................... 2 HOUSING-PUSH ROD ...................................................... 2 PLUG-.13-27 NPTF ............................................................ 1 VALVE-INTAKE ............................................................... 1 VALVE-EXHAUST............................................................ 1 RETAINER-VALVE SPRING ........................................... 2 SCREW - SHAFT RETAINER........................................... 1 SEAL-VALVE GUIDE, INTAKE ...................................... 1 SPRING-VALVE INNER................................................... 2 SPRING-VALVE OUTER.................................................. 2 SEAT-VALVE SPRING ..................................................... 2 KEY VALVE SPRING ....................................................... 4 ROCKER ASS-INT. VALVE ............................................. 1 ROCKER ASS EXH VALVE ............................................. 1 BUSHING-VALVE ROCKER ........................................... 2 SCREW-DRIVE #2............................................................. 2 SHAFT-VALVE ROCKER................................................. 1 GASKET-ROCKER COVER ............................................. 1 COVER-VALVE ROCKER................................................ 1 WASHER-PLAIN ............................................................... 6 WASHER LOCK .25 DIA. ................................................. 9 BOLT-.25-20X.50LG.......................................................... 6 GASKET-EXH FLANGE ................................................... 1 NUT-SELF LOCKING .31-24 ............................................ 2 PACKING-CYL HD BASE ................................................ 1 LIFTER ASS-HYDRAULIC............................................... 2 PLUNGER HYD UNIT....................................................... 2 SOCKET-HYD LIFTER ..................................................... 2 RING-SNAP .594 BORE .................................................... 2 LIFTER-HYDRAULIC....................................................... 2 TUBE ASS-PUSH ROD 652451 ........................................ 2 TUBE ASS-PUSH ROD ..................................................... 2 NUT-PLAIN........................................................................ 3 ADAPTER-PUSH ROD...................................................... 1 GSKT-P/R HSG 3.863X1.911............................................. 1

REVISED YEAR 97

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

3 of 5 SIL97-14

FIGURE & INDEX

PART NUMBER

DESCRIPTION

QUANTITY

1 45 46 47 48 49 50 51 52

632317 629711 20522 630286 641607 22671 646559A1 MS21209C4-10

SPRING-PUSH ROD HSG..................................................2 WASHER-.78 ID X 1.34 OD...............................................4 WASHER-.250X.03125.......................................................3 SEAL-"O"RING...................................................................2 SEAL-PUSH ROD HSG......................................................2 PLUG-SPARK PLUG HOLE ..............................................2 GSKT SET-0200-0300-S/CYL ............................................1 HELICOIL- ROCKER SHAFT RETAINER SCREW........1 EQ KIT BILL OF MATERIALS

EQ6955 Use with Single Cylinder Valve Assy Part Number Nomenclature Qty 653817 Housing, Push Rod 2 630286 Seal, “O” Ring 2 632317 Spring-Push Rod HSG 2 629711 Washer-.78I.D.x1.34O.D. 4 641607 Seal-P/R HSG 2 653818 Adapter-Push Rod 1 20522 Washer-.250 x .03125 3 MS 35338-44 Washer, Lock-.25 3 AN 315-4R Nut, Plain 3 653796 Nut-Self Locking .31-24 2 MS 51963-64 Screw-Shaft Retainer 1 649952 Gasket Push Rod HSG 1 654375 Shaft- Valve Rocker 1

EQ6957 Use with C-90 / O-200 Engine Set Part Number Nomenclature 653817 Housing, Push Rod 630286 Seal, “O” Ring 632317 Spring-Push Rod HSG 629711 Washer-.78I.D.x1.34O.D. 641607 Seal-P/R HSG 653818 Adapter-Push Rod 20522 Washer-.250 x .03125 MS 35338-44 Washer, Lock-.25 AN 315-4R Nut, Plain 653796 Nut-Self Locking .31-24 MS 51963-64 Screw-Shaft Retainer

ISSUED MO

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EQ6956 Use with Single Cylinder Valve Assy Kit Part Number Nomenclature Qty 653817 Housing, Push Rod 2 630286 Seal, “O” Ring 2 632317 Spring-Push Rod HSG 2 629711 Washer-.78I.D.x1.34O.D. 4 641607 Seal-P/R HSG 2 653818 Adapter-Push Rod 1 20522 Washer-.250 x .03125 3 MS 35338-44 Washer, Lock-.25 3 AN 315-4R Nut, Plain 3 653796 Nut-Self Locking .31-24 2 MS 51963-64 Screw-Shaft Retainer 1

Qty 8 8 8 16 8 4 12 12 12 8 4

EQ6958 Use with O-300-A,C & D Engine Set Part Number Nomenclature 653817 Housing, Push Rod 630286 Seal, “O” Ring 632317 Spring-Push Rod HSG 629711 Washer-.78I.D.x1.34O.D. 641607 Seal-P/R HSG 653818 Adapter-Push Rod 20522 Washer-.250 x .03125 MS 35338-44 Washer, Lock-.25 AN 315-4R Nut, Plain 653796 Nut-Self Locking .31-24 MS 51963-64 Screw-Shaft Retainer

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Qty 12 12 12 24 12 6 18 18 18 12 6

PAGE NO REVISION

4 of 5 SIL97-14

CYLINDER DIMENSIONS Description

New Min.

New Max.

4.0625 .000

4.0635 .002

CYLINDER AND HEAD ASSEMBLY Cylinder bore...................................................................................................Diameter: Cylinder bore out-of-round .............................................................................................: Cylinder bore ................................................................. Maximum Allowable Oversize: Cylinder bore surface roughness) cross hatch........................................................................................................... Angle:

.015 22-32 degrees

Microfinish (measured in direction of piston travel) ............................................ .....Ra:

30 to 50

Intake valve seat insert in cylinder head .........................................................Diameter: Exhaust valve seat insert in cylinder head......................................................Diameter: Intake valve guide in cylinder head.................................................................Diameter: Exhaust valve guide in cylinder head..............................................................Diameter: Intake valve in guide .......................................................................................Diameter: Exhaust valve in guide ....................................................................................Diameter: Intake valve face (to stem axis) ........................................................................... Angle: Exhaust valve face (to stem axis) ........................................................................ Angle: Intake valve stem ............................................................................................Diameter: Exhaust valve stem .........................................................................................Diameter:

.0055 T .0085 T .005 T .008 T .001 T .003 T .001 T ,003 T .001 L .004 L .0025 L .0057 L 59°-30' to 60° 44°-30' to 45° .3730 .3735 .3713 .3720

ROCKER ARMS AND SHAFTS Rocker shaft ....................................................................................................Diameter: Rocker boss (inside) ............................................................................ Finish Diameter: Rocker shaft in rocker boss ............................................................................Diameter: Rocker shaft in rocker arm bushing ................................................................Diameter: Rocker arm in support bosses ..............................................................Side Clearance: Rocker arm foot-to-valve stem tip(lifter deflated) Int. and Exh. .................... Clearance: Rocker arm to valve spring retainer .............................................................. Clearance: Rocker shaft Retainer Screw ............................................................................. Torque:

.6082 .6087 .6089 .6099 .0002 L .0017 L .001 L .0025 L .004 .011 .030 .110 .020 45 in. lbs 55 in. lbs

PISTONS, RINGS AND PINS Piston skirt in cylinder (Non Moly Coated) perpendicular to pin bore............ Diameter: Piston skirt in cylinder ( Moly Coated) perpendicular to pin bore ...................Diameter: Top piston ring in groove ......................................................................Side Clearance: Second piston ring in groove ................................................................Side Clearance: Third piston ring in groove ....................................................................Side Clearance: Fourth piston ring in groove ..................................................................Side Clearance: Top ring gap at 1.00 ± .50 inches from open end of barrel.....................................Gap: Second ring gap at 1.00 ± .50 inches from open end of barrel...............................Gap: Third ring gap at 1.00 ± .50 inches from open end of barrel...................................Gap: Fourth ring gap at 1.00 ±. 50 inches from open end of barrel ................................Gap: Piston pin in piston: C-75, C-85, C-90, O-200, O300 .....................................Diameter: Piston Pin in piston: GO-300 ..........................................................................Diameter: Piston pin C-75, C-85, C-90, O-200, O-300....................................................Diameter: Piston pin GO-300...........................................................................................Diameter:

ISSUED MO

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REVISED YEAR 97

MO

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YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

.009 .007 .0065 .005 .005 .002 .023 .015 .015 .015 .0001 L .0002 L .9214 .9984

.012 .011 .0085 .007 .007 .004 .036 .028 .028 .028 .0007 L .0006 L .9216 .9986

PAGE NO REVISION

5 of 5 SIL97-14

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL 98-3A

Contains Useful Information Pertaining to Your Aircraft Engine

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

PRODUCTION RELEASE OF NEW INTAKE AND EXHAUST VALVE SPRINGS

PURPOSE:

PROVIDE PERTINENT INFORMATION ON NEW VALVE SPRINGS INSTALLED ON 5 INCH AND 5.25 INCH CYLINDER ASSEMBLIES

COMPLIANCE: MODELS AFFECTED:

AT CYLINDER REPAIR OR OVERHAUL

E-Series, O-470, IO-470, TSIO-470, IO-520, TSIO-520, LTSIO-520, TSIO-520-BE, IO-550, TSIO-550 AND TSIOL-550 Series Engines.

Teledyne Continental Motors has production released valve springs Part Number 654441 and Part Number 654442. Current production cylinder assemblies installed on the direct drive engines listed in the Models Affected section of this Service Information Letter incorporate this change. NOTE: Cylinder assemblies installed on GTSIO520 series engine continue to incorporate the P/N 637837 and 631521 valve springs. During cylinder repair or cylinder and engine overhaul TCM recommends replacement of the P/N

637837 and P/N 631521 valve springs with P/N 654441 and P/N 654442 valve springs on cylinders installed on the engines listed in the Models Affected Section of this SIL. NOTE: Do not mix valve springs on the same cylinder. Valve springs P/N 654441 & 654442 must be installed with close coils toward the cylinder head. Close coil end of spring is identified with a blue strip. Valve springs, roto-coils and valve keepers are a 100% replacement part at engine overhaul. Refer to SB97-6 or later revision.

Part Number

520105 *

631520 *

631521

637836

637837 *

654441

654442

Free length Solid Height Load (LBS) @ Height Load (LBS) @ Height Direction of Wind Wire Diameter

2.560″ 1.195″ 107-120 @ 1.360″ 65-71 @1.840″ Left Hand .177 ± .005

2.3125″ 1.110″ 117-133 @ 1.275″ 49-55 @ 1.791″ Left Hand .170 ± .0015

2.1250″ 1.020″ 87-97 @ 1.230″ 32-38 @ 1.746″ Right Hand .142 ± .001

2.400″ 1.15″ 78-88 @ 1.329″ 43-49 @ 1.809″ Right Hand .142 ± .001

2.100″ 1.15″ 126-140 @ 1.275″ 49-55 @ 1.791″ Left Hand .177 ± .005

2.600″ 1.20″ 102-111 @ 1.275″ 49-55 @ 1.790″ Left Hand .165 ± .0012

2.300″ 1.10″ 70-77 @ 1.230″ 32-38 @ 1.745″ Right Hand

Color

Blue Strip

Green

Blue

Aluminum

Blue

Orange

Orange

.135 ± .001

* NOTE: P/N 520105 & 631520 were superseded by P/N 637837 P/N 637836 was superseded by P/N 631521

ISSUED MO

DAY

06

12

REVISED YEAR 98

MO

DAY

YEAR

07

17

98

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

1 of 1 SIL98-3A

A

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining to Your Aircraft Engine

CATEGORY 5

SIL 98-5

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

PRODUCTION RELEASE OF P/N 654837A1 CAMSHAFT ASSEMBLY

PURPOSE:

PROVIDE INFORMATION ON NEW PERMOLD ENGINE CAMSHAFT ASSEMBLY P/N 654837A1 AND GOVERNOR DRIVE BEVEL GEAR P/N 654085.

COMPLIANCE: MODELS AFFECTED:

ENGINE OVERHAUL OR CAMSHAFT REPLACEMENT

IO-520B, BA, BB, C, CB, M, & MB; IO-550-A, B, C, G, & N; TSIO-520-B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, & WB; TSIO-550-A, B, C, & E; TSIOL-550-A, B, & C Engines.

Teledyne Continental Motors has production released a new camshaft assembly and governor drive bevel gear, Part Numbers 654837A1 and 654085, for all direct drive Permold series engine’s noted in the Models Affected section of this Service Information Letter. The new camshaft assembly and governor drive bevel gear incorporate a splined type drive. This will require replacement of both the camshaft and governor drive bevel gear when up grading either the camshaft assembly or governor drive bevel gear for the first time.

ISSUED MO 06

REVISED

DAY

YEAR

12

98

MO

DAY

YEAR

Camshaft Assembly P/N 654837A1

Supersedes: 653085A1 649322A1 629726A3

Camshaft Gear P/N 654085

Supersedes P/N 629748

TELEDYNE CONTINENTAL MOTORS

PAGE NO

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

SIL 98-5

An Allegheny Teledyne Company

1 of 2

REVISION

SPLINED GOVERNOR DRIVE GEAR AND CAMSHAFT ASSEMBLY ITEM NUMBER 1

PART NUMBER 654837A1

2 3

524818 654085

DESCRIPTION

QUANTITY

CAMSHAFT ASSY. PLUG, SPECIAL* GEAR-BEVEL

1 2 1

* Lubricate plugs with Loctite #592 and torque to 130 to 150 inch lbs.

ISSUED MO 06

REVISED

DAY

YEAR

12

98

MO

DAY

YEAR

TELEDYNE CONTINENTAL M OTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO

2 of 2 SIL98-5

REVISION

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER Contains Useful Information Pertaining to Your Aircraft Engine

SIL 98-6B

SUPERCEDES SIL 98-6A

SUBJECT:

FUEL INJECTION SYSTEM APPLICATION GUIDE

PURPOSE:

Provide Fuel Injection System To Engine Reference Information

COMPLIANCE:

None Required, Information Only

MODELS AFFECTED:

All Current Production Fuel Injected Models

GENERAL INFORMATION This information bulletin is presented in two parts. The first part is an engine and model specification to fuel system reference table. The second part is a numerical listing of TCM fuel systems and their components. Use the first table to find the engine fuel system part number then the second table to see it’s components. NOTE…Use the part number on the component to be replaced when ordering for engine specifications not shown.

ISSUED MO.

08

DAY

05

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO.

REVISION

1 of 18

B

SIL 98-6

Engine Model And Specification 0470G10B 0470G7B 0470G7F 0470GCI1B GTSI0520C BASIC GTSI0520C19B GTSI0520C20B GTSI0520C7B GTSI0520D BASIC GTSI0520D21B GTSI0520D22B GTSI0520D23B GTSI0520D24B GTSI0520H BASIC GTSI0520H1B GTSI0520H2B GTSI0520H5B GTSI0520H6B GTSI0520L BASIC GTSI0520L1B GTSI0520L2B GTSI0520L3B GTSI0520L4B GTSI0520L5B GTSI0520L6B GTSI0520L7B GTSI0520L8B GTSI0520M BASIC GTSI0520M1B GTSI0520M2B GTSI0520M3B GTSI0520N BASIC GTSI0520N10B GTSI0520N11B GTSI0520N12B GTSI0520N1B GTSI0520N2B GTSI0520N3B GTSI0520N4B GTSI0520N5B GTSI0520N6B GTSI0520N7B GTSI0520N8B GTSI0520N9B I0240A BASIC I0240A1A I0240A1B I0240A3B I0240B BASIC I0240B1B I0240B3B

Fuel System Part Number 649056A6-1 649056A6-1 649056A6-1 649056A6-1 649055A1 649055A1 649055A1 649055A1 Not Serviced 649055A2 649058A2 649055A2-1 649055A3-1 649058A1 649058A1 649058A2 649058A1-1 649058A2-1 649055A5 649055A5 649055A6 649055A5 649055A6 649055A5-1 649055A6-1 649055A5-1 649055A6-1 649055A7 649055A7 649055A7 649055A7 649055A8 649055A9 649055A8 649055A9 649055A8 649055A9 649055A8 649055A9 649055A8 649055A9 649055A8 649055A9 649055A8 649059A1 649059A1 649059A1 649059A1 649059A2 649059A2 649059A2-1

ISSUED MO.

08

DAY

05

Engine Model And Specification I0240B5B I0240B6B I0240B7B I0240B8B I0360A BASIC I0360A5B I0360A8B I0360AB BASIC I0360AB5B I0360C BASIC I0360C11B I0360C12B I0360C13B I0360C5B I0360C6B I0360C7B I0360CB BASIC I0360CB6B I0360CB7B I0360CB8B I0360CB9B I0360D BASIC I0360D12B I0360D15B I0360D20B I0360D21B I0360D22B I0360D30B I0360D31B I0360D32B I0360D33B I0360D35B I0360D37B I0360D5B I0360D9B I0360DB BASIC I0360DB12B I0360DB15B I0360DB19B I0360DB20B I0360DB21B I0360DB22B I0360DB23B I0360DB26B I0360DB30B I0360DB31B I0360DB32B I0360DB33B I0360DB35B I0360DB8B I0360DB9B

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

Fuel System Part Number 649059A2 649059A2 649059A2-3 649059A2-2 649050A1-1 649050A1-2 649050A1-1 649050A1-1 649050A1-2 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1-6 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1-2 649050A1 649050A1 649050A1

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Engine Model And Specification I0360ES1B I0360ES2B I0360ES3B I0360ES4B I0360ES6B I0360ES7B I0360G BASIC I0360G1B I0360G2B I0360GB BASIC I0360GB1B I0360GB2B I0360H3B I0360H5B I0360H6B I0360H7B I0360HB3B I0360HB5B I0360HB6B I0360HB7B I0360HB9B I0360J BASIC I0360J2B I0360J4B I0360J5B I0360JB2B I0360JB4B I0360JB5B I0360K BASIC I0360K1B I0360K2B I0360KB BASIC I0360KB10B I0360KB1B I0360KB2B I0360KB3B I0360KB4B I0360KB5B I0360KB6B I0360KB7B I0360KB8B I0360KB9B I0470C BASIC I0470C8B I0470C9B I0470D BASIC I0470D44B I0470D52B I0470D53B I0470D54B I0470D55B

Fuel System Part Number 649051A10 649051A10-1 649051A10-2 649051A10-2 649051A10-3 649051A10-2 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649050A1-5 649056A1 649056A1 649056A1 649056A2-1 649056A2-1 649056A2-1 649056A2 649056A2 649056A2

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Engine Model And Specification I0470D56B I0470E BASIC I0470E17B I0470E18B I0470E19B I0470E20B I0470F BASIC  I0470F18B  I0470F19B  I0470F26B  I0470F27B  I0470F28B  I0470F29B  I0470F30B  I0470F31B  I0470F32B  I0470F33B  I0470F34B  I0470F36B  I0470F8B  I0470H BASIC I0470H6B I0470J BASIC I0470J1B I0470J8B I0470K BASIC I0470K11B I0470K12B I0470K14B I0470K15B I0470K16B I0470K17B I0470K18B I0470K19B I0470K20B I0470K21B I0470K22B I0470K23B I0470K24B I0470K25B I0470K3B I0470K6B I0470L BASIC I0470L12B I0470L15B I0470L21B I0470L22B I0470L23B I0470L24B I0470L25B I0470L26B I0470L27B I0470L28B

Fuel System Part Number 649056A2-1 649056A2-3 649056A2-3 649056A2-3 649056A2-3 649056A2-3 649056A3 649056A4-1 649056A4 649056A4 649056A4 649056A3 649056A4 649056A4-1 649056A4 649056A4 649056A4 649056A4 649056A4 649056A3 649056A5 649056A5 649056A6 649056A6 649056A6 649056A7 649056A7 649056A7 649056A7-1 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 649056A7 Not Serviced 649056A8-1 649056A8 649056A8 649056A8-2 649056A8-1 649056A8 649056A8-3 649056A8-3 649056A8 649056A8-1

ISSUED MO.

08

DAY

08

Engine Model And Specification I0470L29B I0470M BASIC I0470M5B I0470M6B I0470N BASIC I0470N10B I0470N11B I0470N12B I0470N13B I0470N14B I0470N15B I0470N16B I0470N17B I0470N18B I0470N19B I0470N20B I0470S BASIC I0470S10B I0470S11B I0470S12B I0470S13B I0470S14B I0470S1B I0470S9B I0470U BASIC I0470U4B I0470V BASIC I0470V15B I0470V16B I0470V6B I0470V9B I0520A BASIC I0520A14B I0520A21B I0520A23B I0520A24A I0520A24B I0520A26B I0520A27B I0520A29B I0520A32B I0520A33B I0520A34B I0520A35B I0520A36B I0520A37B I0520A38B I0520A39B I0520A41B I0520A42B I0520A5B I0520B BASIC

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

Fuel System Part Number 649056A8-1 649056A9 649056A9 649056A9 649056A10 649056A11 649056A11 649056A11 649056A11 649056A10 649056A10-1 649056A11 649056A11 649056A10 649056A11 649056A11 649056A12 649056A12 649056A12 649056A12 649056A12 649056A12 649056A12 649056A12 649056A2-2 649056A2-2 649056A13 649056A13 649056A13 649056A13 649056A13 649052A8-1 649052A8-2 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-1 649052A8-3 649052A8-1 649052A8-1 649052A8-3 649052A8-1 649052A1-1

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Engine Model And Specification I0520B6B I0520BA BASIC I0520BA10B I0520BA11B I0520BA12B I0520BA14B I0520BA14M I0520BA17B I0520BA19B I0520BA20B I0520BA21B I0520BA22B I0520BA23B I0520BA24B I0520BA25B I0520BA26B I0520BA27B I0520BA28B I0520BA29B I0520BA2B I0520BA30B I0520BA31B I0520BA32B I0520BA33B I0520BA34B I0520BA35B I0520BA36B I0520BA37B I0520BA38B I0520BA39B I0520BA3B I0520BA6B I0520BB BASIC I0520BB10B I0520BB11B I0520BB12B I0520BB14B I0520BB15B I0520BB16B I0520BB16U I0520BB18B I0520BB18U I0520BB19B I0520BB20B I0520BB21B I0520BB22B I0520BB23B I0520BB24B I0520BB25B I0520BB26B I0520BB27B I0520BB28B

Fuel System Part Number 649052A1-1 649052A1-1 649052A1-1 649052A1-1 649052A1 649052A1 649052A1 649052A1 649052A1-1 649052A1 649052A1 649052A1-1 649052A1-1 649052A1 649052A1 649052A1-1 649052A1-1 649052A1 649052A1 649052A1-1 649052A1-1 649052A1 649052A1 649052A1 649052A1 649052A1 649052A1 649052A1 649052A1-1 649052A1 649052A1-1 649052A1-1 649052A2-1 649052A2-1 649052A2-1 649052A2 649052A2 649052A2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-1 649052A2-1 649052A2 649052A2 649052A2 649052A2-2 649052A2-2

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Engine Model And Specification I0520BB29B I0520BB30B I0520BB31B I0520BB32B I0520BB33B I0520BB34B I0520BB35B I0520BB37B I0520BB38B I0520BB3B I0520BB40B I0520BB41B I0520BB42B I0520BB43B I0520BB44B I0520BB45B I0520BB46B I0520BB47B I0520BB48B I0520BB49B I0520BB50B I0520BB51B I0520BB52B I0520BB53B I0520BB54B I0520BB55B I0520BB56B I0520BB57B I0520BB58B I0520BB59B I0520BB60B I0520BB61B I0520BB64B I0520BB6B I0520C BASIC I0520C10B I0520C11B I0520C12B I0520C13B I0520C14B I0520C15B I0520C16B I0520C17B I0520C3B I0520C6B I0520C7B I0520C8B I0520C9B I0520CB BASIC I0520CB12B I0520CB13B I0520CB14B

Fuel System Part Number 649052A2-2 649052A2-1 649052A2-1 649052A2 649052A2 649052A2 649052A2-2 649052A2-2 649052A2-1 649052A2-1 649052A2-1 649052A2 649052A2 649052A2-1 649052A2 649052A2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2-2 649052A2 649052A2-2 649052A2 649052A2-2 649052A2-2 649052A2 649052A2-2 649052A2-2 649052A2-1 649052A2-1 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A3 649052A4-1 649052A4 649052A4 649052A4

ISSUED MO.

DAY

Engine Model And Specification I0520CB15B I0520CB17B I0520CB18B I0520CB19B I0520CB20B I0520CB21B I0520CB22B I0520CB23B I0520CB25B I0520CB26B I0520CB27B I0520CB28B I0520CB29B I0520CB30B I0520CB31B I0520CB33B I0520CB34B I0520CB36B I0520CB37B I0520CB38B I0520CB39B I0520CB3B I0520CB40B I0520CB41B I0520CB6B I0520CB7B I0520CB8B I0520CB8W I0520CB9B I0520CB9F I0520D BASIC  I0520D100B  I0520D101B  I0520D102B  I0520D105B  I0520D106B  I0520D107B  I0520D108B  I0520D109B  I0520D10B  I0520D110B  I0520D111B  I0520D112B  I0520D113B  I0520D114B  I0520D115B  I0520D116B  I0520D117B  I0520D118B  I0520D119B  I0520D120B  I0520D121B 

REVISED YEAR

MO.

DAY

YEAR

Fuel System Part Number 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4 649052A4 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4 649052A4 649052A4-1 649052A4-1 649052A4 649052A4-1 649052A4 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4-1 649052A4 649052A4 649052A5 649052A6 649052A6-1 649052A6-1 649052A6 649052A6 649052A6-1 649052A6-1 649052A6 649052A5-1 649052A6-1 649052A6-1 649052A6 649052A6-3 649052A6-2 649052A6-1 649052A6-1 649052A6 649052A6-1 649052A6-1 649052A6 649052A6-3

TELEDYNE CONTINENTAL MOTORS

Engine Model And Specification I0520D122B  I0520D123B  I0520D124B  I0520D125B  I0520D126B  I0520D127B  I0520D128B  I0520D129B  I0520D130B  I0520D131B  I0520D132B  I0520D133B  I0520D134B  I0520D135B  I0520D136B  I0520D137B  I0520D138B  I0520D139B  I0520D13B  I0520D140B  I0520D141B  I0520D142B  I0520D144B  I0520D145B  I0520D146B  I0520D147B  I0520D148B  I0520D149B  I0520D150B  I0520D151B  I0520D152B  I0520D153B  I0520D154B  I0520D155B  I0520D156B  I0520D157B  I0520D158B  I0520D159B  I0520D15B  I0520D160B  I0520D161B  I0520D162B  I0520D163B  I0520D164B  I0520D165B  I0520D166B  I0520D167B  I0520D168B  I0520D169B  I0520D170B  I0520D171B  I0520D172B 

PAGE NO.

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B

An Allegheny Teledyne Company

08

05

98

08

23

99

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel System Part Number 649052A6-2 649052A6-1 649052A6-1 649052A6 649052A6-1 649052A6-1 649052A6 649052A6-3 649052A6-2 649052A6-1 649052A6 649052A6-1 649052A6-1 649052A6 649052A6-3 649052A6-2 649052A6-1 649052A6-1 649052A5 649052A6 649052A6-1 649052A6-1 649052A6-1 649052A6-1 649052A6 649052A6-1 649052A6-1 649052A6 649052A6 649052A6 649052A6 649052A6-3 649052A6 649052A6 649052A6 649052A6 649052A6 649052A6 649052A5-3 649052A6-3 649052A6 649052A6 649052A6 649052A6 649052A6 649052A6-3 649052A6 649052A5 649052A5-2 649052A5-4 649052A6 649052A6-1

SIL 98-6

Engine Model And Specification I0520D173B  I0520D174B  I0520D175B  I0520D176B  I0520D177B  I0520D178B  I0520D179B  I0520D180B  I0520D182B  I0520D1B  I0520D22B  I0520D23B  I0520D23M  I0520D24A  I0520D24B  I0520D24M  I0520D26B  I0520D27B  I0520D29B  I0520D30B  I0520D30U  I0520D31B  I0520D32B  I0520D33B  I0520D35B  I0520D39B  I0520D40B  I0520D41B  I0520D43B  I0520D44B  I0520D45B  I0520D47B  I0520D48B  I0520D49B  I0520D50B  I0520D51B  I0520D52B  I0520D53B  I0520D54B  I0520D55B  I0520D56B  I0520D57B  I0520D58B  I0520D59B  I0520D61B  I0520D62B  I0520D63B  I0520D64B  I0520D65B  I0520D66B  I0520D67B 

Fuel System Part Number 649052A6-3 649052A6 649052A6-1 649052A6-1 649052A6 649052A5-1 649052A5 649052A5 649052A5-1 649052A5 649052A6 649052A6 649052A6 649052A6 649052A6 649052A6 649052A6-3 649052A6 649052A6-1 649052A6-1 649052A6-1 649052A6 649052A6-3 649052A6-1 649052A6-2 649052A6-1 649052A6-1 649052A6-2 649052A6 649052A6 649052A6 649052A6 649052A6-3 649052A6 649052A6-1 649052A6-1 649052A6 649052A6-3 649052A6-2 649052A6-1 649052A6-1 649052A6 649052A6 649052A6 649052A6 649052A6-3 649052A6 649052A6-1 649052A6-1 649052A6 649052A6-3

ISSUED MO.

08

DAY

05

Engine Model And Specification I0520D68B  I0520D69B  I0520D70B  I0520D71B  I0520D72B  I0520D73B  I0520D75B  I0520D76B  I0520D77B  I0520D78B  I0520D79B  I0520D7B  I0520D80B  I0520D81B  I0520D82B  I0520D83B  I0520D84B  I0520D85B  I0520D86B  I0520D87B  I0520D88B  I0520D89B  I0520D90B  I0520D91B  I0520D92B  I0520D93B  I0520D94B  I0520D95B  I0520D96B  I0520D97B  I0520D98B  I0520D99B  I0520D9B  I0520E BASIC I0520E11B I0520E14B I0520E1B I0520E2B I0520E3B I0520E6B I0520E7B I0520E7M I0520E8B I0520E9B I0520F BASIC I0520F11B I0520F12B I0520F13B I0520F13K I0520F13U I0520F16B

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

Fuel System Part Number 649052A6-2 649052A6-1 649052A6-1 649052A6 649052A6 649052A6 649052A6 649052A6-3 649052A6 649052A6-1 649052A6-1 649052A5 649052A6 649052A6-3 649052A6-2 649052A6-1 649052A6-1 649052A6 649052A6 649052A6 649052A6 649052A6-1 649052A6-1 649052A6 649052A6 649052A6 649052A6 649052A6-1 649052A6-1 649052A6 649052A6 649052A6 649052A5 649052A7-1 649052A7-1 649052A7 649052A7-1 649052A7 649052A7 649052A7 649052A7 649052A7 649052A7-1 649052A7 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Engine Model And Specification I0520F17B I0520F18B I0520F19B I0520F20B I0520F21B I0520F22B I0520F23B I0520F24B I0520F25B I0520F26B I0520F27B I0520F28B I0520F29B I0520F30B I0520F31B I0520F32B I0520F33B I0520F34B I0520F35B I0520F36B I0520F37B I0520F38B I0520F39B I0520F3B I0520F40B I0520F41B I0520F42B I0520F43B I0520F44B I0520F45B I0520F46B I0520F47B I0520F48B I0520F49B I0520F4B I0520F50B I0520F51B I0520F52B I0520F53B I0520F54B I0520F55B I0520F56B I0520F57B I0520F58B I0520F59B I0520F60B I0520F61B I0520F62B I0520F63B I0520F64B I0520F65B

Fuel System Part Number 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8

PAGE NO.

REVISION

5 of 18

B

SIL 98-6

Engine Model And Specification I0520F67B I0520F68B I0520F69B I0520F6B I0520F70B I0520F7B I0520F9B I0520F9K I0520J BASIC I0520J1B I0520J2B I0520K BASIC I0520K1B I0520K2B I0520L BASIC I0520L12B I0520L13B I0520L14B I0520L15B I0520L16B I0520L17B I0520L18B I0520L19B I0520L1B I0520L22B I0520L23B I0520L24B I0520L25B I0520L26B I0520L27B I0520L30B I0520L31B I0520L32B I0520L33B I0520L34B I0520L35B I0520L39B I0520L41B I0520L43B I0520L45B I0520L46B I0520L47B I0520L48B I0520L49B I0520L50B I0520L51B I0520L52B I0520L53B I0520L54B I0520L5B I0520L7B I0520L8B

Fuel System Part Number 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8-1 649052A8-1 649052A8-1 649052A8-5 649052A8-5 649052A8-5 649052A8 649052A8-4 649052A8-4 649052A8 649052A8 649052A8 649052A8 649052A8-4 649052A8-4 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8-4 649052A8-4 649052A8 649052A8 649052A8 649052A8 649052A8-4 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8 649052A8

ISSUED MO.

08

DAY

05

Engine Model And Specification I0520M BASIC I0520M1B I0520M2B I0520MB BASIC I0520MB1B I0520MB2B I0520P1B I0520P2B I0550A BASIC I0550A2B I0550A3B I0550A4B I0550A5B I0550A6B I0550A7B I0550B BASIC I0550B11B I0550B12B I0550B13B I0550B14B I0550B15B I0550B16B I0550B17B I0550B18B I0550B19B I0550B1F I0550B20B I0550B21B I0550B22B I0550B23B I0550B24B I0550B25B I0550B26B I0550B27B I0550B28B I0550B29B I0550B2F I0550B30B I0550B31B I0550B32B I0550B33B I0550B34B I0550B35B I0550B36B I0550B37B I0550B38B I0550B39B I0550B3F I0550B40B I0550B41B I0550B42B I0550B43B

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

Fuel System Part Number 649052A9 649052A9 649052A9 649052A10 649052A10 649052A10 649053A7 649053A7 649053A4 649053A4 649053A4 649053A4 649053A4 649053A4 649053A4 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1 649053A1-1 649053A1 649053A1 649053A1 649053A1-2 649053A1-3 649053A1-4 649053A1 649053A1-5 649053A1-5 649053A1-5 649053A1-5

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Engine Model And Specification I0550B44B I0550B45B I0550B4F I0550B5F I0550B6F I0550B9F I0550C BASIC I0550C11B I0550C12B I0550C13B I0550C15B I0550C16B I0550C17B I0550C18B I0550C19B I0550C1F I0550C21B I0550C22B I0550C25B I0550C26B I0550C27B I0550C28B I0550C29B I0550C2F I0550C2U I0550C30B I0550C31B I0550C3F I0550C6F I0550C8B I0550C9B I0550D BASIC  I0550D10B  I0550D11B  I0550D12B  I0550D13B  I0550D14B  I0550D15B  I0550D16B  I0550D17B  I0550D18B  I0550D19B  I0550D1B  I0550D20B  I0550D21B  I0550D2B  I0550D3B  I0550D4B  I0550D5B  I0550D7B  I0550D8B  I0550D9B 

Fuel System Part Number 649053A1-6 649053A1-3 649053A1 649053A1 649053A1 649053A1 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2 649053A2-1 649053A2 649053A2 649053A2-2 649053A2-2 649053A2 649053A2 649053A2 649053A2 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11 649052A11-3 649052A11-3 649052A11-1 649052A11-1 649052A11-2 649052A11 649052A11-1 649052A11-1 649052A11

PAGE NO.

REVISION

6 of 18

B

SIL 98-6

Engine Model And Specification I0550E BASIC I0550E1B I0550E3B I0550F BASIC I0550F10B I0550F11B I0550F12B I0550F13B I0550F14B I0550F15B I0550F16B I0550F17B I0550F18B I0550F19B I0550F1B I0550F20B I0550F21B I0550F24B I0550F2B I0550F3B I0550F4B I0550F5B I0550F6B I0550F7B I0550F8B I0550F9B I0550G BASIC I0550G1B I0550G2B I0550G4B I0550G5B I0550G6B I0550L BASIC I0550L10B I0550L11B I0550L12B I0550L13B I0550L14B I0550L15B I0550L16B I0550L1B I0550L3B I0550L4B I0550L5B I0550L6B I0550L7B I0550L8B I0550L9B I0550N BASIC I0550N1B I0550N2B LTSI0360E BASIC

Fuel System Part Number 649053A3-1 649053A3-1 649053A3-3 649053A3 649053A6 649053A6 649053A6 649053A6 649053A6 649053A3 649053A6 649053A3 649053A6 649053A6 649053A3 649053A6 649053A6 649053A6 649053A3 649053A3 649053A3 649053A6 649053A6 649053A6 649053A6 649053A6 649053A5 649053A5 649053A5 649053A5 649053A5-1 649053A5-1 649053A3 649053A3 649053A6 649053A6 649053A6 649053A3 649053A3-4 649053A3 649053A3 649053A3 649053A3 649053A3 649053A3 649053A3 649053A3 649053A3 649053A5 649053A5 649053A5-2 649051A6

ISSUED MO.

DAY

Engine Model And Specification LTSI0360E1B LTSI0360E2B LTSI0360E3B LTSI0360E4B LTSI0360EB BASIC LTSI0360EB10B LTSI0360EB11B LTSI0360EB1B LTSI0360EB12B LTSI0360EB2B LTSI0360EB3B LTSI0360EB4B LTSI0360EB6B LTSI0360EB7B LTSI0360EB8B LTSI0360EB9B LTSI0360KB BASIC LTSI0360KB10B LTSI0360KB11B LTSI0360KB12B LTSI0360KB14B LTSI0360KB15B LTSI0360KB16B LTSI0360KB1B LTSI0360KB3B LTSI0360KB4B LTSI0360KB5B LTSI0360KB6B LTSI0360KB7B LTSI0360KB9B LTSI0360RB BASIC LTSI0360RB1B LTSI0520AE BASIC LTSI0520AE2B LTSI0520AE3B LTSI0520AE4B LTSI0520AE5B TSI0360A BASIC TSI0360A1B TSI0360A3B TSI0360AB BASIC TSI0360AB1B TSI0360AB3B TSI0360C BASIC TSI0360C3B TSI0360C4B TSI0360C5B TSI0360C6B TSI0360CB BASIC TSI0360CB10B TSI0360CB11B TSI0360CB3B

REVISED YEAR

MO.

DAY

YEAR

Fuel System Part Number 649051A6 649051A6 649051A6 649051A6 649051A6 649051A2-4 649051A2-4 649051A6 649051A2-4 649051A6 649051A6 649051A6 649051A6 649051A6 649051A6 649051A2-4 649051A7 649051A7 649051A7 649051A7 649051A7-1 649051A7-1 649051A7-1 649051A7 649051A7 649051A7 649051A7 649051A7-1 649051A7-1 649051A7 649051A9-2 649051A9-2 649054A3-1 649054A3-1 649054A3 649054A3-1 649054A3 649051A8 649051A8 649051A8 649051A8 649051A8 649051A8 649051A1 649051A1 649051A1 649051A1 649051A1-1 649051A1 649051A1-1 649051A1-1 649051A1

TELEDYNE CONTINENTAL MOTORS

Engine Model And Specification TSI0360CB4B TSI0360CB5B TSI0360CB6B TSI0360CB6S TSI0360CB7B TSI0360CB8B TSI0360CB9B TSI0360D BASIC TSI0360D3B TSI0360D4B TSI0360DB BASIC TSI0360DB3B TSI0360DB4B TSI0360E BASIC TSI0360E1B TSI0360E2B TSI0360E3B TSI0360E4B TSI0360EB BASIC TSI0360EB10B TSI0360EB11B TSI0360EB12B TSI0360EB13B TSI0360EB14B TSI0360EB15B TSI0360EB16B TSI0360EB17B TSI0360EB18B TSI0360EB19B TSI0360EB1B TSI0360EB20B TSI0360EB2B TSI0360EB3B TSI0360EB6B TSI0360EB7B TSI0360EB8B TSI0360EB9B TSI0360F BASIC TSI0360F1B TSI0360F2B TSI0360F3B TSI0360F4B TSI0360F5B TSI0360F6B TSI0360F7B TSI0360FB BASIC TSI0360FB12B TSI0360FB14B TSI0360FB15B TSI0360FB16B TSI0360FB17B TSI0360FB18B

PAGE NO.

REVISION

7 of 18

B

An Allegheny Teledyne Company

08

05

98

08

23

99

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel System Part Number 649051A1 649051A1 649051A1-1 649051A1-1 649051A1 649051A1 649051A1 649051A1 649051A1 649051A1 649051A1 649051A1 649051A1 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2-3 649051A2-3 649051A2-3 649051A2 649051A2-3 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2-5 649051A2-5 649051A2-5 649051A2-5 649051A2-5 649051A2-5

SIL 98-6

Engine Model And Specification TSI0360FB1B TSI0360FB2B TSI0360FB3B TSI0360FB4B TSI0360FB5B TSI0360FB6B TSI0360FB7B TSI0360FB9B TSI0360H BASIC TSI0360H1B TSI0360H2B TSI0360HB BASIC TSI0360HB1B TSI0360HB2B TSI0360JB BASIC TSI0360JB1B TSI0360JB2B TSI0360KB BASIC TSI0360KB10B TSI0360KB11B TSI0360KB13B TSI0360KB14B TSI0360KB15B TSI0360KB16B TSI0360KB18B TSI0360KB19B TSI0360KB1B TSI0360KB20B TSI0360KB21B TSI0360KB23B TSI0360KB24B TSI0360KB25B TSI0360KB26B TSI0360KB28B TSI0360KB29B TSI0360KB30B TSI0360KB31B TSI0360KB32B TSI0360KB33B TSI0360KB3B TSI0360KB4B TSI0360KB5B TSI0360KB6B TSI0360KB7B TSI0360KB8B TSI0360KB9B TSI0360LB BASIC TSI0360LB10B TSI0360LB11B TSI0360LB1B TSI0360LB7B TSI0360LB8B

Fuel System Part Number 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2 649051A2-5 649051A2-1 649051A2-1 649051A2-1 649051A2-1 649051A2-1 649051A2-1 649051A2-2 649051A2-2 649051A2-2 649051A4 649051A4-1 649051A4-1 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4-1 649051A4-1 649051A4-1 649051A4-1 649051A4-1 649051A4-1 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A4 649051A5 649051A5 649051A5 649051A5 649051A5 649051A5

ISSUED MO.

08

DAY

05

Engine Model And Specification TSI0360LB9B TSI0360MB BASIC TSI0360MB10B TSI0360MB1B TSI0360MB2B TSI0360MB3B TSI0360MB4B TSI0360MB6B TSI0360MB7B TSI0360MB8B TSI0360MB9B TSI0360RB BASIC TSI0360RB1B TSI0360SB BASIC TSI0360SB1B TSI0360SB2B TSI0520AE BASIC TSI0520AE2B TSI0520AE3B TSI0520AE4B TSI0520AE5B TSI0520AE6B TSI0520AE7B TSI0520AF BASIC TSI0520AF3B TSI0520B BASIC TSI0520B10B TSI0520B11B TSI0520B12B TSI0520B13B TSI0520B14B TSI0520B15B TSI0520B5B TSI0520B9B TSI0520BB BASIC TSI0520BB10B TSI0520BB11B TSI0520BB12B TSI0520BB13B TSI0520BB14B TSI0520BB15B TSI0520BB16B TSI0520BB17B TSI0520BB18B TSI0520BB19B TSI0520BB20B TSI0520BB21B TSI0520BB22B TSI0520BB23B TSI0520BB24B TSI0520BB5B TSI0520BB9B

Fuel System Part Number 649051A5 649051A9 649051A9 649051A9 649051A9 649051A9-1 649051A9 649051A9 649051A9 649051A9 649051A9 649051A9-3 649051A9-3 649051A9-4 649051A9-4 649051A9-4 649054A2-1 649054A2-1 649054A2 649054A2-1 649054A2 649054A2-1 649054A2 649054A5 649054A5 649054A7-1 649054A7 649054A7-1 649054A7 649054A7-1 649054A7 649054A7-1 649054A7-1 649054A7-1 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8 649054A8-1 649054A8-1

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Engine Model And Specification TSI0520BE BASIC TSI0520BE1F TSI0520BE1G TSI0520BE2F TSI0520BE2G TSI0520C BASIC TSI0520C10B TSI0520C11B TSI0520C2B TSI0520C3B TSI0520C5B TSI0520C6B TSI0520C7B TSI0520C8B TSI0520C9B TSI0520CE BASIC TSI0520CE1F TSI0520CE2B TSI0520D BASIC TSI0520D1B TSI0520D3B TSI0520DB BASIC TSI0520DB1B TSI0520DB3B TSI0520E BASIC TSI0520E14B TSI0520E15B TSI0520E16B TSI0520E17B TSI0520E19B TSI0520E20B TSI0520E22B TSI0520E23B TSI0520E4B TSI0520E5B TSI0520E8B TSI0520E9B TSI0520EB BASIC TSI0520EB14B TSI0520EB15B TSI0520EB16B TSI0520EB17B TSI0520EB18B TSI0520EB19B TSI0520EB20B TSI0520EB21B TSI0520EB4B TSI0520EB5B TSI0520EB8B TSI0520EB9B TSI0520G BASIC TSI0520G1B

Fuel System Part Number 649054A6 649054A6 649054A6 649054A6 649054A6 649054A9-2 649054A9 649054A9 649054A9-2 649054A9 649054A9-2 649054A9 649054A9-2 649054A9 649054A9-2 649054A10 649054A10 649054A10 649054A11 649054A11 649054A11 649054A12 649054A12 649054A12 649054A13-1 649054A13-1 649054A13-1 649054A13 649054A13-1 649054A13 649054A13-1 649054A13 649054A13-1 649054A13 649054A13-1 649054A13-1 649054A13 649054A13-3 649054A13-3 649054A13-3 649054A13-2 649054A13-2 649054A13-3 649054A13-2 649054A13-3 649054A13-2 649054A13-2 649054A13-3 649054A13-3 649054A13-2 649054A14 649054A14

PAGE NO.

REVISION

8 of 18

B

SIL 98-6

Engine Model And Specification TSI0520G3B TSI0520H BASIC TSI0520H1B TSI0520H4B TSI0520H5B TSI0520H6B TSI0520H7B TSI0520J BASIC TSI0520J10B TSI0520J12B TSI0520J13B TSI0520J14B TSI0520J1B TSI0520J2B TSI0520J4B TSI0520J9B TSI0520JB BASIC TSI0520JB10B TSI0520JB12B TSI0520JB13B TSI0520JB14B TSI0520JB1B TSI0520JB2B TSI0520JB4B TSI0520JB9B TSI0520K BASIC TSI0520K1B TSI0520K2B TSI0520K5B TSI0520KB BASIC TSI0520KB1B TSI0520KB2B TSI0520KB3B TSI0520KB4B TSI0520L BASIC TSI0520L1B TSI0520L4B TSI0520L7B TSI0520LB BASIC TSI0520LB1B TSI0520LB4B TSI0520LB6B TSI0520M BASIC TSI0520M10B TSI0520M11B TSI0520M6B TSI0520M7B TSI0520M8B TSI0520M9B TSI0520N BASIC TSI0520N10B

Fuel System Part Number 649054A14 649054A9 649054A9 649054A9 649054A9 649054A9 649054A9-3 649054A15 649054A15-5 649054A15-5 649054A15 649054A15-1 649054A15 649054A15-1 649054A15-1 649054A15-4 649054A15-2 649054A15-7 649054A15-7 649054A15-3 649054A15-2 649054A15-2 649054A15-3 649054A15-3 649054A15-6 649054A19 649054A19 649054A19-1 649054A19 649054A19-2 649054A19-2 649054A19-3 649054A19-4 649054A19-5 649054A23-1 649054A23-1 649054A23-1 649054A23-1 649054A23 649054A23 649054A23 649054A23 649054A16 649054A16-3 649054A16-3 649054A16 649054A16 649054A16 649054A16-3 649054A27 649054A29-5

ISSUED MO. 08

DAY 05

Engine Model And Specification TSI0520N12B TSI0520N13B TSI0520N14B TSI0520N16B TSI0520N19B TSI0520N1B TSI0520N20B TSI0520N21B TSI0520N2B TSI0520N4B TSI0520N5B TSI0520N6B TSI0520N8B TSI0520N9B TSI0520NB BASIC TSI0520NB10B TSI0520NB12B TSI0520NB13B TSI0520NB14B TSI0520NB16B TSI0520NB17B TSI0520NB18B TSI0520NB19B TSI0520NB1B TSI0520NB20B TSI0520NB21B TSI0520NB22B TSI0520NB23B TSI0520NB24B TSI0520NB25B TSI0520NB26B TSI0520NB27B TSI0520NB28B TSI0520NB29B TSI0520NB2B TSI0520NB30B TSI0520NB31B TSI0520NB32B TSI0520NB33B TSI0520NB34B TSI0520NB4B TSI0520NB5B TSI0520NB6B TSI0520NB9B TSI0520P BASIC TSI0520P5B TSI0520P6B TSI0520P7B TSI0520P8B TSI0520R BASIC TSI0520R10B

REVISED YEAR 98

MO. 08

DAY 23

YEAR 99

Fuel System Part Number 649054A29-5 649054A27-4 649054A27-5 649054A27-5 649054A27 649054A27 649054A27-1 649054A27-1 649054A27-1 649054A27-1 649054A29-1 649054A29-2 649054A29-2 649054A29-4 649054A27-2 649054A29-7 649054A29-7 649054A27-6 649054A27-7 649054A27-7 649054A29-3 649054A29-3 649054A27-2 649054A27-2 649054A27-3 649054A27-3 649054A29 649054A29-3 649054A29-3 649054A29-6 649054A29-7 649054A29-7 649054A27-6 649054A27-7 649054A27-3 649054A27-7 649054A27-2 649054A27-3 649054A27-6 649054A27-3 649054A27-3 649054A29 649054A29-3 649054A29-6 649054A16 649054A16 649054A16 649054A16-3 649054A16-3 649054A16 649054A16

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Engine Model And Specification TSI0520R11B TSI0520R12B TSI0520R13B TSI0520R14B TSI0520R15B TSI0520R7B TSI0520R9B TSI0520T BASIC TSI0520T1B TSI0520T1F TSI0520T3B TSI0520UB BASIC TSI0520UB10B TSI0520UB11B TSI0520UB12B TSI0520UB13B TSI0520UB14B TSI0520UB15B TSI0520UB16B TSI0520UB17B TSI0520UB1B TSI0520UB2F TSI0520UB3F TSI0520UB4A TSI0520UB4F TSI0520UB5F TSI0520UB6B TSI0520UB7B TSI0520UB8B TSI0520UB9B TSI0520VB BASIC TSI0520VB1B TSI0520VB1F TSI0520VB2B TSI0520VB2F TSI0520VB4B TSI0520VB4F TSI0520VB5F TSI0520VB6F TSI0520VB7F TSI0520WB BASIC TSI0520WB3F TSI0520WB5F TSI0520WB6B TSI0550A BASIC TSI0550A1B TSI0550B BASIC TSI0550B1B TSI0550B2B TSI0550C BASIC TSI0550C1B

PAGE NO. 9 of 18 SIL 98-6

Fuel System Part Number 649054A16-1 649054A16-3 649054A16-4 649054A16 649054A16-1 649054A5-1 649054A16 649054A35 649054A35 649054A35 649054A35 649054A36-1 649054A36-4 649054A36-3 649054A36-4 649054A36-3 649054A36-3 649054A36-5 649054A36-3 649054A36-6 649054A36-1 649054A36 649054A36 649054A36-3 649054A36-4 649054A36-4 649054A36 649054A36 649054A36-1 649054A36 649054A37 649054A37 649054A37 649054A37 649054A37 649054A37 649054A37 649054A37 649054A37 649054A37 649054A23-2 649054A23-2 649054A23-2 649054A23-2 649054A6 649054A6 649054A6-1 649054A6-1 649054A6-1 649054A6 649054A6

REVISION

B

Engine Model And Specification TSI0550E BASIC TSI0550E1B TSI0550E2B TSI0550E3B TSI0550E4B TSI0550E5B TSI0L550A BASIC TSI0L550A1G TSI0L550A3B TSI0L550A5B TSI0L550A7B TSI0L550A8B TSI0L550B BASIC TSI0L550B1B TSI0L550C BASIC TSI0L550C1B

Fuel System Part Number 649054A6 649054A6 649054A6 649054A6 649054A6 649054A6 649054A39 649054A39 649054A39 649054A39 649054A39 649054A39 649054A40 649054A40 649054A38 649054A38

 If replacing old style throttle body that has cast mount legs it will be necessary to order, in addition to new throttle assembly, a 639411 bracket and 4 each 530346 bolts .

ISSUED MO. 08

DAY 05

REVISED YEAR 98

MO. 08

DAY 23

YEAR 99

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO. 10 of 18 SIL 98-6

REVISION

B

FUEL INJECTION SYSTEMS Fuel Inj. Assembly

649050A1-1

649364-2A1 Opt. 646759-2A1 649364-2A1

649050A1-2

649364-2A2

640563-15A2

649050A1-4

649368-4A1

640563-15A2

649050A1-5

649364-2A1

640563-15A2

649050A1-6

649364-2A1

640563-15A2

649051A1

640563-12A5 Opt. 640563-4A11 640563-12A5

649051A10

649368-1A1 Opt. 646758-1A1 649368-1A2 Opt. 646758-1A2 649368-22A1

652844-1A1

Manifold Valve 631351-11A7M 631351-11A7P 631351-11A13M 631351-11A13P 631351-11A13M 631351-11A13P 631351-11A7M 631351-11A7P 631351-11A11M‘ 631351-11A11P‘ 631351-11A7M 631351-11A7P 641032-13A4M 641032-13A4P 641032-13A4M 641032-13A4P 646508-10A1

649051A10-1

649368-22A2

652844-1A2

646508-10A3

632147-10J

649051A10-2

649368-22A3

652844-1A4

646508-10A5

632147-10J

649051A10-3

649368-22A4

652844-1A3

646508-10A5

632147-10J

649051A2

640563-15A4

649051A2-4

649368-2A1 Opt. 646758-2A1 649368-2A2 Opt. 646758-2A2 649368-11A1 Opt. 646758-11A1 649368-3A1

649051A2-5

649368-2A1

640563-15A9

649051A4

649368-6A2 Opt. 646758-6A2 649368-6A2 Opt. 646758-6A2 649368-6A1

640563-14A2

641032-11A7M 641032-11A7P 641032-11A2M 641032-11A2P 641032-11A2M 641032-11A2P 641032-11A7M 641032-11A7P 641032-11A7M 641032-11A7P 641032-11A7M 641032-11A7P 641032-11A7M 641032-11A7P 646508-4A3

633608-12D 633608-12E 633608-12D 633608-12E 633608-12D 633608-12E 633608-12D 633608-12E 633608-12D 633608-12E 633608-12D 633608-12E 633608-12D 633608-12E 633608-13B

649368-3A1 Opt. 646758-3A1 649368-10A1 Opt. 646758-10A1 649368-6A2 Opt. 646758-6A2 649368-4A1

640563-15A4

646999-3A1

633608-12D 633608-12E 633608-12D 633608-12E 633608-12D 633608-12E 633608-12A 633608-12B 633608-13B

649051A9-1

649368-16A1 Opt. 646758-16A1 649368-16A2

641032-11A7M 641032-11A7P 641032-11A7M 641032-11A7P 641032-11A7M 641032-11A7P 631351A34M 631351A34P 646508-4A9

646999-3A1

646508-4A10

633608-13B

649051A9-2

654351-1A1

654480A5

652432-5A3

633608-13B

649050A1

649051A1-1

649051A2-1 649051A2-2

649051A4-1 649051A5 649051A6 649051A7 649051A7-1 649051A8 649051A9

Fuel Pump

ISSUED MO.

08

DAY

05

Throttle /Met. Unit or Throttle /Control 640563-15A2 640563-15A2

640563-15A4 640563-15A4 640563-15A12

640563-14A2 640563-16A1

640563-14A2 640563-14A3 640563-14A2 640563-15A2

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

Fuel Control

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel Nozzle 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K 633608-12C 633608-12D 633608-12C 633608-12D 632147-10J

Fuel Press. Regulator

PAGE NO.

REVISION

11 of 18

B

SIL 98-6

Fuel Inj. Assembly 649051A9-3

654351-2A1

Throttle/Met. Unit Throttle/Control 654480A5

649051A9-4

649368-24A1

646999-4A1

649052A1

646212-2A3 Opt. 638154-2A9 646212-2A1

631415A7

629904-2A11

631415A7

629904-2A11

641028A1

632916-2A3

639715A7

639717-2A2

639715A17

639717-2A2

639715A19

639717-2A4

639715A18

639717-2A2

631415A7

629904-2A11

631415A7

629904-2A11

631415A7

629904-2A11

653377A3

629904-2A6

653377A3

629904-2A6

653377A3

629904-2A6

640117A10

625219-2A21

640116A4

625219-2A22

640119A4

625219-2A23

640117A10

625219-2A21

640117A10

625219-2A21

639715A18

639717-2A2

639715A18

639717-2A2

639715A7

639717-2A2

639715A7

639717-2A2

636887A2

629904-2A4

636887A2

625219-2A9

629399A8

629703-2A3

649052A1-1 649052A10 649052A11 649052A11-1 649052A11-2 649052A11-3 649052A2 649052A2-1 649052A2-2 649052A3 649052A4 649052A4-1 649052A5 649052A5-1 649052A5-2 649052A5-3 649052A5-4 649052A6 649052A6-1 649052A6-2 649052A6-3 649052A7 649052A7-1 649052A8

Fuel Pump

646212-17A1 Opt. 638154-17A1 646212-1A5 Opt. 638154-1A18 646824-3A2 646212-1A5 Opt. 638154-1A18 646212-1A5 Opt. 638154-1A18 646212-16A2 Opt. 638154-16A5 646212-16A1 Opt. 638154-16A4 646212-16A2 Opt. 638154-16A5 646212-2A2 Opt. 638154-2A8 646212-16A3 Opt. 638154-16A6 646212-16A3 646212-1A5 Opt. 638154-1A18 646212-1A8 Opt. 638154-1A21 646212-1A6 Opt. 638154-1A19 646212-1A7 Opt. 638154-1A20 646212-1A16 Opt. 638154-1A18 646212-1A5 Opt. 638154-1A18 646212-1A9 Opt. 638154-1A23 646212-1A9 Opt. 638154-1A23 646212-1A9 Opt. 638154-1A23 646212-4A1 Opt. 638154-4A4 646212-4A1 Opt. 638154-4A4 646212-1A14 Opt. 638154-1A16

ISSUED MO.

DAY

REVISED YEAR

MO.

DAY

YEAR

Fuel Control Unit

Manifold Valve

Fuel Nozzle

652432-5A3

633608-13B

646508-4A9

633608-13B

631427-2A9M 631427-2A9P 631427-2A9M 631427-2A9P 641032-21A1M 641032-21A1P 646508-15A1M 646508-15A1P 646508-15A1M 646508-15A1P 646508-15A1M 646508-15A1P 646508-15A7M 646508-15A7P 631427-2A9M 631427-2A9P 631427-2A9M 631427-2A9P 631427-2A13M 631427-2A13P 631427-2A11M 631427-2A11P 631427-2A15M 631427-2A15P 631427-2A11M 631427-2A11P 631351-17A3M 631351-17A3P 631351-17A3M 631351-17A3P 631351-17A3M 631351-17A3P 631351-17A3M 631351-17A3P 631351-17A3M 631351-17A3P 631351-17A3M 631351-17A3P 631351-17A3M 631351-17A3P 631351-15A25M 631351-15A25P 631351-17A3M 631351-17A3P 631427-2A9M 631427-2A9P 631427-2A9M 631427-2A9P 631351-17A5M 631351-17A5P

627335D13AA 627335D13A 627335D13AA 627335D13A 627335D12C 627335D12D 627335D12E 627335D12D 627335D12E 627335D12D 627335D12E 627335D12D 627335D12E 627335D12D 627335D13AA 627335D13A 627335D13AA 627335D13A 627335D13AA 627335D13A 627335D13AA 627335D13A 627335D13AA 627335D13A 627335D13AA 627335D13A 627335D13A 627335D13B 627335D13A 627335D13B 627335D13A 627335D13B 627335D13A 627335D13B 627335D13A 627335D13B 627335D13A 627335D13B 627335D13A 627335D13B 627335D13B 627335D13C 627335D13A 627335D13B 627335D13AA 627335D13A 627335D13AA 627335D13A 627335D13A 627335D13B

TELEDYNE CONTINENTAL MOTORS

PAGE NO.

REVISION

12 of 18

B

An Allegheny Teledyne Company

08

05

98

08

23

99

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel Press. Regulator

SIL 98-6

Fuel Inj. Assembly 649052A8-1

Fuel Pump 646212-1A11 Opt. 638154-1A8 646212-1A11 Opt. 638154-1A8 646212-1A12

649052A8-2 649052A8-3 649052A8-4

Throttle/Met. Unit Throttle/Control 629399A8

Fuel Control Unit 629703-2A3

629399A8

629703-2A3

629399A8

629703-2A3

629399A8

629703-2A3

629399A8

629703-2A3

649052A9

646212-1A15 Opt. 638154-1A25 646212-1A13 Opt. 638154-1A12 646212-5A1

641028A1

632916-2A3

649053A1

646766-4A1

646628A7

649468-2A1

649053A1-1

646766-4A1

646628A7

649468-2A1

649053A1-2

646212-18A1

646628A7

649468-2A1

649053A1-3

646212-18A2

646628A7

649468-2A1

649053A1-4

646212-18A1

646628A7

649468-2A1

649053A1-5

646212-18A2

646628A7

649468-2A1

649053A1-6

646766-4A1

646628A7

649468-2A1

649053A2

646767-1A1

646637A9

649468-2A2

649053A2-1

646767-1A1

646637A9

649468-2A2

649053A2-2

646212-19A1

646637A9

649468-2A2

649053A3

646824-3A3

629399A24

629703-2A3

649053A3-1

646824-3A1

654714A3

629904-2A10

649053A3-3

646824-3A1

654714A4

629904-2A13

649053A3-4

646212-20A1

629399A24

629703-2A3

649053A4

646767-1A3

641028A1

632916-2A3

649053A5

649364-4A1

653353-1

649053A5-1

649364-4A3

653353-1

649053A5-2

649364-4A4

653353-1

649053A6

646212-1A14

629399A8

629703-2A3

649053A7

646212-1A14

629399A25

629703-2A3

649052A8-5

ISSUED MO.

DAY

REVISED YEAR

MO.

DAY

YEAR

Manifold Valve 631351-15A35M 631351-15A35P 631351-15A35M 631351-15A35P 631351-17A9M 631351-17A9P 631351-17A5M 631351-17A5P 631351-17A1M 631351-17A1P 641032-21A1M 641032-21A1P 646508-14A1M 646508-14A1P 646508-13A1M 646508-13A1P 646508-14A1M 646508-14A1P 646508-14A1M 646508-14A1P 646508-17A1

Fuel Nozzle

646508-14A3M 646508-14A3P 646508-13A3

627335D13B 627335D13C 627335D13B 627335D13C 627335D13A 627335D13B 627335D13A 627335D13B 627335D13A 627335D13B 627335D12C 627335D12D 627335D13AA 627335D13A 627335D13A 627335D13B 627335D13AA 627335D13A 627335D13AA 627335D13A 655234T13B, CYLS. 1 & 2 655234T12E, CYLS. 3 & 4 655234T12D, CYLS. 5 & 6 627335D13AA 627335D13A 655234T13B, CYLS. 1 & 2 655234T12E, CYLS. 3 & 4 655234T12D, CYLS. 5 & 6 627335D13AA 627335D13A 627335D13B

646508-14A3M 646508-14A3P 646508-15A1M 646508-15A1P 646508-15A1M 646508-15A1P 646508-15A1M 646508-15A1P 646508-15A1M 646508-15A1P 641032-21A1M 641032-21A1P 646433-3M 646433-3P 646433-3M 646433-3P 646433-3M 646433-3P 646508-15A1M 646508-15A1P 646508-19A5M 646508-19A5P

627335D13AA 627335D13A 627335D12D 627335D12E 627335D12D 627335D12E 627335D12D 627335D12E 627335D12E 627335D12D 627335D12C 627335D12D 652312-12D 652312-12E 652312-12D 652312-12E 652312-12D 652312-12E 627335D12D 627335D12E 643318-14A 643318-14B

646508-14A1M 646508-14A1P 646508-13A1

TELEDYNE CONTINENTAL MOTORS

PAGE NO.

REVISION

13 of 18

B

An Allegheny Teledyne Company

08

05

98

08

23

99

Fuel Press. Regulator

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

SIL 98-6

Fuel Inj. Assembly

Fuel Pump

Throttle/Met. Unit Throttle/Control 646723A18

Fuel Control Unit 649452-7A2

649054A10

646768-1A3

649054A11

649054A13

649368-5A1 Opt. 646758-5A1 649368-8A1 Opt. 646758-8A1 646210-2A1

632855-1A7

632916-8A1

649054A13-1

646210-2A1

632855-1A7

632916-8A1

649054A13-2

646210-11A2

632855-1A7

632916-8A1

649054A13-3

646210-11A2

632855-1A7

632916-8A1

649054A14

646768-2A1 

632774-1A10

629703-8A1

649054A15

636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 636143A13 Opt. 636143A7 632774-2A14

632916-11A1

649054A16

646210-2A2 Opt. 632818-2A2 646210-2A3 Opt. 632818-2A3 646210-11A1 Opt. 632818-11A1 646210-11A6 Opt. 632818-11A6 646210-2A2 Opt. 632818-2A2 646210-2A3 Opt. 632818-2A3 646210-11A1 Opt. 632818-11A1 646210-11A6 Opt. 632818-11A6 646768-1A1 

629703-11A2

649054A16-1

646768-1A2

632774-2A14

629703-11A2

649054A16-3

646768-1A1 

632774-2A18

629703-11A2

649054A16-4

646768-1A2 

632774-5A13

629703-11A5

649054A19

646210-2A2 Opt. 632818-2A2 646210-2A3 Opt. 632818-2A3 646210-11A1 Opt. 632818-11A1 646210-11A6 Opt. 632818-11A6 646210-11A1 Opt. 632818-11A1 646210-11A6 Opt. 632818-11A6 649368-12A3

637735A6 Opt.. 637735A4 637735A6 Opt.. 637735A4 637735A6 Opt.. 637735A4 637735A6 Opt.. 637735A4 637735A6 Opt.. 637735A4 637735A6 Opt.. 637735A4 653297-1A3

632916-11A2

649054A12

649054A15-1 649054A15-2 649054A15-3 649054A15-4 649054A15-5 649054A15-6 649054A15-7

649054A19-1 649054A19-2 649054A19-3 649054A19-4 649054A19-5 649054A2

ISSUED MO.

08

DAY

05

640564-1A4 640564-1A4

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

632916-11A1 632916-11A1 632916-11A1 632916-11A1 632916-11A1 632916-11A1 632916-11A1

632916-11A2 632916-11A2 632916-11A2 632916-11A2 632916-11A2

Manifold Valve 640718-10A1M 640718-10A1P 631351A26M 631351A26P 631351A26M 631351A26P 634326-11A3M 634326-11A3P 634326-11A1M 634326-11A1P 634326-11A3M 634326-11A3P 634326-11A1M 634326-11A1P 631351A35M 631351A35P 634326-12A3M 634326-12A3P 634326-12A3M 634326-12A3P 634326-12A3M 634326-12A3P 634326-12A3M 634326-12A3P 640718-11A3M 640718-11A3P 640718-11A3M 640718-11A3P 640718-11A3M 640718-11A3P 640718-11A3M 640718-11A3P 634326-12A1M 634326-12A1P 634326-12A1M 634326-12A1P 634326-12A1M 634326-12A1P 634326-4A21M 634326-4A21P 634326-6A4M 634326-6A4P 634326-6A4M 634326-6A4P 634326-6A4M 634326-6A4M 634326-6A4M 634326-6A4P 640718-9A1M 640718-9A1P 640718-9A1M 640718-9A1P 641032-19A5M 641032-19A5P

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel Nozzle 632748-17C 632748-17D 632748-15B 632748-15C 632748-15B 632748-15C 632748-15AA 632748-15AB 632748-15AA 632748-15AB 632748-15AA 632748-15AB 632748-15AA 632748-15AB 632748-15C 632748-15D 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14C 632748-14D 632748-14C 632748-14D 632748-14C 632748-14D 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 643318-14A 643318-14B

Fuel Press. Regulator

642100-5 642100-5 642100-5 642100-5 642100-5 642100-5 642100-5 642100-5

642100-5 642100-5 642100-5 642100-5 642100-5 642100-5

PAGE NO.

REVISION

14 of 18

B

SIL 98-6

Fuel Inj. Assembly

Fuel Pump

Throttle/Met. Unit Throttle/Control 653297-1A1

649054A2-1

649368-12A4

649054A23

646765-7A1

649054A23-1

646765-6A1

649054A23-2

646765-7A1

649054A27

646210-2A2

649054A27-1

649054A3

646210-2A4 Opt. 632818-2A4 646210-11A1 Opt. 632818-11A1 646210-11A3 Opt. 632818-11A3 646210-2A2 Opt. 632818-2A2 646210-2A4 Opt. 632818-2A4 646210-11A1 Opt. 632818-11A1 646210-11A3 Opt. 632818-11A3 646210-11A4 Opt. 632818-11A4 646210-2A5 Opt. 632818-2A7 646210-2A6 Opt. 632818-2A8 646210-11A5 Opt. 632818-11A5 646210-2A5 Opt. 632818-2A7 646210-2A6 Opt. 632818-2A8 646210-11A4 Opt. 632818-11A4 646210-11A5 Opt. 632818-11A5 649368-13A3

646506-1 SERVO 646506-1 SERVO 646506-2 SERVO 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A14 Opt. 636143A8 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 636143A15 Opt. 636143A9 653297-1A4

649054A3-1

649368-13A4

653297-1A2

649054A35

646210-9A1

639715A10

649054A36

649368-9A2 Opt. 646758-9A2 649368-9A2 Opt. 646758-9A2 649368-9A3 Opt. 646758-9A3 649368-9A3 Opt. 646758-9A3

642703A65

649054A27-2 649054A27-3 649054A27-4 649054A27-5 649054A27-6 649054A27-7 649054A29 649054A29-1 649054A29-2 649054A29-3 649054A29-4 649054A29-5 649054A29-6 649054A29-7

649054A36-1 649054A36-3 649054A36-4

ISSUED MO.

08

DAY

05

642703A64 642703A66 642703A69

REVISED YEAR 98

MO.

08

DAY

23

YEAR

99

Fuel Control Unit

632916-11A1 632916-11A7 632916-11A7 632916-11A1 632916-11A1 632916-11A1 632916-11A1 632916-11A1 632916-11A6 632916-11A6 632916-11A6 632916-11A6 632916-11A6 632916-11A6 632916-11A6 632916-11A6

629904-11A1

Manifold Valve 641032-19A5M 641032-19A5P 652432-3A1M 652432-3A1P 652432-3A1M 652432-3A1P 652432-3A1M 652432-3A1P 634326-12A3M 634326-12A3P 634326-12A3M 634326-12A3P 634326-12A3M 634326-12A3P 634326-12A3M 634326-12A3P 640718-11A1M 640718-11A1P 640718-11A1M 640718-11A1P 640718-11A1M 640718-11A1P 640718-11A1M 640718-11A1P 634326-12A5M 634326-12A5P 634326-12A5M 634326-12A5P 634326-12A5M 634326-12A5P 634326-12A5M 634326-12A5P 640718-11A1M 640718-11A1P 640718-11A1M 640718-11A1P 640718-11A1M 640718-11A1P 640718-11A1M 640718-11A1P 641032-19A7M 641032-19A7P 641032-19A7M 641032-19A7P 641032-16A9M 641032-16A9P 641032-15A6M 641032-15A6P 641032-15A3M 641032-15A3P 641032-15A6M 641032-15A6P 641032-15A6M 641032-15A6P

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel Nozzle 643318-14A 643318-14B 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 632748-14B 632748-14C 643318-14A 643318-14B 643318-14A 643318-14B 632748-15C 632748-15D 632748-17A 632748-17B 632748-17A 632748-17B 632748-17A 632748-17B 632748-17A 632748-17B

Fuel Press. Regulator

642100-5 642100-5 642100-5 642100-5 642100-5 642100-5 642100-5 642100-5

PAGE NO.

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Fuel Inj. Assembly

Fuel Pump

649054A36-5

Throttle/Met. Unit Throttle/Control 642703A58

Fuel Control Unit

649054A38

649368-9A2 Opt. 646758-9A2 649368-9A3 Opt. 646758-9A3 646210-8A1 Opt. 632818-8A2 649368-23A1

649054A39

646210-11A8

649868A4

649054A40

649368-19A1

642703A34

649054A5

646768-1A2 

632774-3A12

629703-11A5

649054A5-1

646768-1A2

632774-5A11

629703-11A5

649054A6

649368-20A2

646081

649054A6-1

649368-20A1

646081

649054A7

646210-1A1

632855-1A7

632916-8A1

649054A7-1

646210-1A1

632855-1A7

632916-8A1

649054A8

646210-10A1

632855-1A7

632916-8A1

649054A8-1

632855-1A7

632916-8A1

649054A9

646210-1A1 Opt. 632818-10A1 646768-2A1 

632774-1A10

629703-8A1

649054A9-2

646768-2A1 

632774-1A10

629703-8A1

649054A9-3

646768-2A1 

632774-1A12

629703-8A1

649055A1

646210-4A1 

632658A3

630255-7A1

649055A2

646211-2A3 

639626A11

633573-9A17

649055A2-1

646211-2A3 

639626A11

633573-9A17

649055A3

646211-2A2 

639625A9

633573-9A18

649055A3-1

646211-2A4 

639625A9

633573-9A18

649055A5

646210-3A5

642387A6

633573-9A19

649055A5-1

646210-3A5

642387A6

633573-9A19

649055A6

646210-3A6

642386A6

633573-9A20

649055A6-1

646210-3A6

642386A6

633573-9A20

649055A7

646210-3A7

633573-10A2

649055A8

643367A2

641864A17 Opt. 641864A14 642387A7

649054A36-6 649054A37

ISSUED MO.

DAY

642703A66 642702A9

632916-11A5

654539A2 632916-11A7

REVISED YEAR

MO.

DAY

YEAR

643322-1A4

Manifold Valve

Fuel Nozzle

641032-15A3M 641032-15A3P 641032-15A8M 641032-15A8P 641032-17A3M 641032-17A3P 646508-16A1M 646508-16A1P 646508-8A4M 646508-8A4P 646508-11A3M 646508-11A3P 634326-12A1M 634326-12A1P 634326-12A1M 634326-12A1P 646433-1M 646433-1P 646433-1M 646433-1P 631351-18A3

632748-17A 632748-17B 632748-17A 632748-17B 632748-16A 632748-16B 639368-17C 639368-17D 639368-14B 639368-14C 639368-13D 639368-13E 632748-14B 632748-14C 632748-14B 632748-14C 639368-19B 639368-19C 639368-19B 639368-19C 632748-15B

631351-18A1M 631351-18A1P 631351-18A3M 631351-18A3P 631351-18A1

632748-15B 632748-15C 632748-15B 632748-15C 632748-15B

631351-16A13M 631351-16A13P 631351-16A9M 631351-16A9P 631351-16A13M 631351-16A13P 631351A27M 631351A27P 634326-7A8M 634326-7A8P 640718-8A1M 640718-8A1P 634326-7A8M 634326-7A8P 640718-8A1M 640718-8A1P 641032-1A6M 641032-1A6P 640718-1A6M 640718-1A6P 641032-1A6M 641032-1A6P 640718-6A1M 640718-6A1P 641032-1A6M 641032-1A6P 640718-6A1M 640718-6A1P

632748-14C 632748-14D 632748-14C 632748-14D 632748-14C 632748-14D 632848-17C 632848-17D 633723D19AA 633723D19A 633723D19AA 633723D19A 633723D19AA 633723D19A 633723D19AA 633723D19A 639368-19AA 639368-19A 639368-19AA 639368-19A 639368-19AA 639368-19A 639368-19AA 639368-19A 639368-19AA 639368-19A 639368-19AA 639368-19A

TELEDYNE CONTINENTAL MOTORS

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642100-3A1 642100-3A1 642100-3A2 642100-3A2 642100-4A1

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An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel Press. Regulator

SIL 98-6

Fuel Inj. Assembly

Fuel Pump

649055A9

643367A2

Throttle/Met. Unit Throttle/Control 642386A7

649056A1

646212-9A3

626836A9

625219-2A25

649056A10

646212-9A3

628776A5

625219-2A25

649056A10-1

646212-9A8

628776A5

625219-2A25

649056A11

646212-9A3

639123A5

629904-2A11

649056A12

646212-9A7

629399A9

629703-2A4

649056A13

646212-3A1 Opt. 638154-3A2 646212-9A14 Opt. 638154-9A33 646212-9A14 Opt. 638154-9A33 646212-9A14 Opt. 638154-9A33 646212-9A4

632855-2A3

632916-2A2

627315A14

625219-2A2

630074A3

629904-2A1

630074A3

629904-2A1

627315A16

625219-2A3

640120A3

625219-2A7

640118A4

625219-2A6

640118A4

625219-2A6

626836A10

625219-2A27

625487A6

625219-1A4

649056A2 649056A2-1 649056A2-2 649056A2-3 649056A3

646212-9A9 Opt. 638154-9A27 646212-9A5 Opt. 638154-9A23 646212-9A13 Opt. 638154-9A31 646212-9A3 Opt. 638154-9A21 646212-12A3

649056A4 649056A4-1 649056A5 649056A6 649056A6-1

Fuel Control Unit 643322-1A5

625487A6

625219-1A4

649056A7

646212-9A15 Opt. 638154-9A35 646212-12A1

628428A5

625219-1A3

649056A7-1

646212-12A2

649443A2

639717-1A1

649056A8

646212-9A18

629770A10

625219-2A26

649056A8-1

646212-9A12

629770A11

625219-2A26

649056A8-2

646212-9A18

629770A10

625219-2A26

649056A8-3

646212-9A17

642770A10

625219-2A26

649056A9

646212-9A6

636887A2

625219-2A9

649058A1

646211-2A1 

639626A11

633573-9A17

649058A1-1

646211-2A1 

639626A11

633573-9A17

ISSUED MO.

08

DAY

05

REVISED YEAR 98

MO.

DAY

YEAR

Manifold Valve 640718-6A1M 640718-6A1P 631427A22M 631427A22P 631427A22M 631427A22P 631427A22M 631427A22P 631427A27M 631427A27P 631427A30M 631427A30P 631351-10A7M 631351-10A7P 631427A22M 631427A22P 631427A22M 631427A22P 631427A22M 631427A22P 631427A22M 631427A22P 631427A30M 631427A30P 631427A30M 631427A30P 631427A30M 631427A30P 631427A22M 631427A22P 631427A22M 631427A22P 631427A22M 631427A22P 631427A26M 631427A26P 631427A26M 631427A26P 631427-4A1M 631427-4A1P 631427-4A1M 631427-4A1P 631427-4A3M 631427-4A3P 631427-4A1M 631427-4A1P 631427A23M 631427A23P 634326-7A8M 634326-7A8P 640718-3A3M 640718-3A3P

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

08

23

99

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

Fuel Nozzle

Fuel Press. Regulator

639368-19AA 639368-19A 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12B 627335D12C 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12C 627335D12D 627335D12A 627335D12B 627335D12A 627335D12B 627335D12A 627335D12B 627335D12A 627335D12B 627335D12C 627335D12D 633723D19AA 633723D19A 633723D19AA 633723D19A

642100-1A1 642100-1A1

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Fuel Inj. Assembly

Fuel Pump

Throttle /Met. Unit or Throttle /Control 639625A9

Fuel Control 633573-9A18 633573-9A18

649058A2

646211-2A2 

649058A2-1

639625A9

649059A1

646211-2A2  Opt. 642380-1A4 653351-2A1

649059A2

653351-2A2

653898-1A4

649059A2-1

653351-2A3

653898-1A5

649059A2-2

653351-2A4

653898-1A4

649059A2-3

653351-2A2

653898-1A6

653346-2A4

Manifold Valve 634326-7A8M 634326-7A8P 640718-8A1M 640718-8A1P 641032-20A1M 641032-20A1P 646508-12A1M 646508-12A1P 646508-12A1M 646508-12A1P 646508-12A1M 646508-12A1P 646508-12A3M 646508-12A3P

Fuel Nozzle 633723D19AA 633723D19A 633723D19AA 633723D19A 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K 632147-10J 632147-10K

Fuel Press. Regulator 642100-2A1 642100-2A1

FOOTNOTES:  New style pump. To install as a replacement for a Lear single stage pump (no longer available) order in addition to new pump or system, Kit Part Number EQ6537. If engine has Lear 2 stage pump 634627-1A2 (no longer Available) order as above and also see Cessna service bulletin ME71-13 for additional airframe parts required.  New style pump. To Install as replacement for Lear pump (no longer available) order in addition to F/l system, tube, air manifold to pump, Part Number 643746 and Kit Part Number EQ6537. ‘ Remove plug from metered connection port and install 643763 fitting Utilize available fitting or purchase separately. COMMENTS: Some turbocharged engine throttle bodies or manifolds may be equipped with mechanical bosses for pressurized magneto supply fittings. Properly plug or cap the location if not required for specific application.

ISSUED MO.

08

DAY

05

REVISED YEAR 98

MO.

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

08

23

99

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL98-9A

Contains useful Information Pertaining to Your Aircraft Engine

TECHNICAL PORTIONS FAA APPROVED SUPERSEDES M91-8

Reason for Revision:

Addition of engine to TBO listing. Clarification to Note 1.

SUBJECT:

TIME BETWEEN OVERHAUL PERIODS

PURPOSE:

PROVIDES TIME LIMITS BETWEEN MAJOR OVERHAULS

MODELS AFFECTED:

ALL

Teledyne Continental Motors (TCM) and the aircraft manufacturers provide operational limitations and instructions for your engine along with the requirements for continued airworthiness as specified in the engine Operators, Maintenance and Overhaul Manuals and Service Bulletins. The Time Between Engine Overhaul (TBO) provided in this Service Information Letter apply only to engines that have been operated and maintained in accordance with these instructions. Engine mounted components and accessories require overhaul at the same hourly and calendar intervals as the engine, unless otherwise specified by the component or accessory manufacturer. An engine’s published TBO DOES NOT mean that every engine will operate the number of hours or years listed without requiring component replacements and unscheduled maintenance events. Non compliance with TCM’s instructions for continued airworthiness, operational and environmental factors may necessitate repair or replacement of the engine, engine components and accessories. TCM recommends that the following information be used, along with the engine’s published TBO, in determining the engine’s continued airworthiness: 1. Whether the engine has been operated regularly or has been in storage; gaskets, seals synthetic and natural rubber goods deteriorate over time. Environmental corrosion can occur internally and externally on the engine. This naturally occurring process can inevitably ISSUED MO

DAY

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17

affect continued airworthiness of the engine and engine mounted components and accessories. For these reasons, overhaul the engine at least every twelve (12) years, or on accumulation of the operating hours listed for the engine model. 2. For aircraft used in aerial spraying, overhaul the engine after the accumulation of 1200 hours or twelve (12) years whichever occurs first. 3. Aircraft used in parachute jumping, glider towing, banner towing, etc., may require more frequent engine overhauls than listed for the specific engine. 4. The quality of parts, accessories and workmanship utilized during routine maintenance, engine top overhaul and major overhaul directly affect the service life of the engine. The TBO’s listed are predicated on the engine having been maintained in accordance with TCM’s FAA approved instructions for continued airworthiness specified in the engine Maintenance Manual, Overhaul Manual, and Service Bulletins and operated within the limitations published in TCM’s Engine Operators Manual and the aircraft manufacturer’s Aircraft Flight Manual / Pilots Operating Handbook (AFM / POH) 5. TCM cannot provide a TBO for engines that: •

Have been assembled with non-TCM approved parts.

REVISED YEAR 98

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03

© 2003 Teledyne Continental Motors, Inc.

P.O. Box 90 Mobile Alabama • 251-438-3411

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•

Have been assembled with parts that do not conform to the original type design for the engine.

•

Have been modified from the original type certificate configuration.

•

Have been overhauled or repaired in a manner that is inconsistent with the specifications, limits, and instructions provided in the TCM engine overhaul manuals, service bulletins, parts catalogs, and FAA Air Worthiness Directives.

NOTE: The TBO's provided in this Service Bulletin are only estimates and do not reflect warranty periods. For engine warranty coverage, refer to the official Teledyne Continental Motors aircraft engine warranty received with the engine.

Engine Time Between Overhaul (TBO) Engine Model SEE NOTE A65, A75 Series ......................................................................................................................... C75, C85, C90 Series................................................................................................................. C125, C145 Series ..................................................................................................................... E165, E185, E225 Series ........................................................................................................... O-200-A, -B ............................................................................................................................... O-300-A, -B, -C, -D, -E ............................................................................................................. GO-300-A, -C, -D, -E ................................................................................................................ O-470-A, B, E, G, J, K, L, M, N, P, R, S, U.............................................................................. O-470-U ..................................................................................................... .............................. O-470-U ..................................................................................................... ‘........................... W670 Series ............................................................................................................................... IO-240-A, B ............................................................................................................................... IOF-240-B.................................................................................................................................. IO-346-A, B ............................................................................................................................... IO-360-A, AB, B, C, CB, D, DB, G, GB, H, HB, J, JB, K........................................................ IO-360-ES, KB .......................................................................................................................... IO-470-C thru H, J thru N, P, R, S, U, V, VO .......................................................................... IO-520-A, B, BA, BB, C, CB, D, E, F, J, K, L, M, MB ............................................................ IO-520-P .................................................................................................................................... LIO-520-P .................................................................................................................................. IO-550-A, B, C, D, E, F, L ........................................................................................................ IO-550-G, N, P, R ...................................................................................................................... IOF-550-B, C, N, P, R ............................................................................................................... TSIO-360-EB, KB, RB .............................................................................................................. LTSIO-360-EB, KB, RB............................................................................................................ TSIO-360-FB, GB, LB, MB & SB ............................................................................................ TSIO-360-A, AB, B, C, CB, D, DB, E, F, G, H, HB, JB .......................................................... LTSIO-360-E ............................................................................................................................. TSIO-470-B, C, D...................................................................................................................... GIO-470-A................................................................................................................................. TSIO-520-B, BB, C, D, DB, E, EB, G, H, J, JB, K, KB, L, LB, M, N, NB, P, R .................... ISSUED MO

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REVISED YEAR 98

HRS 1800 1800 1800 1500 1800 1800 1200 1500 1500 2000 1000 2000 2000 1500 1500 2000 1500 1700 2000 2000 1700 2000 2000 1800 1800 1800 1400 1400 1400 1000 1400

YRS 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12

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P.O. Box 90 Mobile Alabama • 251-438-3411

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Engine Time Between Overhaul (TBO) (continued) Engine Model SEE NOTE TSIO-520-NB ............................................................................................  ....................... TSIO-520-M, P, R ...................................................................................... ............................ TSIO-520-M, P, R ...................................................................................... ’ ........................ TSIO-520-AF, CE, UB, VB, WB .............................................................................................. TSIO/LTSIO-520-AE ................................................................................................................ TSIO-520-BE............................................................................................................................. TSIO-520-T ............................................................................................................................... GTSIO-520-C, D, H, .................................................................................. ............................ GTSIO-520-C, D, H, ..................................................................................  ........................ GTSIO-520-L, M, N .................................................................................................................. GTSIO-520- F, K ....................................................................................................................... GIO-550-A................................................................................................................................. TSIO-550-B ............................................................................................................................... TSIO-550-C ............................................................................................................................... TSIO-550-E ............................................................................................................................... TSIOL-550-A, B, C ................................................................................................................... 6-285 Series ...............................................................................................................................

HRS 1600 1400 1600 1600 2000 2000 1400 1200 1600 1600 1200 1700 1600 2000 1600 2000 1200

YRS 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12

Engine Notes Note 1 - Applies to GTSIO-520-C, D, H engine models listed utilizing cylinder part number 653453 or subsequent (cylinder production released 4/1993-verify part number on cylinder flange). Also, all parts must be replaced as directed by the applicable current service bulletins, parts catalogs, and overhaul manuals. A log book entry is required. Note 2 - Applies to: New TSIO-520-NB engines with serial numbers 521391 thru 521399, 521400, 521405, 521406, 521411, 521419, and subsequent. Rebuilt TSIO-520-NB engines which have serial numbers 234070, 234074, and subsequent only. TSIO-520-NB engines, other than those listed above, may be made eligible for the 1600-hour TBO by the installation of new cylinder assemblies P/N 642594A1 or subsequent part number, pistons P/N 648044 or subsequent part number, and exhaust valve lifters P/N 646277 or subsequent part number. All parts must be replaced as directed by the applicable current service bulletins, parts catalogs, and overhaul manuals. A log book entry is required. Note 3 - Applies to: new and rebuilt O-470U Spec. 11, 12, 13, 14, 17, 18, and subsequent specification numbers. O-470-U engines, other than those listed, above may be made eligible for the 2000 hours TBO with the installation of new P/N 646267A2 or subsequent cylinder and valve assemblies, P/N 648029 pistons or subsequent part number, P/N 649226 ring sets or subsequent part number, exhaust lifters P/N 646277 or subsequent part number, oil pump with integral oil filter adapter P/N 643779 or subsequent part number, oil pump gasket P/N 643749 or subsequent part number, oil filter P/N 649923 (Champion P/N) and two each P/N 402129P003 studs. Piston pin P/N 539467 must be replaced with a new pin of the same P/N. Crankshaft counterweight pin and plate configuration must conform to the current parts catalog number ISSUED MO

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REVISED YEAR 98

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P.O. Box 90 Mobile Alabama • 251-438-3411

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X30587A. A log book entry is required. Install a new engine data plate with the correct engine model and specification number as noted in the following table. Original Spec. No.

New Spec. No.

Original Spec. No.

New Spec. No.

O-470-U (1)

O-470-U (13)

O-470-U (4)

O-470-U (18)

O-470-U (2)

O-470-U (14)

O-470-U (5)

O-470-U (17)

O-470-U (3)

O-470-U (17)

O-470-U (6)

O-470-U (18)

Note 4 - Applies to: New and rebuilt TSIO-520-M Spec. 6, 7, and 8 TSIO-520-P Spec. 5 and 6 TSIO-520-R Spec. 7, 9, 10, and 11 New and rebuilt TSIO-520-M, P, and R model engines with subsequent specification numbers. TSIO-520-M, P, and R engines except those listed above may be eligible for a 1600 hour TBO increase by installing; new cylinder and valve assemblies P/N 646657A1 or subsequent part number, pistons P/N 648044 or subsequent part number, ring sets P/N 649227 or subsequent part number, exhaust valve lifters P/N 646277 or subsequent part number, throttle body P/N 649185A4 or subsequent part number, TCM (formerly Bendix) P/N646957, or subsequent part number, R.H. magneto, P/N 646958, or subsequent part number, L.H. magneto, P/N 636951, or subsequent part number, Harness, or EQ6583 pressurized magneto and harness kit, oil pump assembly P/N 643717-1 or subsequent part number, P/N 643749, or subsequent part number, oil pump gasket, and oil filter with integral filter adapter P/N 649923 or subsequent part number. To install a new oil pump, remove one each P/N 402159 and P/N 402157 stud. Replace stud P/N 401852 with stud P/N 402129P003 and install spacer P/N 646582-1.35 and P/N 646582-2.00 on existing studs after oil pump is installed. A log book entry is required. Install a new engine data plate with the correct engine model and

specification number as noted in the following table. Original Spec. No.

New Spec. No.

Original Spec. No.

New Spec. No.

TSIO-520-M (1)

TSIO-520-M (6)

TSIO-520-P (3)

TSIO-520-P (6)

TSIO-520-M (2)

TSIO-520-M (7)

TSIO-520-R(1)

TSIO-520-R(9)

TSIO-520-M (3)

TSIO-520-M (7)

TSIO-520-R (3)

TSIO-520-R (10)

TSIO-520-M (3)

TSIO-520-M (3)

TSIO-520-R (4)

TSIO-520-R (9)

TSIO-520-P (1)

TSIO-520-P (5)

TSIO-520-R (5)

TSIO-520-R (10)

TSIO-520-P (2)

TSIO-520-P (6)

TSIO-520-R (6)

TSIO-520-R (11)

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL99-1

CONTAINS USEFUL INFORMATION PERTAINING TO THE CONTINENTAL AIRCRAFT ENGINE

Technical Portions FAA Approved Supercedes M91-5

SUBJECT:

ENGINE PRESERVATION FOR ACTIVE AND STORED AIRCRAFT

PURPOSE:

Provide current engine preservation information

COMPLIANCE: MODELS AFFECTED:

During periods as specified by this document

All Continental Engine Models

GENERAL There is no practical procedure that will insure corrosion prevention on installed aircraft engines. Susceptibility to corrosion is influenced by geographical location, season and usage. The owner/operator is responsible to recognize the conditions that are conducive to corrosion and take appropriate precautions.

ENGINE PRESERVATION Corrosive attack can occur in engines that are flown only occasionally regardless of geographical location. In coastal areas and areas of high humidity, corrosive attack can occur in as little as two days. The best method of reducing the likelihood of corrosive attack is to fly the aircraft at least once every week for a minimum of one hour.

2. Perform a ground run-up. Perform a pre-flight inspection and correct any discrepancies. Fly the aircraft for one hour at normal operation temperatures.

WARNING To prevent possibility of serious bodily injury or death, before moving the propeller accomplish the following: a. Disconnect all spark plug leads. b. Verify magneto switches are connected to magnetos, that they are in the "OFF" Position and "P" leads are grounded.

NOTE...

c. Throttle position "CLOSED."

Corrosive attack may reduce engine service life. Of primary concern are cylinders, piston rings, valves, valve guides, camshaft and lifters.

d. Mixture control "IDLE-CUT-OFF."

TEMPORARY STORAGE (Aircraft that are not flown for 30 to 90 days) Preparation for storage. 1.

Remove oil sump drain plug and drain oil. Replace drain plug, torque and safety. Remove oil filter. Install new oil filter, torque and safety. Service engine to proper sump capacity with oil conforming to MIL-C-6529 Type II. ISSUED

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e. Set brakes and block aircraft wheels. Insure that aircraft tie-downs are installed and verify that the cabin door latch is open. f. Do not stand within the arc of the propeller blades while turning the propeller.

TELEDYNE CONTINENTAL MOTORS

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3. After flight remove all spark plug leads and remove the top spark plugs. Protect the ignition lead ends with AN-4060 Protectors. Using a common garden sprayer or equivalent, spray atomized preservative oil that meets MIL-P 46002, Grade 1, at room temperature through upper spark plug hole of each cylinder with the piston at bottom dead center position. Rotate crankshaft as opposite cylinders are sprayed. Stop crankshaft with none of the pistons at top dead center. 4. Re-spray each cylinder. To thoroughly cover all surfaces of the cylinder interior move the nozzle or spray gun from the top to the bottom of the cylinder. 5. Install top spark plugs but do not install spark plug leads. 6. Seal all engine openings exposed to the atmosphere using suitable plugs and covers. Attach a red "REMOVE BEFORE FLIGHT" streamer at each location. 7. Tag each propeller in a conspicuous place with the following notation on the tag: DO NOT TURN PROPELLER - ENGINE PRESERVED - PRESERVATION DATE .

NOTE... If the engine is not returned to flyable status on or before the 90-day expiration, it must be preserved in accordance with "Indefinite Storage" procedures in this document.

INDEFINITE STORAGE (Aircraft that are not flown for 90 days) PREPARATION FOR STORAGE 1. Remove oil sump drain plug and drain oil. Replace drain plug, torque and safety. Remove oil filter Install new oil filter torque and safety. Service engine to proper sump capacity with oil conforming to MIL-C-6529 Type II. 2. Perform a ground run-up. Perform a pre-flight inspection and correct any discrepancies. Fly the aircraft for one hour at normal operation temperatures.

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WARNING To prevent possibility of serious bodily injury or death, before moving the propeller accomplish the following: a. Disconnect all spark plug leads. b. Verify magneto switches are connected to magnetos, that they are in the "OFF" Position and "P" leads are grounded. c. Throttle position "CLOSED." d. Mixture control "IDLE-CUT-OFF." e. Set brakes and block aircraft wheels. Insure that aircraft tie-downs are installed and verify that the cabin door latch is open. f.

Do not stand within the arc of the propeller blades while turning the propeller.

3. After flight remove all spark plug leads and remove the spark plugs. Protect the ignition lead ends with AN-4060 Protectors. Install protective plugs P/N 22671 in bottom spark plug holes. Using a common garden sprayer or equivalent, spray atomized preservative oil that meets MIL-P-46002, Grade 1, at room temperature through upper spark plug hole of each cylinder with the piston at bottom dead center position. Rotate crankshaft as opposite cylinders are sprayed. Stop crankshaft with none of the pistons at top dead center. 4. Re-spray each cylinder. To thoroughly cover all surfaces of the cylinder interior move the nozzle or spray gun from the top to the bottom of the cylinder. 5. Install dehydrator plugs MS27215-1 or -2 in each of the upper spark plug holes. Make sure each plug is blue in color when installed.

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6. Attach a red "REMOVE BEFORE FLIGHT" streamer to each bag of desiccant. Place a bag of desiccant in the exhaust pipes and seal the openings. 7. Seal all engine openings exposed to the atmosphere using suitable plugs and covers. 8. Tag propeller in a conspicuous place with the following notation on the tag: DO NOT TURN PROPELLER - ENGINE PRESERVED PRESERVATION DATE .

INDEFINITE STORAGE INSPECTION PROCEDURES 1. Aircraft prepared for indefinite storage must have the cylinder dehydrator plugs visually inspected every 15 days. The plugs must be changed as soon as they indicate other than a dark blue color. If the dehydrator plugs have changed color in one-half or more of the cylinders, all desiccant material on the engine must be replaced. 2. The cylinder bores of all engines prepared for indefinite storage must be re-sprayed with corrosion preventive mixture every 90 days.

a. Disconnect all spark plug leads. b. Verify magneto switches are connected to magnetos, that they are in the "OFF" Position and "P" leads are grounded. c. Throttle position "CLOSED." d. Mixture control "IDLE-CUT-OFF." e. Set brakes and block aircraft wheels. Insure that aircraft tie-downs are installed and verify that the cabin door latch is open. f. Do not stand within the arc of the propeller blades while turning the propeller. 4. Rotate propeller by hand several revolutions to remove preservative oil. 5. Service and install spark plugs and ignition leads in accordance with the manufacturer's instructions. 6. Service engine and aircraft in accordance with the manufacturer's instructions.

RETURNING AN ENGINE TO SERVICE AFTER STORAGE

7. Thoroughly clean the aircraft and engine. Perform visual inspection.

1. Remove seals and all desiccant bags.

8. Correct any discrepancies.

2. Remove cylinder dehydrators and plugs or spark plugs from upper and lower spark plug holes.

9. Conduct a normal engine start.

3. Remove oil sump drain plug and drain the corrosion preventive mixture. Replace drain plug, torque and safety. Remove oil filter. Install new oil filter torque and safety. Service the engine with oil in accordance with the manufacturer's instructions.

WARNING To prevent possibility of serious bodily injury or death, before moving the propeller accomplish the following:

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10. Perform operational test in accordance with "Operational Inspection," of the applicable Maintenance Manual. 11. Correct any discrepancies. 12. Perform a test flight in accordance with airframe manufacturer's instructions. 13. Correct any discrepancies prior to returning aircraft to service. 14. Change oil and filter after 25 hours of operation.

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TELEDYNE CONTINENTAL MOTORS

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TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL99-2B

CONTAINS USEFUL INFORMATION PERTAINING TO THE CONTINENTAL AIRCRAFT ENGINE

Technical Portions FAA Approved

REASON FOR CHANGE:

Updated material listings. See revision bars.

SUBJECT:

CURRENT LISTING OF SEALANTS, LUBRICANTS, & ADHESIVES AUTHORIZED BY TCM.

PURPOSE:

Provide current application of sealants, lubricants & adhesives.

COMPLIANCE: MODELS AFFECTED:

During maintenance, overhaul or component repair or replacement.

All Continental Engine Models.

Lubricating oils qualified for use in Teledyne Continental Motors engines are required to meet SAE (Society of Automotive Engineers) specifications. SAE specification J 1899 (formerly MIL-L-22851) is the approval for aircraft piston engine ashless-dispersant oil. SAE specification J 1966 (formerly MIL-L-6082E) is the approval for aircraft piston engine non-dispersant mineral oil. NOTE: MIL-L-6082E dated 1 November 1995 and MIL-L-22851D dated 1 November 1995 is hereby cancelled. Refer to SAE specification SAE J 1966 and SAE J 1899. Teledyne Continental Motors listing of accepted SAE J 1899 oils by manufacturer and brand name is for the convenience of our customers. Always refer to the label on the oil to ensure that the oil meets the appropriate SAE specification. QPL-J 1899: Qualified Products List is available from: SAE Headquarters 400 Commonwealth Drive Warrendale, PA 15096-001 The Naval Air Systems Command is required to maintain QPL-J-1899 and QPL-J-1966. Naval Air Systems Command Air 4.4.5 Jefferson Davis Highway Arlington, VA. 22243-5120

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Recommended Oil Grade: Above 40°F ambient air, sea level Below 40°F ambient air, sea level

SAE 50 or Multi Viscosity SAE 30 or Multi Viscosity

NOTE… See TCM Engine Preservation for Active and Stored Aircraft Service Information Letter SIL99-1 for preservation information. In listing the product names, TCM makes no claim of verification of the marketer’s statements or claims. Listing is made alphabetically and is provided only for convenience of the users. If the aviation oil you use or wish to use is not listed, contact the Naval Air Systems Command QUALIFIED LUBRICATING OIL-ASHLESS DISPERSANT (SAE J 1899) SUPPLIER BP Oil Corporation Castrol Castrol Limited (Australia) Chevron USA Continental Oil Delta Petroleum Company Exxon Company, USA Exxon Company, USA Gulf Oil Company Mobil Oil Company NYCO SA Pennzoil Company Phillips Petroleum Company Phillips Petroleum Company Quaker State Oil & Refining Co. Red Ram Limited (Canada) Shell - Australia Shell Canada Limited Shell USA Shell USA Sinclair Oil Company Texaco Inc. Total France Union Oil Company of California

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BRAND BP Aero Oil Castrol Aero AD Oil Castrol Aero AD Oil Chevron Aero Oil Conoco Aero S Delta Avoil Oil Exxon Elite Exxon Aviation Oil EE Gulfpride Aviation AD Mobile Aero Oil Turbonycoil 3570 Pennzoil Aircraft Engine Oil Phillips 66 Aviation Oil, Type A 100 AD, 120 AD X/C Aviation Multiviscosity Oil SAE 20W-50, SAE 25W-60 Quaker State AD Aviation Oil Red Ram X/C Avaition Oil 20W-50 Aeroshell (R) W Aeroshell Oil W, 15W – 50 Anti-wear Formulation Aeroshell Oil W, 15W – 50 Anti-wear Formulation Aeroshell Oil W100 Plus, W80 Plus Sinclair Avoil Texaco Aircraft Engine Oil-Premium AD Total Aero DM 15W - 50 Union Aircraft Engine Oil HD

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Break-in Oil SAE J 1966- Aviation (replaces MIL-L-6082) non-dispersant mineral lubricating oil for piston aircraft engines. MIL-C-6529 Type II Corrosion preventive mineral oil (fly-away-oil) NOTE . . . Mineral oil conforming with MIL-C-6529 Type II contains a corrosion preventive additive and must not be used for more than 25 hours or six months, whichever occurs first. If oil consumption has not stabilized in this time, drain and replenish the oil and replace the oil filter.,

Preservative Oil TYPE

EQUIVALENT

APPLICATION

MIL-P-46002 MIL-P-46002

Grade 1 oil, (NOX RUST VCI-105)

For Temporary and Indefinite storage For Temporary and Indefinite storage

Motorstor Engine Protectant

OIL CHANGE INTERVALS Refer to the engine operator/maintenance manual and/or the aircraft manufacturer’s or Supplemental Type Certificate (STC) holders POH/AFM for fuel specifications, specified oil change intervals and inspection procedures. The oil change intervals published in the Operators Manuals are minimum requirements. Teledyne Continental Motors feels that more frequent oil and filter changes enhance engine service life. As such TCM recommends that engine oil be drained and replenished every 25 hours of operation or 4 months for engines that incorporate an oil screen. Engines with full flow oil filters, either large or small, should have the oil changed every 50 hours or 4 months. NOTE… When using the small (4.80 inch high oil filter) do not exceed 50 hours and/or 6 months between oil and filter changes. When using the larger (5.80 inch high oil filter) do not exceed 100 hours and/or 6 months between oil and filter changes. Oil screens and oil filter elements must be inspected for contaminates at each oil change. Oil analysis may be used in addition to the oil screen or filter element inspection, but not as a replacement for it. ADDITIVES There are many fuel and oil additives and/or concentrates on the market today which were formulated primarily for automotive and industrial engine applications. From time to time, we receive inquiries as to the use of these products in our aircraft engines. Most of these additives and concentrates, while they may be highly beneficial to automotive and industrial operation, are not compatible with air-cooled, light aircraft engines in their operating environments. With the exception of the use of isopropyl alcohol and ethylene glycol monomethyl ether compound as described in the following paragraph, we do not recommend the use of additives or concentrates in any of our aircraft engines. In fact, the use of such can be cause for voiding the warranty. Use only fuels and lubricants as recommended herein and in current engine operating manuals. Under certain ambient conditions of temperature/humidity, water can be supported in the fuel in sufficient quantities to create restrictive ice formation along various segments of fuel system. To alleviate the possibility of this occurring, it is permissible to add Isopropyl Alcohol to the fuel supply in quantities not to exceed 3 percent of the total. Also, Diethylene Glycol Monomethyl Ether (DEGMME) conforming to military specification MIL-DTL-85470B, if approved for use in the aircraft fuel system by the aircraft manufacturer, may be added for this purpose. The DEGMME compound must be carefully mixed with the fuel in concentrations not to exceed 0.15 percent by volume.

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WARNING Mixing of the DEGMME compound with the fuel is extremely important because concentration in excess of that recommended (0.15 percent volume maximum) could have a harmful effect on engine components. Use only blending equipment and procedures that are recommended by the manufacturer to obtain proper proportioning.

Lubricants TYPE Molyshield Grease

APPLICATION Starter Worm Gear Drive Teeth & Bevel Gear Teeth Needle bearings and ball bearings Valve stems Adapter-Tach Reduction All Accessory drive splines and couplings Idler gear and pin

P/N 656817-1 6 Gallon Can P/N 656817-2 14OZ Cartridge

Oil Seal Lips only Fuel injection controls, o-rings, springs, shafts and bushings Magneto rubber drive bushings Oil Pumps (Pressure & Scavenge) Grade 50 Break-in Non-compounded Aviation Oil SAE J 1966

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Crankshaft Bearings Connecting Rod Bearings Prop Driver, Driven Gears & Bearings Camshaft Bearings Tachometer Gears & Adapters Accessory Spur Gear Teeth Quill Shaft Splines Prop Governor Trans Collar & Sleeve Starter Cone, Bushing & Nut Starter Clutch Spring (ID & OD) Valve Guide Seals Pistons, Piston Pins & Piston Rings Fuel connections to carb. (male threads only) V.T.C. Unit Pistons & centrifugal valves. Rocker arms, pivots, valves and tappets Thrust Washers Oil Filter adapter seals O-Rings

REMARKS All Models At engine Assembly (TSIO & L/TSIO 360) All models as applicable GTSIO/IO/TSIO-520, IO/O/TSIO-470 all 550 All Models Except models: TSIO-520-D, all 360, & GTSIO-520-K which use grade 50 W Motor oil All Models All Models / Coat gear cavity at assembly of pump All Models

All Models / Apply to sealing surface All Models Carburetor equipped models TIARA 6-285, 6-230

REVISED DAY YEAR 17

All Models

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Lubricants (continued) Dow Corning® G-N Paste [Dow Corning® G-N Paste is a registered trademark of Dow Corning Corporation.] Shell Alvania # 2 P/N 654561 Shell #5 MIL-G-3545-C Grease

P/N 646943 - Anti Seize Lubricant or Loctite 76732 Anti-Seize Lubricant

or

SAE J 1966

At engine assembly

Apply a light coat at point of contact between nut seat and ferrule on ignition lead All Fuel injection linkages O-Rings on Fuel Pumps Fuel pressure regulator spring seat Mixture Shaft Bushings All fuel injector nozzles (at cylinder head)

P/N 654468-1 1 Gallon Can

50 Weight Non-compounded Ashless Dispersant Aviation Oil

Camshaft lobes and tappet faces

Exhaust studs All mechanical tach drive housing threads not through to an oil source Plug Vernatherm All .3125 and larger studs unless otherwise noted Oil sump return fitting Air Reference Fittings on all Throttle bodies Cylinder studs and through bolts, crankcase studs, connecting rod bolts and nuts and engine accessory studs unless otherwise specified

All Models

All Models / At assembly

Fuel Injected Models / Use sparingly on male threads only Apply in accordance with Figure 8 All Models (nut end before torquing) At engine assembly

IO-360-ES3B & IO-360-HB9B Engine Models as applicable All Models / Lube thread and nut seat before tightening nuts

CHAMPION® - Spark Plug Thread Lubricant No. 2612 [CHAMPION® is a registered trademark of Cooper Industries.]

Spark plugs

All Models

Chesterton #995 Release agent

Induction system hose and flex duct connections, Fuel Pump Aneroid Seal

All Models

Apply to rubber oil seal of spin-on oil filter

Engine Models as applicable

or WD-40 Dow Corning® No. 4

Gaskets - Governor pad (both sides) Gaskets-Mag adapter (both sides) Lubriplate 930 AA CRC 3-36 Compound

MO 03

Rust

ISSUED DAY YEAR 29

99

Preventative

MO 10

O.D. of Valve Guides

All models at installation of guide

Spray exhaust end of turbocharger

For engine preservation

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Sealants TYPE Permatex Aviation Grade 3D And P/N 641543 Silk Thread

APPLICATION Crankcase parting face Starter adapter to accessory case Accessory Drive Adapter Pressure oil pump covers, Pressure scavenge pump covers Crankcase crankshaft nose oil seal area

P/N 653692 - Primer P/N 653692-1 1.75 Oz Bottle or Loctite LocQuic Primer 7649

REMARKS All Models / Apply in accordance with Figures 1 through 7 as applicable Apply in accordance with Figure 19 Apply in accordance with Figure 20 Apply in accordance with Figures 10 through 18 All models

Sump to crankcase

TSIO-520-UB, TSIOL-550-B

Crankcase parting face

All Models / Apply in accordance with Figures 1 through 7 as applicable

P/N 646942 - Gasket Maker or Loctite 515Gasket Eliminator Sealant

Engine nose seal, scavenge oil pump covers, between crankcase and sump gasket, oil pump covers Between starter adapter gasket & crankcase Between Oil sump and Sump Gasket 642910 OIL SEAL, O.D. of all uncoated oil seals, except fuel pump adapter seal All gaskets both sides, except magneto gasket & gaskets between intake manifold & cylinder heads Gasket - Accessory case to crankcase (Crankcase side only) Gasket - Cam bore cover (except beaded gaskets) Gasket - Idler Pin Gasket - Intake Manifold Oil drain back tubes Gasket & Oil filler neck holes Gasket - Oil cooler both sides Oil seal at alternator drive (O.D. only) All press type plugs (Hubbard etc) In parting line area of 3-way joints

P/N 642188 - Gasket Sealant (K & W Copper Coat 1504-12)

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All Models Permold model engines All Models (Non beaded gaskets only) All models where applicable

TIARA 6-285, 6-230

C-90, O-200, O-300, 360 & IO-240 470, 520, 550, GTSIO-520 Models and IO-240 470, 520, GTSIO-520, all 550 All models C-90, O-200, O-300 470, 520, 550 (Sandcast) and GTSIO-520 All 360 models TIARA 6-285, 6-230 All Models Sump to crankcase or sump to crankcase to accessory case

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Sealants (Continued) Continued P/N 642188 - Gasket Sealant (K & W Copper Coat 1504-12) Loctite 592 Teflon PS/T Pipe Sealant

P/N 646940 - F/I Sealant or Loctite 569 Hydraulic Sealant P/N 649246 Loctite 290 Sealant

Oil seal accessory drive (O.D. only)

TSIO-360, A, AB, C, CB, D, DB and IO360-C, CB,G,GB

2 Bolt suction tube gasket - both sides Use on all pipe threads except as noted All pressure relief valve housing threads Permold 2 studs engine mount 1-3-5 side bottom All threaded fasteners installed in a through hole to an oil source All pipe thread fittings in fuel injection system

All 470, 520, 550 models as applicable

Data plate screw installation on throttle bodies Ignition harness terminals at magneto block end

Miller-Stephenson MS 122DF

Apply before installing threaded part Apply in accordance with Figure 9

All models where applicable All Models

Adhesives TYPE Loctite 271 High Strength Adhesive Sealant (used with P/N 653693 Primer or Loctite 7471)

APPLICATION Rocker cover stud, rocker arm pivot studs, push rod retainer stud Cylinder deck studs Crankcase breather tubes Bolts for nose seal retainer to crankcase Squirt nozzle Mechanical Tach Drive Studs to an oil source Oil pump gear mounting pin in accessory cover All press fit breather and oil filler necks Intake manifold mount studs V.T.C. unit bushing retaining screw V.T.C. unit housing to crankshaft Top accessory drive gear (breather slinger) bolts Studs on coolant manifold Fuel manifold valve diaphragm & plunger assembly

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MO 10

REMARKS TIARA 6-285, 6-230 only All models breakaway torque 100 inlbs. after 2 hrs 470 & 520 (Sandcast) & GTSIO-520 All Models All Models Engine models as applicable 360 models 360 & IO-240 models C-75, C-85, C-90 & O-200 TIARA 6-285, 6-230 All liquid cooled models IO-240 All 360, 470, 520, 550 models

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Adhesives (Continued) Loctite 271 High Strength Adhesive Sealant (used with #653693 Primer or Loctite 7471) (Cont’d)

Loctite 222 Sealant (optional Loctite Hydraulic Sealant 569) or TCM P/N 646940-1

P/N 654562-1 (50 ml) P/N 654562-2 (250ml) Loctite 609 Adhesive / Sealant

Loctite 620 Adhesive/Sealant P/N 654743 / 3M Scotchcast 10 (XR5241) Epoxy P/N 654470-1 / 3M Brand EC 1252 White Spot Seal Putty

P/N 655114-1 Adhesive Sealant (Devcon) P/N 649366 (Loctite 242)

Oil gauge rod housing to crankcase

Timing indicator pin Through stud holes on accessory end of crankcase Solenoid valve assembly (Bracket to valve) Manifold valve to bracket screws Coolant pump impeller ring screws Studs .25 diameter and smaller Data plate screws on manifold valve assembly Bearing O.D. installed on starter clutch assembly

Fuel pump adapter seal Fuel pump shaft seal Coolant pump mechanical seal Epoxy field coil leads to starter housing Air throttle & fuel metering assembly Magneto flanges Cylinder deck stud nuts & all through bolts All fuel pump, manifold valve, throttle and control fittings Use for sealing aneroid air reference path between basic fuel pump housing and vapor separator body (Setup only) Fitting Magneto Housing (Pressurization)

All IO-360 & TSIO-360, IO-470, All O-470, All TSIO-470 all IO-520-A, D, E, G, J, K, L; IO-550-D, E, F TSIO-520-A, AE, AF, C, CE, G, H, M, P, R, T All GTSIO-520 All 470, 520, 550 models (apply when installing studs) TSIO-360-MB & SB & IO-360-ES2B All Models All liquid cooled models All Models All Models O-200-A, B, IO-240-A, B, O-300-A

All Models All liquid cooled models 24 Volt Starters

All Models

Fuel Pumps 646766, 646767 & 646824 Engine models as applicable

Miscellaneous TYPE TCM P/N 626531-1 Enamel - Gold (1qt) TCM P/N 626531-2 Enamel - Gold (1 gal) TCM P/N 535011 Lockwire -.032 in dia. Steel, Corrosion Resistant “ACCELAGOLD” Turco® Products

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MO 10

APPLICATION High temp. paint for cosmetic and corrosion protection

REMARKS

Where applicable for lockwiring

Corrosion protection interior and exterior aluminum parts

REVISED DAY YEAR 17

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Product Locator Dow Corning® G-N Paste is a registered trademark of Dow Corning Corporation Dow Corning® No. 4 For Distributor information call - 1-800-248-2481, have state & city information available Permatex Permatex Aviation Grade 3D For Distributor information call: Permatex Customer Service @ Phone: 1-877-376-2839

3M Brand EC1252 White Spot Putty 3M Scotchcast 10 (XR5241) Epoxy For Distributor Information: 1-888-364-3577

Loctite Loctite Gasket Eliminator Loctite LocQuic Primer 7649 Loctite Teflon PS/T Pipe Sealant Loctite Hydraulic Sealant 569 Loctite 271 Loctite LocQuic Primer 7471 Loctite Adhesive Sealant 222 May be purchased through your local TCM Distributor or For Distributor information: Henkel Loctite Customer Service @ Phone: 1-800-243-4874 Alvania (Shell #2) MIL-S-3545C Grease (Shell #5) For Distributor information: Shell Product Information Center, Phone: 1-800-231-6950 CHAMPION® is a registered trademark of Cooper Industries For Champion Products Distributor information: Phone: 864-843-5400 K&W Copper Coat For Distributor information call: CRC Industries Customer Service Phone: 1-800-423-9446 Miller-Stephenson MS 122/C02 Spray For Distributor information: Miller-Stephenson Customer Service, Phone: 1-800-992-2424 www.miller-stephenson.com

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MO 10

Super Molyshield Grease May be purchased through: American Lubricants 1227 Deeds Dayton, Ohio 45401 Phone: (937) 222-2851

“ACCELAGOLD” by Turco ® Henkel Surface Technologies North American Headquarters 32100 Stephenson Hwy. Madison Heights, MI 48071 (248) 583 - 9300 Phone (248) 583 - 2976 Fax MIL-P-46002 Grade 1 oil, (NOX RUST VCI-105) May be purchased through: Daubert Chemical 4700 South Central Ave Chicago, IL 60638 708-563-8325 Motorstor ® (11oz Spray Can) May be purchased through: Highland Aerospace P.O. Box 3214 Peachtree City, GA 30269 404-403-5602 www.highaero.com

Chesterton Technical Product Information Phone: 1-781-438-7000

REVISED DAY YEAR 17

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FIGURE 1. C75, C85, C90, 0200 CRANKCASE THREADING DIAGRAM Permatex was applied on 2-4 case half except the CRANKCASE SEALANT AND through bolt bosses. THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

4. Apply and position grade D silk thread P/N 641543 on case halves as specified in Figure 1. Be sure free ends of thread are covered by gaskets except at the nose oil seal. 5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker. 6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

NOTE… Do not apply Permatex to crankshaft nose seal area. 3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3 case half. Apply Gasket Maker in all areas that will mate with areas where

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SILK THREAD P/N 641543 NOT REQUIRED IN THESE POSITIONS IF USING THROUGH BOLTS P/N 531212 WITH NEW O-RINGS P/N AS3570-011

CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4-6 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

FIGURE 2. 0300 CRANKCASE THREADING DIAGRAM

CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3-5 case half. Apply Gasket Maker in all areas that will mate with areas where Permatex was applied on 2-4-6 case half. 4. Apply and position grade D silk thread P/N 641543 on 2-4-6 case half as specified in Figure 2. Be sure free ends of thread are covered by gaskets except at the nose oil seal.

as

5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker.

2. Apply Permatex Number 3D to the 2-4-6 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

NOTE… Do not apply Permatex to crankshaft nose seal area.

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FIGURE 3. I0240 CRANKCASE THREADING DIAGRAM Permatex was applied on 2-4 case half except the through bolt bosses.

CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

NOTE… Do not apply Permatex to crankshaft nose seal area.

4. Apply and position grade D silk thread P/N 641543 on 2-4 case half as specified in Figure 3. Be sure free ends of thread are covered by gaskets except at the nose oil seal. 5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker. 6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3 case half. Apply Gasket Maker in all areas that will mate with areas where

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SILK THREAD P/N 641543 NOT REQUIRED IN THESE POSITIONS IF USING THROUGH BOLTS P/N 652420-5.56, 652420-6.80, 6524209.02 OR 652420-9.42 WITH NEW O-RINGS P/N 630979-9

FIGURE 4. I0360, L/TSI0360 CRANKCASE THREADING DIAGRAM CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4-6 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

NOTE… Do not apply Permatex to crankshaft nose seal area.

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3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3-5 case half. Apply Gasket Maker in all areas that will mate with areas where Permatex was applied on 2-4-6 case half. 4. Apply and position grade D silk thread P/N 641543 on 2-4-6 case half as specified in Figure 4. Be sure free ends of thread are covered by gaskets except at the nose oil seal. 5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker. 6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

REVISED DAY YEAR 17

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SILK THREAD P/N 641543 NOT REQUIRED IN THESE POSITIONS IF USING THROUGH BOLTS P/N 652887-5.31, 652887-6.74, 652887-6.50, 652887-6.19, 652887-6.96 OR 652887-7.58 WITH NEW O-RINGS P/N MS29513-011

FIGURE 5. I0520, TSI0520, I0550, TSI0550 PERMOLD ENGINE CRANKCASE THREADING DIAGRAM CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4-6 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

NOTE… Do not apply Permatex to crankshaft nose seal area.

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3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3-5 case half. Apply Gasket Maker in all areas that will mate with areas where Permatex was applied on 2-4-6 case half. 4. Apply and position grade D silk thread P/N 641543 on 2-4-6 case half as specified in Figure 5. Be sure free ends of thread are covered by gaskets except at the nose oil seal. 5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker. 6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

REVISED DAY YEAR 17

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SILK THREAD P/N 641543 NOT REQUIRED IN THESE POSITIONS IF USING THROUGH BOLTS P/N 652887-8.88, 652887-10.00, OR 652887-11.35 WITH NEW O-RINGS P/N 630979-9

FIGURE 6. 0470, I0470, L/I0520, L/TSI0520, I0550 SANDCAST ENGINE CRANKCASE THREADING DIAGRAM Be sure free ends of thread are covered by gaskets except at the nose oil seal.

CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4-6 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker. 6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

NOTE… Do not apply Permatex to crankshaft nose seal area. 3.

Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3-5 case half. Apply Gasket Maker in all areas that will mate with areas where Permatex was applied on 2-4-6 case half.

4. Apply and position grade D silk thread P/N 641543 on case halves as specified in Figure 6.

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FIGURE 7. GTSI0520 CRANKCASE THREADING DIAGRAM

CRANKCASE SEALANT AND THREADING PROCEDURE 1. Use full strength non-thinned Permatex aviation grade 3D. Shake or mix well before using.

WARNING Apply thread illustrated.

and

permatex

only

as

2. Apply Permatex Number 3D to the 2-4-6 case half. Apply Permatex only in areas where thread is shown. When applying, use short light brush strokes until an even thin coat is obtained. The Permatex should be viscous enough that most of the brush marks disappear; if not, use a new can of Aviation Permatex. Allow the Permatex to air dry to a tacky condition before threading.

NOTE… Do not apply Permatex to crankshaft nose seal area.

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3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to 1-3-5 case half. Apply Gasket Maker in all areas that will mate with areas where Permatex was applied on 2-4-6 case half. 4. Apply and position grade D silk thread P/N 641543 on 2-4-6 case half as specified in Figure 7. Be sure free ends of thread are covered by gaskets except at the nose oil seal. 5. Clean crankcase crankshaft front oil seal land with Locquic Primer “N” and apply an even coat of gasket maker. 6. Assemble crankcase halves, install and torque all crankcase hardware in proper sequence in accordance with the applicable overhaul manual as soon as possible.

NOTE… Take care to prevent displacement or damage to the crankshaft oil seal and silk thread. Insure thrust washer halves and bearing halves remain in place.

REVISED DAY YEAR 17

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CAUTION…NEVER USE TEFLON TAPE ON FLUID FITTINGS OR FUEL NOZZLES

FIGURE 8. GENERAL ANTISEIZE LUBRICANT APPLICATION

FIGURE 9. GENERAL FUEL INJECTION SEALANT APPLICATION

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FIGURE 10. THREADING DIAGRAM FOR 640741A1, 652019, 652019A1, 655713A1 SCAVENGE PUMP BODIES USED ON STARTER ADAPTERS 642087A15, A18, A23, A27, A31, A35, A41, A47, A51, A55, A59, A64 AND CORRESPONDING 0.015 OVERSIZE ADAPTERS

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines.

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5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

REVISED DAY YEAR 17

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FIGURE 11. THREADING DIAGRAM FOR 639407, 640194 SCAVENGE PUMP BODIES USED ON STARTER ADAPTERS 642085A2 THROUGH A9, A11 THROUGH A18 AND CORRESPONDING 0.015 OVERSIZE ADAPTERS

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines.

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5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

REVISED DAY YEAR 17

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FIGURE 12. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 632623A16, A17, A20, A21, A22, A24, A25, A26, A27 AND A28

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines.

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5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

REVISED DAY YEAR 17

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FIGURE 13. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 632563A25, A26, A27, A28, A29, A30, A31, A32, A35, A36, A38 AND A39

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines.

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5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

REVISED DAY YEAR 17

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FIGURE 14. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 646194A1, 653536A1, A2, A3, 655121A1, A2 AND A3

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines. 5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

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FIGURE 15. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 637709 637709-2 AND 641602

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines. 5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

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FIGURE 16. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 632770A1, A2, A3, A4, 643716A3, A4 643717-1, 653538A2, A3, A4, A5, AND 655119A2, A3

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines. 5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

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FIGURE 17. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 643716A3, A4, 643717-1, 643743-1A1, 643778, 643778-1, 643779, 653494A2, 653538A2, A3, A4, A5, 653542, 653542A1, 653553, 655117A2, 655119A2, A3, 655124, 655127 AND 655127A1

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines. 5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

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FIGURE 18. THREADING DIAGRAM USED ON OIL PUMP ASSEMBLIES 632970, 632977A4, A5, A6, A7, A8, A9, A10, A11, 654437 AND 655680

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines. 5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

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FIGURE 19. THREADING DIAGRAM USED ON STARTER ADAPTER ASSEMBLIES 641348A7, 641348A11, 641348A12, 653074A1, 653074A1M015, 653074A2, 653074A2M015, 653074A3, 653074A4, 653074A4M015, 653074A6, 653074A7, 653074A7M015, 653074A8, 653074A8M015, 653074A9, 653074A9M015, 653074A10, 653074A11, 653074A11M015, 653074A12, 653074A12M015, 653074A13, 653074A123M015, 653074A14, 653074A14M015, 653074A15, 653074A16, 653074A16M015, 653074A17, 653074A17M015, 653074A18, 653074A18M015, 653074A19, 653074A19M015, 653074A20, 653074A21, 653074A21M015, 653074A22, 653074A22M015, 653074A23, 653074A24, 653074A25, 653074A26, 653074A26M015, 653074A27, 653074A28, 653074A28M015, 653074A29, 653074A29M015, 653074A30, 653074A30M015, 653074A31, 653074A31M015, 653074A32, 653074A32M015, 653074A33, 653074A34, 653074A34M015, 653074A35, 653074A35M015, 653074A36, 653074A36M015, 653074A37, 653074A38, 653074A38M015, 653074A39, 653074A40, 653074A40M015, 653074A41, 653074A41M015, 653074A42, 653074A42M015, 653074A43, 653074A43M015, 653074A44, 653074A44M015, 653074A45, 653074A45M015, 653074A46 AND 653074A46M015, 653074A47, 653074A47M015, 653074A48, 653074A48M015, 653074A49, 653074A50, 653074A51, 653074A51M015, 653074A52 AND 653074A52M015

INSTALLATION: After permatex and thread have been applied to the starter adapter in accordance with the above illustration and prior to installation, apply a thin coat of blue loctite gasket maker to the accessory case, starter adapter mounting flange. Temporarily install the starter adapter to make an impression of

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the thread on the accessory case. Carefully remove the starter adapter so that the shaft gear does not pull out. Inspect the thread impression for 100% contact between the adapter and accessory case. Wipe excess gasket maker off of accessory case and install starter adapter in accordance with the applicable overhaul instructions.

REVISED DAY YEAR 17

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FIGURE 20. ACCESSORY DRIVE ADAPTER THREADING PROCEDURE FOR STARTER ADAPTER ASSEMBLIES: 641348A7, 641348A11, 641348A12, 653074A1, 653074A1M015, 653074A2, 653074A2M015, 653074A3, 653074A4, 653074A4M015, 653074A6, 653074A7, 653074A7M015, 653074A8, 653074A8M015, 653074A9, 653074A9M015, 653074A10, 653074A11, 653074A11M015, 653074A12, 653074A12M015, 653074A13, 653074A123M015, 653074A14, 653074A14M015, 653074A15, 653074A16, 653074A16M015, 653074A17, 653074A17M015, 653074A18, 653074A18M015, 653074A19, 653074A19M015, 653074A20, 653074A21, 653074A21M015, 653074A22, 653074A22M015, 653074A23, 653074A24, 653074A25, 653074A26, 653074A26M015, 653074A27, 653074A28, 653074A28M015, 653074A29, 653074A29M015, 653074A30, 653074A30M015, 653074A31, 653074A31M015, 653074A32, 653074A32M015, 653074A33, 653074A34, 653074A34M015, 653074A35, 653074A35M015, 653074A36, 653074A36M015, 653074A37, 653074A38, 653074A38M015, 653074A39, 653074A40, 653074A40M015, 653074A41, 653074A41M015, 653074A42, 653074A42M015, 653074A43, 653074A43M015, 653074A44, 653074A44M015, 653074A45, 653074A45M015, 653074A46 AND 653074A46M015, 653074A47, 653074A47M015, 653074A48, 653074A48M015, 653074A49, 653074A50, 653074A51, 653074A51M015, 653074A52 AND 653074A52M015

1. Use full strength, non thinned, aviation Permatex Grade 3D. shake or mix well before using.

3. Apply a thin translucent coat of TCM Gasket Maker P/N 646942 not to exceed .010 inch thick to all mating areas on non threaded part.

2. Apply Permatex to the surface to be threaded using short light brush strokes until an even, thin coat is obtained. the Permatex should be viscous enough that most of the brush marks disappear, if not, use a new can of Permatex. Allow the Permatex to dry to a tacky condition before threading.

4. Apply silk thread part number 641543 and position as shown by dashed lines. 5. Assemble and torque as soon as possible in accordance with the applicable overhaul manual.

MO 03

ISSUED DAY YEAR 29

99

MO 10

REVISED DAY YEAR 17

PAGE NO REVISION

2005 P.O. Box 90 Mobile Alabama • 251-438-3411

28 of 28 SIL99-2

B

®

TELEDYNE CONTINENTAL AIRCRAFT ENGINE

CATEGORY 5

SERVICE INFORMATION LETTER

SIL 99-4

Contains Useful Information Pertaining to Your Aircraft Engine SUBJECT:

TSIO-520-UB EXHAUST TAIL PIPE

PURPOSE:

Provide replacement parts information

COMPLIANCE:

MODELS AFFECTED:

Anytime the exhaust system is removed from the engine for any reason. TSIO-520-UB, TSIOL-550-C

GENERAL INFORMATION: The following changes have been made to the exhaust system components utilized on engines listed in the models affected section of this Service Information Letter. TAIL PIPE ASSEMBLY: Tail pipe assembly part number 655164 has replaced earlier tail pipe assemblies part numbers 654344 and 642392. ELBOW ASSEMBLY: Elbow assembly part number 655236 has replaced earlier elbow assemblies part numbers 654343 and 642665. TAIL PIPE BRACKET: Tail pipe bracket part number 655276 has replaced earlier bracket part number 642539. REPLACEMENT INSTRUCTIONS: When installing tail pipe assembly part number 655164, you must install a new elbow assembly part number 655236 and bracket part number 655276.

ISSUED MO

DAY

05

19

REVISED YEAR 99

MO

TECHNICAL PORTIONS FAA APPROVED

DAY

YEAR

Torque the tail pipe to turbocharger “V” band coupling (not shown in FIGURE 1) using the following procedure. 1. Install “V” band coupling and lightly snug nut. 2. Lightly tap the periphery of the coupling with a rawhide or rubber mallet to seat coupling. 3. Final torque of “V” band coupling to be accomplished in accordance with the instruction provided in the latest revision of the aircraft manufacturer’s maintenance manual. WARNING Failure to correctly install and torque the “V” band coupling will result in damage to the coupling, loss of engagement and possible fire.

Bracket part number 655276 may be installed as a direct replacement for bracket part number 642539. However, clamp part number 642537 must be repositioned when bracket part number 655276 is installed. Refer to Figure 1 for replacement part information.

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO

1 of 2 SIL99-4

REVISION

FIGURE 1 Item Number 1 2 3 4 5 6 7 8

Part Number 655164 655236 655276 642520 MS20034-5 NAS1587-4 MS20500-428 642537

ISSUED MO

DAY

05

19

REVISED YEAR 99

MO

DAY

YEAR

Description Tail Pipe Elbow Assembly Bracket-Tail Pipe Gasket Bolt Washer Nut Clamp

TELEDYNE CONTINENTAL MOTORS

Quantity 1 1 1 2 4 8 4 1

PAGE NO

An Allegheny Teledyne Company

2 of 2

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

SIL99-4

REVISION

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains Useful Information Pertaining to Your Aircraft Engine

CATEGORY 5

SIL 99-5

TECHNICAL PORTIONS FAA APPROVED

SUBJECT:

TCM PART NUMBER 629141 THERMO UNIT

PURPOSE:

Notify owners, operators and technicians of discontinued part

COMPLIANCE:

MODELS AFFECTED:

At engine installation or whenever part number 629141 Thermo Unit requires replacement

IO-470-J and IO-470-K Series Engines

Teledyne Continental Motors has been advised by our vendor that part number 629141 thermo unit is no longer available. Therefore this unit will no longer be supplied by TCM on Rebuilt IO-470- J and IO-470-K series engines.

specifications, the thermo unit, wiring, and cylinder head temperature gauge will have to be replaced.

The engine thermo unit and the aircraft cylinder head temperature gauge must be compatible. If the thermo unit currently installed on the engine is operational and the cylinder head temperature indicating system meets the aircraft manufacturer’s specifications the system may be continued in service.

1. Norwich Aero Products, Inc. East River Route 23 P.O. Box 109 Norwich, NY 13815 Phone: 607-336-7636

If the thermo unit installed on the engine is inoperative, and the cylinder head temperature indicating system does not conform to the aircraft manufacturer’s

ISSUED MO

DAY

05

19

REVISED YEAR 99

MO

DAY

YEAR

Replacement systems may be purchased from:

2. Rochester Gauges, Inc. 11616 Harry Hines Blvd. P.O. Box 29242 Dallas, TX. 75229 Phone: 214-241-2161

TELEDYNE CONTINENTAL MOTORS An Allegheny Teledyne Company

P.O. Box 90 Mobile Alabama 36601 Ph. 334-438-3411

PAGE NO REVISION

1 of 1 SIL99-5

TELEDYNE CONTINENTAL

®

AIRCRAFT ENGINE

SERVICE INFORMATION LETTER Contains useful information pertaining to your aircraft engine

CATEGORY 5

SIL99-7

SUBJECT:

PRECISION AIRMOTIVE CORPORATION SIL RS-46 Rev. 1

PURPOSE:

To provide inspection and repair procedures for Precision RSA-5AD2, Parts List 2576540-4, Fuel Injection Servo installed on L/TSIO-360-RB Engines.

COMPLIANCE: As specified in the “INSPECTION SECTION” section of Precision Airmotive Corporation SIL RS-46 Rev. 1. MODELS AFFECTED:

All LTSIO-360 RB and TSIO-360 RB engines.

Teledyne Continental Motors recommends compliance with Precision Airmotive Corporation SIL RS-46 Rev. 1 as specified in the “INSPECTION SECTION” section of this bulletin. NOTE: Precision Airmotive Corporation RSA-5AD2 Part List 2576540-4 is available from Teledyne Continental Motors as TCM P/N 654353.

ISSUED

REVISED

MO

DAY

YEAR

09

22

99

MO

DAY

YEAR

TELEDYNE CONTINENTAL MOTORS

An Allegheny Teledyne Company P.O. Box 90 Mobile Alabama 36601 334-438-3411

PAGE NO

1 of 1 SIL99-7

REVISION