CONTINENTAL AIRCRAFT ENGINE

MAINTENANCE
MANUAL
STANDARD PRACTICE
FOR SPARK IGNITED ENGINES

Technical Portions Accepted by the Federal Aviation Administration

Publication M-0 CHANGE 4

©
2017 CONTINENTAL MOTORS JUL 2017
 Supersedure Notice
This manual incorporates maintenance and service information contained in Continental Motors Service
Documents common to the horizontally opposed, spark ignition, AvGas aircraft engines conforming to Type
Certificate held by Continental Motors. This document is supplemental to the Instructions for Continued
Airworthiness provided in the manuals listed in Section 1-1.1. Instructions contained in the Service Documents
listed in Section 1-2.4 are superseded by instructions in this manual upon release, except for those Mandatory
Service Bulletins (MSBs) and Critical Service Bulletins (CSBs).

Effective Changes for this Manual

0 ................15 April 2016 4................... 31 Jul 2017
1 ................ 30 May 2016
2 .................30 Sep 2016
3 ................. 15 Jan 2017
List of Effective Pages
Document Title: Standard Practice Maintenance Manual
Publication Number: M-0 Initial Publication Date: 15 April 2016
Page Change Page Change Page Change Page Change
Cover............................ 4 2-9 thru 2-12 .................0 6-7................................ 0 6-53 thru 6-66............... 0
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Published and printed in the U.S.A. by Continental Motors

Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601

Copyright © 2016, 2017 Continental Motors. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise altered
without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher will not be
held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content is subject to
change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.

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 Introduction
Chapter 1. Introduction
1-1. Scope and Purpose of This Manual
This manual provides maintenance instructions for spark ignition, Standard Practices
operating on aviation gasoline (AvGas). These Instructions for Continued Airworthiness
(ICA) are supplied to the owner with the engine. Instructions in this manual are standard
practices, with differences identified by model, for A-65, A-75, C-75, C-85, C-90, C-125, C-
145, E-165, E-185, E-225, O-200, GO-300, O-300, IO-240, IOF-240, IO-346, IO-360,
LTSIO-360, TSIO-360, O-470, IO-470, TSIO-470, GTSIO-520, IO-520, LTSIO-520, TSIO-
520, IO-550, IOF-550, TSIO-550, TSIOF-550, TSIOL-550 and TIARA (6-285 and 6-320)
series aircraft engines. For information specific to the Continental Motors engine series,
accessories, or the airplane, refer to the appropriate manual. For the specific instructions
regarding the electronic equipment on FADEC engines, or for unlisted engine models, refer
to the primary ICA.
A list of tools for all applicable engines is provided in Chapter 2. Consumables items, such
as lubricants, sealants, and adhesives are listed in Chapter 3. Airworthiness limitations are
in Chapter 4. Chapter 5 contains generic installation instructions applicable to our engines.
Chapter 6 provides schedule inspection and service intervals and instructions, as well as
unscheduled maintenance instructions. Chapter 7 contains general engine operating
instructions, applicable to all models. Chapter 8 contains engine troubleshooting
instructions. Engine preservation and storage instructions are in Chapter 9. Non-overhaul
engine part replacement instructions are in Chapter 10. Chapter 11 contains Non-
Destructive Inspection guidelines. Chapter 12 contains part cleaning instructions.
Appendix A contains a glossary of common terms and acronyms used throughout the
manual; Appendix B provides torque specifications, and Appendix C contains
maintenance standards.
1-1.1. Instructions for Continued Airworthiness
Continental Motors Part No. M-0, is supplemental, as defined by Title 14 CFR§33.4, to
the maintenance and overhaul manuals listed below. Together, this manual and those listed
below comprise the instructions for continued airworthiness for applicable engines. This
manual, and the overhaul manuals and component service manuals (as applicable to
engine specification) listed below are delivered to the customer with the engine. Service
documents and Airworthiness Directives may also affect ICAs. Refer to Section 1-2.5 for
instructions to check current publication status.
Part No. Title Applicability
M-2 Maintenance and Overhaul Manual O-200-D, X
M-6 Maintenance and Overhaul Manual IO-240
M-7 Maintenance and Overhaul Manual IO-360
M-11 Maintenance Manual IO-520 Permold
M-16 Maintenance and Overhaul Manual IO-550 Permold
M-18 Maintenance and Overhaul Manual TSIO-550 Permold

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Introduction
M-22 Maintenance and Overhaul Manual IOF-240
M-24 Maintenance Manual IOF-550-A, B, C, G, N, P & R
M-26 Maintenance and Overhaul Manual TSIOF-550
OH-15 Overhaul Manual TSIOL-550-C
OH-24 Overhaul Manual IOF-550
OMI-15 Operation, Maintenance and TSIOL-550-C
Installation Manual
X30008 Overhaul Manual A-65, A-75
X30010 Overhaul Manual C-75, C,85, C90, O-200-A, B
X30013 Overhaul Manual C-125, C-145, O-300
X30016 Overhaul Manual E-165, E-185, E-225
X30019 Overhaul Manual GO-300
X30027 Overhaul Manual IO-346
X30033 Overhaul Manual TSIO-470
X30039 Overhaul Manual IO-520
X30045 Overhaul Manual GTSIO-520
X30144 Overhaul Manual TIARA 6-285 and 6-320
X30531 Alternator Service Instructions Continental alternators
X30571 Maintenance and Operator’s Manual TSIO-360-LB
X30574 Overhaul Manual TSIO-520-B, BB, BE, D, DB,
DB, E, EB, J, JB, K, KB, L, 
LB, N, NB, U, UB, VB, 
WB Permold series
X30575 Overhaul Manual LTSIO-520-AE
TSIO-520-C, CE, G, H, M, P,
R, T, AE, AF Sandcast series
X30586 Overhaul Manual O-470-A, B, E, G, J, K, L, M
R, S, U
X30588 Overhaul Manual IO-470-C, D, E, F, G, H, J, K,
L, M, N, P, R, S, U, V, VO
X30592 Starter Service Instructions Energizer® starters
X30596 Overhaul Manual LTSIO-360-EB, KB & RB,
TSIO-360-A, AB, B, C, CB, 
D, DB, E, EB, F, FB, G, GB,
H, HB, J, JB, K & KB, LB, 
MB, SB

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 Introduction
X30596S1 Overhaul Manual LTSIO-360-RB,
TSIO-360-RB
X30600 Overhaul Manual TSIOL-550-A
X30601 Maintenance and Operator’s Manual TSIOL-550-A
X30605 Maintenance Manual IO-550-D, E, F & L
X30607 Overhaul Manual IO-550-D, E, F & L
X30645 Maintenance Manual LTSIO-360-RB
TSIO-360-RB
X30672 Maintenance Manual TSIO-360-MB, SB
1-1.2. Advisories
This manual utilizes three types of advisories; defined as follows:
WARNING
A warning emphasizes information which, if disregarded, could
result in severe injury to personnel or equipment failure.
CAUTION: Emphasizes certain information or instructions, which if
disregarded, may result in damage to the engine or accessories.
NOTE: Provides special interest information, which may facilitate
performance of a procedure or operation of equipment.
Warnings and cautions precede the steps to which they apply; notes are placed in the
manner which provides the greatest clarity. Warnings, cautions, and notes do not impose
undue restrictions. Failure to heed advisories will likely result in the undesirable or unsafe
conditions the advisory was intended to prevent. Advisories are inserted to ensure
maximum safety, efficiency, and performance. Abuse, misuse, or neglect of equipment can
cause eventual engine malfunction or failure.
1-1.3. Effectivity Symbols
Variations in engine configuration may require specific instructions or illustrations. When
information pertains to only a subset of the applicable engine models, an effectivity
symbol will precede the information. Effectivity symbols found in this publication are:
FWD Forward Mounted Gear Driven Alternator
AFT Aft Mounted Gear Driven Alternator
EZR Energizer Starter
SKY SkyTec Starter

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Introduction
1-1.4. Using this Manual
This manual, the primary engine ICA listed in Section 1-1.1, applicable FAA ADs and
Continental Motors service documents, the accessory manuals listed in Table 1-2, and all
changes incorporated in the ICAs as revisions constitute the Instructions for Continued
Airworthiness (ICAs) prepared by Continental Motors and accepted by the FAA. We
prepared this manual in a user-friendly format suited equally for electronic viewing and
print. Illustrations in this manual are for reference only, depicting the most prominent
configuration in the engine series. Consult the electronic illustrated parts catalog for
engine model-specific illustrated parts breakdowns. The current information available
from Continental Motors must be used to perform engine service, repair or overhaul.
Continental Motors provides Instructions for Continued Airworthiness based on the
design, testing, and certification of engines and parts for which Continental Motors is the
holder of the Type Certificate (TC) or Parts Manufacture Approval (PMA) issued by the
Federal Aviation Administration (FAA).
WARNING
Continental Motors Instructions for Continued Airworthiness
are applicable only to Continental Motors engines conforming
to the approved, type certified engine model configuration.
Continental Motors ICAs must not be used for aftermarket
parts or products modified by Supplemental Type Certificate.
Installation of aftermarket parts on a Continental Motors engine constitutes a deviation
from type-design criteria. Continental Motors has not participated in design, test, or
certification of any aftermarket parts. Continental Motors does not provide product
manufacturing specifications to aftermarket parts manufacturers and accepts no liability
for the suitability, durability, longevity, or safety of such parts installed on Continental
Motors engines. Installation of aftermarket parts on a Continental Motors engine must be
performed using Instructions for Continued Airworthiness prepared by the manufacturer
and approved by the FAA for the subject installation. For work with the engine installed in
the aircraft, the aircraft maintenance manual may also be required to gain access to,
perform maintenance, or install some items. Use only the current information from the
aircraft manufacturer.
Exploded assembly illustrations accompany instructions throughout the manual. Parts in
illustrations (Figure 1-1) are identified with either alpha or numerical callouts (indexes).
Corresponding parts listings follow the illustrations for reference. The first time
instructions refer to an illustration, the figure number is identified in parentheses, followed
by the callout. In subsequent parts references, only the callout will be specified unless the
referenced illustration changes.

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 Introduction
1-2.4.1. Service Documents Incorporated in this Manual
Applicable technical maintenance and service information contained in the Service
Documents listed below, relevant to the engine models covered by this engine manual,
have been incorporated in this M-0 Standard Practice Maintenance Manual. This manual
supersedes and retires these older Service Documents (where applicable) excluding
Mandatory Service Bulletins (MSBs) and Critical Service Bulletins (CSBs) identified
with an asterisk below.
The full content of active Continental Motors Service Documents is available at
www.continentalmotors.aero. Refer Section 1-3, “Contact Information” for Continental
Motors web site details.
Table 1-1. Service Documents Incorporated in Manual
Service Document Subject Affected Chapter
M67-12, Overboost of Turbocharged Engines Unscheduled Maintenance 6
M72-17R1, Maximum Weight Difference Between Parts Replacement 10
Connecting Rods and Pistons in the Same Engine
M76-4, Propeller Shaft or Crankshaft Oil Seal Unscheduled Maintenance 10
Replacement
M76-8, Intake Valve Change Unscheduled Maintenance 10
M77-3, Use of Alternate Fuels in Engines Originally Engine Operation 7
Certified for 80/87, 91/96 and 100/130 Grade Fuels
M84-5, Gear Driven Alternator Inspection Procedure Alternator Replacement 10
M85-10, Cylinder Hold Down Nuts Cylinder Replacement 10
M87-15, Alternator Ground Strap Alternator Replacement 10
M88-9, Lightning Strikes Unscheduled Maintenance 6
M88-10, Contaminated Fuels Unscheduled Maintenance 6
M 8 9 - 7 R 1 , E n g i n e O p e r a t i o n a f t e r C y l i n d e r Unscheduled Maintenance 7
Replacement and/or Major Overhaul
M89-9, Excessive Crankcase Pressure Unscheduled Maintenance 8
M90-17, Crankcase Inspection Criteria Scheduled Maintenance 6
SIL93-11B, Service Document Format Service Documents 1
SIL93-15, General Practices for Installation of Lock Standard Practices Appendix C
Wire, Tab Washers, and Cotter Pins
* MSB94-8D, Magneto to Engine Timing Scheduled Maintenance 6
SB95-2, Inspection and Maintenance of Engine Control Inspection 6
Cables and Linkage
SB95-3B, Alternator/Generator Drive Coupling Alternator Maintenance 6, 10
SIL95-5, Hose and Tubing Installation Hose and Tubing installation Appendix C
SB96-7D, Torque Limits Fastener Torque Appendix B
* MSB96-10B, Crankshaft Ultrasonic Inspection Engine Overhaul or Crankshaft 10
Repair

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Introduction
Table 1-1. Service Documents Incorporated in Manual
Service Document Subject Affected Chapter
SB96-11B, Propeller Strikes and Hydraulic Lock Unscheduled Inspection 6
SB96-12, Cylinder Continued Airworthiness Scheduled Inspection 6 & 10
SID97-2B, Design, Operation Maintenance and Engine Maintenance 6
Warranty of Cylinders
SID97-3G, Continuous Flow Fuel Injection Systems O p e r a t i o n a l Checks and 6
Adjustment Specifications and Instructions Adjustments
SID97-4F, Cylinder Bore and Piston Fit Specifications Overhaul & Service Limits 10
SB97-6B, Mandatory Replacement Parts Engine Inspection & Assembly Appendix C
SIL98-9E, Time Between Overhaul Periods Scheduled Maintenance 6
SIL99-1, Engine Preservation for Active and Stored Engine Preservation and Recovery 9
Aircraft
SIL99-2C, Sealants, Lubricants and Adhesives Materials 3
Authorized by CMI
SB00-3A, Crankshaft, Counterweight and Connecting Repair Specifications 10
Rod Repair Information
SIL00-9A, Engine Data Plates Data Plate Replacement Appendix C
SIL00-11B, Release of new Cylinder Induction Port Cylinder Assembly 10
Drain Connector
SIL03-1, Cold Weather Operation - Engine Preheating Engine Operation 7
SIL03-2C, Currently Active Approved Spark Plug Spark Plugs 6
Application
SB03-3, Differential Pressure Test and Borescope Inspection Criteria 6
Inspection
S I L 0 4 - 1 2 A , A u t h o r i z e d E n g i n e A d j u s tm e n t s , Engine Specification 5
Component Replacement and Repositioning
SB05-2, Overspeed Limitations Unscheduled Maintenance 6
* CSB08-3C, Throttle & Mixture Control Levers Fuel Injection System Assembly 6
SB08-13 , Induction System Hose an d Clamp Induction System Inspection & 6
Installation Assembly
SB11-3, Alternator and Drive Coupling Installation Alternator Replacement 6, 10
SIL13-2A, Alternator Instructions for Continued Alternator Replacement 6, 10
Airworthiness
SB14-8, Exhaust Flange to Cylinder Installation Exhaust System Installation 10
SB16-3, Turbocharger Check Valve Inspection and Exhaust System Inspection 6
Cleaning
* Documents remain active in the service bulletin set.

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 Lubricants, Sealants, and Adhesives
Table 3-4. Sealants
CM
Part
Number Type Application Remarks
Crankcase parting face
Starter adapter to accessory case
654663 Loctite 30516 Gasket Sealant Apply according to assembly
(with P/N 641543 Silk Thread) Accessory drive adapter instructions
Pressure oil pump covers
Pressure scavenge pump covers
Use on all pipe threads to oil coolers All models (use sparingly on
657042 Loctite 565 Adhesive Sealant and other oil sources male threads only)
Ignition harness terminals at magneto
N/A Miller-Stephenson MS-122AD All models
block end & spark plug / ECU terminals
Use on all pipe threads except as noted
elsewhere
All pressure relief valve housing threads All models, where applicable
Loctite 592 Teflon PS/T Pipe Permold 2 studs engine mount 1-3-5
N/A
Sealant side bottom
All threaded fasteners installed in a stud Apply before installing threaded
hole through to an oil source fastener

Table 3-5. Lubricants

CM
Part Type Application Remarks
Number
Fuel injector nozzles  See Figure 3-1
(at cylinder head)
Mechanical tachometer drive housing
threads not connected through to an oil At engine assembly
source.
Exhaust studs (applied to nut end
Loctite 76732 Anti-Seize before torque), exhaust slip joints All except TSIOL550
646943
Lubricant Vernatherm plug At engine assembly
All 0.3125 and larger studs unless At engine assembly
otherwise noted At engine assembly
Throttle body air reference fittings Where applicable
Oil sump return fitting IO360ES3B, 14B, &
IO360HB9B
Fuel injection linkages At engine assembly
654468 Shell #5 MIL-G-3545-C Grease Apply at pivot points during
Throttle & mixture control linkages assembly and periodic
maintenance
654514 CRC 336 Rust Preventative Spray exhaust end of turbocharger After engine test
Compound
Light coat at contact point between nut All models, where applicable
seat and ignition lead ferrule
Shell Gadus S2 V220 2
654561 formerly LTSIO360E, EB, RB;
Apply to oil seal lip only (alternator seal) TSIO360E, EB, F, FB, GB, KB,
Shell Alvania # 2 LB
Apply to crankshaft nose oil seal lip All models

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Lubricants, Sealants, and Adhesives
Table 3-5. Lubricants
CM
Part Type Application Remarks
Number
Starter worm gear & bevel gear teeth
Needle bearings and ball bearings All models during engine
assembly
Valve stems
Accessory drive splines and couplings Where applicable
Idler gear and pin 470, 520, 550
Magneto rubber drive bushings
656817 Super Molyshield Grease All models
Oil seal lips only
Except 360, TSIO520D, 
Fuel injection controls, o-rings, springs,
shafts, and bushings GTSIO520K, which use 50W
motor oil
Oil pumps (pressure & scavenge) Coat gear cavity during pump
assembly
Adapter (tach reduction) TSIO & LTSIO360
Use only manufacturer’s
N/A recommended spark plug Spark plugs All models
thread lubricant
Chesterton #995 Release Induction system hoses and flex duct
N/A Agent connections, pipe plugs in throttle body All models
or WD-40 units
Rubber oil seal of spin-on oil filters. Do
not apply to oil filter P/N 658753,
658754, or 658755 filters with anti-stick
N/A Dow Corning No. 4 coating on seal. All models where applicable
Governor pad gaskets (both sides)
Starter adapter cover o-rings
N/A Dow Corning G-N Paste Camshaft lobes and tappet faces During engine assembly
Throttle and Mixture Control Valves Apply at pivot points during
N/A LPS 2 Linkages maintenance
Throttle and Mixture Control Valves Apply at pivot points during
N/A Lubriplate 630 AA (optional) Linkages assembly
All models during valve guide
N/A Lubriplate 930 AA O.D. of valve guides installation
Carbon solvent used on
N/A Mouse Milk Wastegate butterfly and linkage turbocharged engines during
preventive maintenance
Quill Shaft Springs GTSIO520
Crankshaft bearings
Connecting rod bearings During engine assembly
Prop driver, driven gears & bearings
SAE J1966 Grade 50  Camshaft bearings
N/A Aviation Oil Tachometer gears & adapters
Accessory spur gear teeth
Prop governor transfer collar & sleeve
Starter cone, bushing & nut
Starter clutch spring (ID & OD)

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 Engine Inspection and Service
Table 6-4. Fuel System Adjustment Values
Idle and FULL POWER Fuel Pressures and Flows
Manifold
Absolute Metered
Prop. Pressure Unmetered Nozzle Fuel Fuel
Engine1 RPM (MAP) Pump PSI2 PSI3 (lbs/hr)4 (gal/hr)4
TSIO-520-BE 600 - 5.5 - 7.0 - - -
2600 38.0 25.0 - 28.0 12.7 - 14.1 214 - 224 36.5 - 38.2
TSIO-520-C, H 600 - 5.5 - 7.0 - - -
2700 32.5 29.0 - 32.0 15.3 - 17.2 160 - 170 27.3 - 29.0
TSIO-520-CE 600 - 5.5 - 6.5 - - -
2700 37.0 33.0 - 36.0 16.2 - 18.0 215 - 225 36.6 - 38.3
TSIO-520-D, DB 600 - 5.5 - 7.0 - - -
2700 32.5 29.0 - 32.0 13.3 - 15.1 160 - 170 27.3 - 29.0
TSIO-520-E, EB 600 - 5.5 - 6.5 - - -
2700 34.5 31.0 - 34.0 15.6 - 17.7 175 - 185 29.8 - 31.5
TSIO-520-G 600 - 5.5 - 6.5 - - -
2700 35.0 31.0 - 34.0 15.8 - 17.6 181 - 191 30.8 - 32.5
TSIO-520-J, JB 600 - 5.5 - 6.5 - - -
2700 36.0 31.0 - 34.0 16.9 - 18.7 170 - 178 29.0 - 30.3
TSIO-520-K, KB 600 - 5.5 - 7.0 - - -
2700 33.0 29.0 - 32.0 15.1 - 17.4 163 - 175 27.8 - 29.8
TSIO-520-L, LB 600 - 25 Minimum MFG10 - -
2700 38.0 45.0 - 55.0 180 - 190 30.7 - 32.4
TSIO-520-M, R 600 - 5.5 - 6.5 - - -
2700 36.5 33.0 - 37.0 16.9 - 19.9 170 - 186 29.0 - 31.7
TSIO-520-N, NB 600 - 5.5 - 6.5 - - -
2700 38.0 32.0 - 35.0 16.9 - 19.9 170 - 186 28.9 - 31.7
TSIO-520-P 600 - 5.5 - 6.5 - - -
2700 36.5 33.0 - 37.0 18.4 - 19.9 180 - 186 30.7 - 31.7
TSIO-520-T 600 - 5.5 - 6.5 - - -
2700 39.5 33.0 - 37.0 16.3 - 18.1 185 - 195 31.5 - 33.2
TSIO-520-UB 600 - 5.5 - 6.5 - - -
2700 36.0 33.0 - 37.0 14.4 - 16.0 195 - 205 33.2 - 34.9
TSIO-520-VB 600 - 5.6 - 6.5 - - -
2700 40.5 36.0 - 39.5 16.9 - 18.7 200 - 210 34.1- 35.8
TSIO-520-WB 600 - 25 Minimum - - -
2700 39.5 45.0 - 55.0 MFG11 190 - 200 32.4 - 34.1
GTSIO-520-C 525 - 4.0 - 7.0 - - -
2400 34.5 30.0 - 33.0 16.5 - 17.5 215 - 225 36.6 - 38.3
GTSIO-520-D, H 467 - 4.0 - 7.0 - - -
2267 39.5 30.5 - 35.0 15.7 - 17.3 250 - 260 42.6 - 44.3
GTSIO-520-F, K11 600 - 6.75 - 7.25 - - -
2267 44.5 38.0 - 41.0 17.4 - 18.8 300 - 310 51.1 - 52.8
GTSIO-520-L, N11 467 39.0 4.0 - 7.0 - - -
GTSIO-520-M 2234 40.0 29.5 - 35.0 16.4 - 17.9 255 - 265 43.4 - 45.1
GIO-550-A 600 - 25 Minimum - - -
2267 45 - 55 MFG11 175 - 185 29.8 - 31.5
IO-550-A 6 600 - 8.0 -10.0 - - -
2700 - 32.0 - 36.0 17.7 -20.0 142 - 150 24.2 - 25.6
IO-550-B 6 600 - 8.0 -10.0 - - -
2700 - 29.2 - 36.2 16.5 - 18.4 146 - 156 24.9 - 26.6

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Engine Inspection and Service
Table 6-4. Fuel System Adjustment Values
Idle and FULL POWER Fuel Pressures and Flows
Manifold
Absolute Metered
Prop. Pressure Unmetered Nozzle Fuel Fuel
Engine1 RPM (MAP) Pump PSI2 PSI3 (lbs/hr)4 (gal/hr)4
IO-550-C 6 600 - 8.0 -10.0 - - -
2700 - 31.6 - 37.8 17.6 - 19.6 152 - 160 25.9 - 27.3
IO-550-D, E, F, L 6 600 - 8.0 - 10.0 - - -
2700 32.0 - 36.0 17.2 - 20.0 143 - 155 24.4 - 26.4
IO-550-G 600 - 8.0 -10.0 - - -
2500 - 22.0 - 26.0 14.7 - 16.0 125 - 130 21.3 - 22.1
IO-550-N, P, R 600 - 8.0 -10.0 - - -
2700 - 28.0 - 30.0 19.0 - 21.3 150 - 160 25.6 - 27.3
TSIO-550-B 600 - 7.0 - 9.0 - - -
2700 38.0 32.0 - 36.0 15.3 - 16.9 241 - 252 41.0 - 42.9
TSIO-550-C 600 - 7.0 - 9.0 - - -
2600 35.5 26.0-29.0 12.7 - 13.9 212 - 224 36.1 - 38.1
TSIO-550- E 600 - 7.0 - 9.0 - - -
2700 38.5 32.0 - 36.0 15.3 - 16.9 244 - 254 41.5 - 43.3
TSIO-550- G 600 - 7.0 - 9.0 - - -
2700 34.0 20.5 - 28.5 12.4 - 13.6 201 - 211 35.2 - 35.9
TSIO-550-G  600 - 7.0-9.0 - - -
MOONEY 12 2500 33.5 20.0-23.0 10.4-11.6 177-180 30.0-30.7
TSIO-550- K, N 600 - 7.0 - 9.0 - - -
2500 37.5 20.5 - 28.5 14.2 - 14.8 210 - 220 35.8 - 37.5
TSIOL-550-A 600 - 5.5 - 6.5 - - -
2600 35.0 32.5 - 35.5 17.0 - 19.0 170 - 180 29.0 - 30.7
TSIOL-550-B 600 - 6.0 - 8.0 - - -
2700 35.0 36.0 - 40.0 20.0 - 22.5 175 - 185 29.8 - 31.5
TSIOL-550-C 600 - 6.0 - 8.0 - - -
2600 39.5 37.0 - 40.0 15.0 – 16.5 204 - 216 34.8 – 36.8

1. 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 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. CM will not accept responsibility or liability for any modified engine set up
according to the instructions contained in these instructions.
2. FULL POWER unmetered fuel pump pressure limits are provided for reference only. Use metered fuel pressure specifications for adjust-
ments at full power.
3. Use for full power, maximum RPM adjustment only. All other parameters for reference only, Footnote 2 applies.
4. 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.
5. IO-360-DB engine model specifications equipped with altitude compensating fuel pumps; Flight Test (Section 7-2.4.2) required after fuel
system adjustment.
6. Engine model equipped with altitude compensating fuel pump; Flight Test (Section 7-2.4.2) required after fuel system adjustment.
7. This engine is installed in Cirrus SR20 aircraft. IO-360-ES engines has been derated by Cirrus from original 210 HP at 2800 RPM to 200 HP
at 2700 RPM. Engine data plate reflects original CM data of 210 HP at 2800 RPM. Refer to Cirrus SR20 Maintenance Manual and POH.
8. Engine model certified for five minute rated takeoff power at 2800 RPM. Max. continuous power is 2600 rpm.
9. Refer to the aircraft manufacturer's instructions for adjustment procedures.
10. Refer to the aircraft manufacturer's instructions for adjustment procedures.
11. Refer to the aircraft manufacturer's instructions for adjustment procedures.
12. TSIO-550-G installed in Mooney aircraft has been rated to a power level that is less than the approved Type Certificate Data Sheet. Refer to
the Mooney Aircraft Maintenance Manual for setup instructions.

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 Engine Inspection and Service
6-4.7.5. Magneto RPM Drop Check
WARNING
Absence of RPM drop during magneto check may be an
indication of a faulty ignition circuit (Hot Magneto). Should the
propeller be turned by hand (as in during preflight), the engine
could inadvertently start and cause personal injury or death.
Flight is prohibited until the condition is corrected.
CAUTION: When operating on single ignition, some RPM drop and
slight engine roughness as each magneto is switched off should be
noted. Excessive (greater than 150 RPM) RPM drop may indicate a
faulty magneto or fouled spark plugs.
NOTE: If the engine runs roughly after single magneto operation,
increase engine speed to 2200 RPM in the BOTH position and lean the
mixture control until the RPM peaks for ten seconds before returning to
the full rich position to clear the spark plugs and smooth operation before
returning to single magneto operation.
Procedure
1. Start the engine according to the “Engine Start” instructions in Section 7-3.2.
RESULT: No defects noted. Allow the engine oil to warm to normal (100°F (38°C)
for turbocharged engines or 75°F (24°C) operating temperature.
CAUTION: Avoid prolonged single magneto operation to preclude
spark plug fouling.
NOTE: In the instructions below, the term “Magneto Switch” applies to
the method the aircraft manufacturer uses to control the magnetos. Some
manufacturers use a wafer switch to control the starter with four
additional positions for magneto control, labeled OFF, L, R and BOTH.
Toggle switches may be used to accomplish the same action. Adjust
instructions according to the available aircraft controls.
2. Throttle............................................................. 1700 RPM
3. Magneto Switch ............................................... R
RESULT: RPM drop does not exceed 150 RPM; record Left Magneto channel drop
result. Maximum allowable RPM drop spread between magneto channels is 50
RPM.
4. Magneto Switch ............................................... BOTH
5. Magneto Switch ............................................... L
RESULT: RPM drop does not exceed 150 RPM; record Right Magneto channel drop
result. Maximum allowable RPM spread between magneto channels is 50 RPM.
6. Magneto Switch ............................................... BOTH
7. Throttle............................................................. Reduce to IDLE
8. If no further checks are required, proceed to “Engine Shutdown” on page 32.

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Engine Inspection and Service
6-4.7.6. Engine Shutdown
Procedure
1. Perform a normal engine shutdown according to the “Engine Shutdown”
instructions in Section 7-3.4.
2. Remove installed test equipment.
a. Disconnect the metered fuel pressure test hose from the aircraft fittings.
b. Disconnect the unmetered fuel pressure test hose from between the fuel pump
and the fuel control assembly.
c. Remove any fittings added to adapt the plumbing to the test equipment.
3. Reconnect and torque the fuel system hoses to Appendix B specifications.
a. Connect the unmetered pressure hose between the fuel pump and the fuel control
assembly.
CAUTION: Use only P/N 639494 cap on the tee fitting. Installation
of a pipe thread cap on the flared fitting may damage the fitting.
b. Install the protective caps (P/N 639494) (or airframe-installed fitting to cockpit
metered pressure gauge) on the fuel manifold valve (metered pressure) or throttle
body inlet tee (metered pressure) fittings, if equipped, and torque the cap to
standard torque for a #4 steel fitting in Table B-8.
4. Leak Check
a. Master Power Switch .................................. ON
b. Mixture........................................................ FULL RICH
c. Boost Pump Switch (if equipped) ............... ON
d. Throttle........................................................ WIDE OPEN
e. Check for leaks in the following areas and correct any discrepancies before
releasing the engine for flight:
1) Induction System
2) Exhaust System
3) Fuel System
4) Lubrication System
f. Boost Pump................................................. OFF
g. Throttle........................................................ IDLE
h. Mixture........................................................ IDLE CUT-OFF
i. Master Power Switch .................................. OFF

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 Engine Inspection and Service
6-4.8.2. Oil Change
Perform an oil change within 30 minutes of engine shutdown (to obtain a useful oil
sample) according to the oil changes intervals specified in Section 6-2.
NOTE: More frequent oil changes are recommended under extreme usage
(flight training, shuttle service, or crop dusting) or adverse (desert or
arctic climates) weather conditions.
Procedure
1. Place a catch basin, approved for collecting oil, beneath the oil sump. Remove the
oil sump drain plug (Figure 6-7 through Figure 6-22), or quick drain fitting, and
drain the oil into the catch basin.
2. Collect an oil sample according to the “Oil Sample Collection” instructions in
Section 6-4.8.4. Inspect the oil sump drain plug for evidence of wear material. Metal
fragments on the drain plug may indicate excessive wear or part disintegration.
Evidence of bronze in the oil sump suggests piston pin bushing loss. Remove the
cylinders and inspect the piston pin bushings for proper installation according to
instructions in Section 10-10.
CAUTION: Dispose of used engine oil in accordance with local
environmental standards.
NOTE: Continental Motors recommends customers submit a sample of
the oil drained during each oil change, or if engine trouble is suspected,
for spectrographic oil analysis. The first three samples establish the oil
analysis trend baseline. 

The amount of wear material present in new, rebuilt, or overhauled
engines is typically greater during the engine break-in period, tapering off
during subsequent oil changes. If the amount of wear material does not
decrease during subsequent oil changes, note the wear material
characteristics (refer to Section 6-4.8.5, “Oil Trend Monitoring and
Spectrographic Oil Analysis”) and troubleshoot the engine according to
instructions in Chapter 8.
3. Oil Filter or Integral Screen Change
Engines covered in this manual are equipped with either a screw-on, disposable oil
filter or an integral screen (Figure 6-23). Maintenance pertaining to the filter media
is listed in the “Engine Inspection and Maintenance Schedule” in Section 6-2. To
change disposable filters, follow the instructions in step a; for the integral screen,
follow the instructions in step b.
a. Remove the oil filter (Figure 6-8 through Figure 6-22).Cut the oil filter in two
parts using an Oil Filter Can Cutter (P/N CT-923 (Table 2-1, “Special Tools
List”)).
1) Inspect the oil filter element for metal debris trapped within the filter to
assess the engine condition. If debris is found, wash the filter media in a clean
glass container to determine content. Use a magnet to differentiate the ferrous
materials from non-ferrous particulate.

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Engine Inspection and Service
2) New, rebuilt, or overhauled engines exhibit more wear material during the
break-in period; material found in the filter media will diminish over time. If
wear material in the oil filter does not diminish, or increases, note the
characteristics of the wear material (Section 6-4.8.5, “Oil Trend Monitoring
and Spectrographic Oil Analysis” ) and troubleshoot the engine according to
instructions in Chapter 8.

Figure 6-23. Disposable Oil Filter and Integral Screen

b. If the engine is equipped with an integral oil screen (Figure 6-23), cut the safety
wire from the oil screen and remove the fastening hardware. The integral screen
is not disposable, rinse the integral screen with mineral spirits over filter paper to
clean the media. Use a magnet to differentiate the ferrous materials from non-
ferrous particulate.
4. Install the oil filter or screen. For disposable filters, follow the instructions in step a;
for the integral screen, follow the instructions in step b.
NOTE: Spin-on oil filters are available with an anti-stick coating on the
gasket. Part numbers 658753, 658754, and 658755 oil filters feature a a
dry graphite coating and are designed to be installed dry. Before applying
any lubricant to the oil filter gasket, read the manufacturer’s instructions
(Figure 6-23.1) on the oil filter. Application of any form of lubricant to
the gasket of the anti-stick spin-on oil filter will defeat the anti-stick
properties.
a. Read the oil filter label to determine the gasket type and proceed with installation
according to the filter manufacturer’s instructions. Install the new oil filter;
torque the filter to Appendix B specifications and safety wire the filter according
to instructions in Appendix C-3.
b. After thorough cleaning, install a new copper gasket on the oil screen flange and
install the oil screen in the oil pump, or oil screen adapter. Place a new copper
gasket on the plug (or oil temperature sensor provided by aircraft manufacturer)
and thread the screen (or plug) into the housing. Torque to Appendix B
specifications and safety wire according to instructions in Appendix C-3.

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 Engine Inspection and Service
5. Reinstall the oil drain plug with a new crush washer (gasket) according to
instructions in Appendix C-10.1; torque the drain plug to Appendix B specifications
and safety wire the drain plug according to instructions in Appendix C-3.
6. Add fresh oil and check the oil level according to instructions in Section 6-4.8.1.
7. Check for oil leaks according to instructions in Section 6-4.8.3.

Figure 6-23.1. Oil Filter with Anti-Stick Gasket Label (typical)

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Engine Inspection and Service

Intentionally Left Blank

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 Engine Operation
Table 7-1. Aviation Fuel Specifications

Fuel Specification Fuel Grades Color

ASTM D910 - Standard Specification for Aviation Gasolines 100 (100/1301) Green
100LL Blue
100VLL Blue
80 (80/871) Red
91 (91/961) Brown
ASTM D7547 - Standard Specification for Hydrocarbon Unleaded Avia- UL91 Colorless
tion Gasoline Colorless
UL942
GOST 1012 - Aviation Petrol B95/130 Amber
Russian Federation of States B91/115 Green
GB 1787 - Aviation Piston Engine Fuels 95 (RH95/130) Saffron
People’s Republic of China 100 (RH100/130)
1. Inactive - consult the latest revision of ASTM D910.
2. ASTM 7547/UL94 is acceptable for use on aircraft and engines certificated for operation with ASTM 7592/UL94 - reference FAA
SAIB HQ-16-05

NOTE: All certified Continental Motors engines previously certified for

operation with 91/96 octane or grade 100/130 aviation gasoline will
operate satisfactorily on Grade 100LL. It is recommended that Grade
100LL be used in these engines because of the reduction in combustion
chamber deposits realized with the lower tetraethyl lead content.
Table 7-2. Authorized Fuels by Engine Model

Certified Fuel Current

Engine Model on Type Certificate Alternate Authorization
NOTE: Engine operation with RH95/130 and UL94 fuel may
limit engine performance, operating ceiling, and/or maximum
recommended cruise power. Consult the engine specifications
and operating limits section of the primary ICA for
amplification.
A-65, A-75 80/87 100LL
C-75, C-85, C-90, C-125, C-145 80/87 100LL
E-165, E-185, E-225 80/87 100LL
O-200-A, B 80/87 100LL
O-200-D, X 100/100LL, RH100/130 N/A
IO-240-A, B 100/100LL, B95/130, N/A
RH95/130
IOF-240-B 100/100LL, B95/130, N/A
RH95/130
O-300, GO-300 80/87 100LL
IO-360-A, AB, C, CB, D, DB, E, ES, G, GB, H, HB, J, 100/100LL, B95/130, N/A
JB, K, KB RH95/130
IO-360-B 80/87 100/100LL

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Engine Operation
Table 7-2. Authorized Fuels by Engine Model

Certified Fuel Current

Engine Model on Type Certificate Alternate Authorization
NOTE: Engine operation with RH95/130 and UL94 fuel may
limit engine performance, operating ceiling, and/or maximum
recommended cruise power. Consult the engine specifications
and operating limits section of the primary ICA for
amplification.
IO-360-AF 100/100LL/100VLL, N/A
UL91, UL94, B95/130,
RH95/130
TSIO-360-A, AB, B, BB, C, CB, D, DB, E, EB, F, FB, 100/100LL N/A
G, GB, H, HB, JB, KB, LB, MB, NB, PB, SB;
LTSIO-360-E, EB, KB
TSIO-360-RB; 100/100LL, B95/130, N/A
LTSIO-360-RB RH95/130
IO-346 91/96 100/100LL
O-470-4, 11, 13, 15 80/87 100LL
O-470-A, F, J, K, L, R & S 80/87 100LL
O-470-B, G, H, M, N & P 91/96 100/100LL
O-470-T & U 100LL 100/100LL
LIO-470, IO-470-A, C, G, P & T 91/96 100/100LL
IO-470-D, E, F, H, L, M, N, S, U, V & VO 100/130 100/100LL
GIO-470; TSIO-470
IO-520-A, B, BA, BB, C, CB, J, M, MB, 100/100LL, RH95/130, or N/A
B95/130
IO-520-D, E, F, K, L, N, NB 100/100LL, N/A
B95/130
GTSIO-520 100/130 100/100LL
LIO-520 100/100LL, N/A
B95/130
TSIO-520 100/130 100/100LL
TIARA 6-285, 6-320 100/130 100/100LL
IO-550-A, B, C, G, N, P & R; 100/100LL, RH95/130, or N/A
IOF-550-A, B, C, G, N, P & R B95/130
IO-550-D, E, F, L; 100/100LL, RH95/130, or N/A
IOF-550-D, E, F, L; B95/130
TSIO-550-A 100/100LL N/A
TSIO-550-B 100/100LL, RH95/130, or N/A
B95/130
TSIO-550-C, E, G, N 100/100LL, RH95/130, or N/A
B95/130
TSIO-550-K 100/100LL, RH95/130, or N/A
B95/130, UL94

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 Engine Operation
Table 7-2. Authorized Fuels by Engine Model

Certified Fuel Current

Engine Model on Type Certificate Alternate Authorization
NOTE: Engine operation with RH95/130 and UL94 fuel may
limit engine performance, operating ceiling, and/or maximum
recommended cruise power. Consult the engine specifications
and operating limits section of the primary ICA for
amplification.
TSIOF-550-D, J, K & P 100/100LL, RH95/130, or N/A
B95/130
TSIOL-550-A, B, C 100/100LL N/A

Some older engine models, originally certified for use with 80/87 grade fuels, particularly
low compression ration engines may experience lead build-up or spark plug fouling as a
result of the higher octane and lead content of 100/100LL. Engines most affected by the
higher octane include the A-65, A-75, C-75, C-85, C-90, C-125, C-145, O-200, O-300 and
GO-300 engine series. Compliance with the instructions in Section 10-6.10 on these
engines will improve engine operation with the higher grade fuels.
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 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 burn off of deposits accumulated during
descent and taxiing. Mixture cutoff should be accomplished at this RPM without returning
to idle.
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.
Refer to the mixture leaning procedures in the AFM/POH to limit lead accumulation on
low compression engines originally certified for 80/87 octane fuel.

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Engine Operation
7-2.3. Engine Operation after Cylinder Replacement and/or Major Overhaul
NOTE: Instructions within this section apply to steel, nitrided, through-
hardened, or chrome plated cylinders. For engine operating instructions
with nickel silicon carbide (NiC3) plating, refer to the operating
instructions in the latest revision of SB15-6.
Proper operation of the engine following cylinder replacement or major overhaul is
extremely important. The following procedures should be followed to ensure that
adequate lubrication is being provided to newly installed components and that the piston
ring seating will occur as soon as possible.
1. 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 (Section 3-1).
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
according to the instructions in Section 5-2.9. Spark plugs are installed
during the pre-oiling instructions.
b. Test Cell Operational Procedure
1) Perform the Post-Overhaul testing according to the instructions in the engine
primary ICA (Ref: Section 1-1.1).
2. 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
2) 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°F or oil temperature to exceed 200°F.
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.
3. Engine Operation After Cylinder Overhaul or New Cylinder Installation
a. Engine Starting and Ground Operation
CAUTION: 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.

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 Non-Overhaul Repair and Replacement
CAUTION: Piston ring reinstallation is not recommended. If the
piston rings are removed for any reason, discard the removed piston
rings and install a new set of piston rings, with end gaps adjusted for
the destination cylinder.
12. Remove the piston pin and piston from the connecting rod. Inspect the piston and
piston pin according to the instructions in the primary ICA. If piston ring removal is
required, discard the piston rings and obtain, gap and install a new set of piston rings
according to the instructions in the primary ICA.
13. Remove the cylinder o-ring (or packing). Wrap the old cylinder base o-ring (or
packing) in a figure 8 pattern (Figure 10-14) around four of the crankcase studs and
stretch the two vertical segments of the packing over the connecting rod to secure it.

Figure 10-14. Cylinder Base O-Ring supporting Connecting Rods

14. Before commencing any cylinder repairs, perform a static leak check on the
cylinder:
CAUTION: Do not allow the fiber drift to contact the valve spring
retainer or rotocoil.
a. Place a fiber drift on the rocker arm directly over the valve stem.
b. Tap the drift several times with a hammer to dislodge any debris that may be
between the valve face and seat.
c. Invert the removed cylinder with the spark plugs installed.
d. Fill the inverted cylinder bore with nonflammable solvent.
15. Look for leaks in the cylinder head to barrel junction. If the cylinder head and barrel
seal is leaking, discard the cylinder. If the intake or exhaust seat seals or the spark
plug seals are leaking, note the discrepancy and repair according to the instructions
in the primary ICA.
16. Disassemble, clean, inspect, and make appropriate repairs to return the cylinder to
the published service limits according to the instructions in the primary ICA.

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Non-Overhaul Repair and Replacement
10-6.1.2. Cylinder Installation
Replace worn or out of tolerance components based on the following criteria:
• Only allow parts that meet the service limits may remain in service.
• If a part has reached a service limit tolerance, it must be replaced with a part that con-
forms to the specified new part tolerances or service limits.
• Clean cylinders and pistons according to the instructions in the primary ICA.
• Perform fluorescent penetrant, magnetic particle inspections according to instructions
in Section 11-2 and dimensional inspections on specified cylinder and piston parts
according to instructions in the primary ICA.
• Install serviceable lifters in the same location from which they were removed.
• Assemble cylinders which meet the inspection criteria and service limits according to
the instructions in the primary ICA with serviceable pistons and new piston rings.
WARNING
Do not apply any form of sealant to the crankcase cylinder
deck, chamfer, cylinder mounting flange, cylinder base O-ring,
or cylinder fastener threads. The use of RTV silicone, Gasket
Maker or any or other sealant on the areas listed above during
engine assembly will cause a loss of cylinder deck stud or
through-bolt torque. Subsequent loss of cylinder attachment
load, loss of main bearing crush or fretting of the crankcase
parting surfaces will occur. The result will be cylinder
separation, main bearing movement, or oil starvation and
catastrophic engine failure. USE ONLY CLEAN 50 WEIGHT
AVIATION ENGINE OIL ON SURFACES LISTED.
1. Inspect a new cylinder base o-ring (or packing) for cracks or deformities. If
serviceable, lubricate the new cylinder base o-ring (9) with clean 50-weight aviation
engine oil.
2. Install the new cylinder base O-ring (or packing), lubricated with clean 50-weight
aviation engine oil on the cylinder base flange; verify the O-ring is not twisted on
the cylinder base flange after installation.
3. Lubricate cylinder through bolt and deck stud threads using clean 50 weight aviation
engine oil.
4. Install a serviceable piston, fitted with new piston rings, and piston pin partially in
the cylinder bore.
5. Carefully rotate the crankshaft, placing the connecting rod of the cylinder being
installed in the outermost position. Remove the packing that was installed for
connecting rod support.
6. Line the piston up with the connecting rod and slide the piston pin into the
connecting rod.
7. Using a ring compressor, compress the piston rings and push the cylinder until the
fourth piston ring is positioned inside the cylinder barrel.

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 Non-Overhaul Repair and Replacement
8. Remove the ring compressor and push the cylinder assembly against the crankcase
cylinder deck with the stud holes aligned.
CAUTION: Engine crankcases featuring the seventh stud and
associated hardware use beveled seat brackets, part numbers
646297 and 646298 in combination with a self-aligning nut, part
number 646312. The spherical flange nut and the beveled seat
bracket work together to align the brackets on the seventh stud.
Cylinder flange hold down nuts and crankcase through-bolt nuts
feature a flat seat to evenly distribute fastener torque to the cylinder
mating flange.
9. While supporting the cylinder, install, but do not torque, the cylinder base fasteners.
a. Install the cylinder base flange nuts on the cylinder base studs.
b. Install flanged through-bolt nuts at the through-bolts.
c. For engines featuring the seventh stud, position the cylinder hold down brackets
on the seventh stud to overlap the cylinder base flange and secure with the self-
aligning, spherical nut.

Figure 10-14.1. Cylinder Flange Fasteners

10. For cylinder replacement, torque the cylinder fastening hardware according to the
“Cylinder Torque” instructions in Section 10-6.1.3.
11. Rotate the crankshaft through multiple revolutions to verify smooth rotation of the
crankshaft. If rotation is not smooth or binding is evident, disassemble the engine to

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31 Jul 2017 CHANGE 4
Non-Overhaul Repair and Replacement
determine the cause. Verify crankshaft end play (end clearance) is within the
tolerance specified in the primary ICA. If no end play is present, disassemble the
engine to determine the cause.
12. Install the valve train and pushrods according to the instructions in the primary ICA.
13. Install cylinder baffles and baffle supports (if equipped), as required by the
instructions in the primary ICA.
14. Connect cylinder drains, if equipped, according to primary ICA instructions.
15. Install fuel injectors and connect the fuel injection lines according to the instructions
in the primary ICA.
16. Install the induction and exhaust system according to the primary ICA instructions.
CAUTION: Service the engine with SAE J1966 mineral oil for
engine break-in.
17. Service the engine with mineral oil according to instructions in Section 6-4.8.
18. Perform a leak check on the fuel injection system according to the instructions in the
primary ICA.
19. Install the spark plugs and ignition harness according to the instructions in the
primary ICA.
20. Perform an initial engine run according to the instructions in the primary ICA.
21. Install the aircraft cowling and aircraft-supplied accessories according to the aircraft
manufacturer’s instructions.
22. Perform an “Engine Operational Check” and adjust engine fuel system to meet
engine model specifications according to the instructions in Section 6-4.7.
23. Perform a “Flight Check” according to the instructions in Section 7-2.4 prior to
release to normal operation.
24. Follow the “Engine Break-In” instructions in Section 7-2.4.1 for the first 25 hours of
operation.
25. Perform an “25-Hour Initial Operation Inspection” in Section 6-4.2 after the first 25
hours of engine operation. When oil consumption has stabilized, replace the mineral
oil with ashless dispersant aviation engine oil according to Section 6-4.8.

10-34.2 Standard Practice Maintenance Manual

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 Non-Overhaul Repair and Replacement

Intentionally Left Blank

Standard Practice Maintenance Manual 10-35

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Non-Overhaul Repair and Replacement
10-6.1.3. Cylinder Torque
CAUTION: This cylinder torque procedure is for individual
cylinder installation. For complete engine assembly and torque,
refer to instructions in the primary ICA.
1. Lubricate the cylinder base stud threads, through-bolt threads and nut threads on
BOTH sides of the engine with clean, 50-weight aviation oil.
WARNING
Failure to torque through-bolt nuts on both sides of the engine
may result in a loss of main bearing crush, main bearing shift,
crankshaft fracture, and engine failure.
2. Install and torque the through-bolt nuts and cylinder base nuts to one half of the final
torque value specified in Appendix B in the sequence shown in Figure 10-15.
3. Torque the through-bolt nuts and cylinder base nuts to the full final torque value
specified in Appendix B in the sequence shown in Figure 10-15. Torque the through-
bolt nuts on both sides of the engine (even if only one cylinder is being installed).
NOTE: Seventh studs are not used on all installations. For single cylinder
torque, the seventh stud locations are torqued last at each cylinder
location.

Eight Bolt Flange Six Bolt Flange

Figure 10-15. Cylinder Torque Sequence

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 Non-Overhaul Repair and Replacement
7. Remove the crankshaft nose oil seal, reinforcing ring (if used), and spring as shown
in Figure 10-44). Gentle force may be required to remove the nose oil seal parts
from the counterbore.
8. 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.
9. Clean surfaces thoroughly making certain that no foreign material remains on the
shaft or in the seal counterbore. Wash oil seal counterbore area with acetone. To
remove the Gasket Maker residue out of the counterbore recess using a chlorinated
solvent such as Loctite Chisel or methylene chloride followed by a naptha solvent
such as Loctite ODC-Free Cleaner and Degreaser. Remove all residue and debris
from the bore.

Figure 10-44. Crankshaft Nose Oil Seal Parts

10. Prepare the exposed portion of the crankshaft according to the instructions in
Section 10-9.3.
10-10.2. Solid Nose Oil Seal Installation
WARNING
Turn the Ignition Switch OFF and disconnect engine electrical
power before commencing maintenance or inspections.
Confirm continuity between the magneto capacitor and aircraft
ground to prevent accidental engine start during maintenance.
Do not stand or place equipment within the arc of the propeller.
1. Prepare the exposed portion of the crankshaft with a fresh helix pattern according to
instructions in Section 10-9.3.
2. Remove the spring and reinforcing ring from the crankshaft nose oil seal.
3. Unhook the spring ends using an unwinding motion.
4. Verify the seal spring length is 7.80” to 7.83” as illustrated in Figure 10-44. If the
spring length is not within this tolerance, replace it.
5. Place the spring around the crankshaft in the helix area.

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15 April 2016
Non-Overhaul Repair and Replacement
6. Turn the spring ends in a winding direction and allow one end to wind into the other
end.
7. Apply Part No. 654561 Grease to the lip of the new seal and the propeller flange.
8. Squeeze the seal until it is egg shaped and install it on the crankshaft, groove side in,
starting from the bottom of the propeller flange using the Crankshaft Oil Seal
Installer Tool (Chapter 3, Kent-Moore Part No. 5209).
9. After the oil seal is installed on the crankshaft, wipe the grease from the oil seal and
crankshaft. Verify the outer diameter of the oil seal is clean and dry.
10. Press the reinforcing ring into the oil seal recess in both directions from the split.
Ensure the reinforcing ring is in the deepest part of the recess all the way around.
11. Install the spring in the oil seal cavity.
12. Spray a thin film of Part No. 653692 Primer on the oil seal counterbore and allow it
to dry for 1 to 2 minutes.
13. Apply a translucent coat of Gasket Maker (Part No. 646942) to the oil seal
counterbore. Refer to Gasket Maker application instructions in Appendix C.
14. Apply Gasket Sealant (Part No. 654663) to the outside diameter of the oil seal.
15. Using thumb pressure, work the seal into the crankcase counterbore.
16. After the seal is in place, wipe any remaining sealant from the seal and crankshaft.
17. Spray the exposed portion of the lightly scratched crisscross area with aluminum
paint and allow it to dry.
18. Apply Part No. 653693, General Purpose Primer, to the crankcase oil seal retainer
screw holes.
19. Apply Part No. 646941, High Strength Adhesive Sealant, to the oil seal retainer
screws.
20. Install the crankshaft nose oil seal retainer plates and secure them with the nose oil
seal retainer screws. Torque the screws to Appendix B specifications.
21. Inspect the propeller according to the propeller manufacturer’s and aircraft
manufacturer’s instructions.
22. Install the propeller, if serviceable, according to the propeller manufacturer’s and
aircraft manufacturer’s instructions.
23. Perform a normal “Engine Start” (Section 7-3.2) and “Ground Run-up” (Section 7-3.3).
Run the engine for a minimum of five minutes to reach normal operating temperatures.
Shut down the engine according to the “Engine Shutdown” (Section 7-3.4) instructions
and inspect the Crankcase Nose Oil Seal area for leaks.

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 Non-Overhaul Repair and Replacement
10-10.3. Split Nose Oil Seal Removal
Follow same procedures 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 Section 10-10.1 will have to be accomplished manually without
engine rotation.
NOTE: On left hand rotating engines (LTSIO360) the helix must be
applied in the opposite direction as shown in Figure 10-41. Stroke the
strip of emery cloth outward toward the flange in the direction of rotation
(CW toward you using maximum hand pressure.).
10-10.4. Split Type Nose Oil Seal Installation
1. Prepare the exposed portion of the crankshaft with a fresh helix pattern according to
the instructions in Section 10-9.3.
2. Use appropriate split type nose oil seal depending on engine model (refer to
illustrated parts catalog).
3. Remove the spring (Figure 10-45) from the new crankshaft nose oil seal assembly
and unhook the spring ends.
4. Verify the seal spring length is 7.53” to 7.59” as illustrated in Figure 10-45. If the
spring length is not within this tolerance, replace it.
5. Place the spring around the crankshaft in the helix area and connect the ends of the
spring.
6. Apply Part No. 654561 Grease to the lip of the new oil seal and the crankshaft
propeller flange.
7. Install a new oil seal on the crankshaft outboard of the spring with the opening
facing the crankcase.
CAUTION: The nose oil seal split line must not align with the
crankcase mating flanges.
8. Position the split line of the crankshaft nose oil seal at the 2:00 or 4:00 o’clock
position of the crankcase.
9. Position the spring hooks 180° away from the split line of the nose oil seal and
install the spring in the oil seal cavity.
10. After the seal is positioned on the crankshaft, wipe the grease from the oil seal and
crankshaft. Verify the outer diameter of the oil seal is clean and dry.
11. Mask the crankshaft where it exits the crankcase. Spray a thin film of Part No.
653692, Primer, on the oil seal counterbore and allow it to dry for one to two minutes.
12. Apply Part No. 646942, Gasket Maker to the crankcase oil seal counterbore.
Remove the masking tape from the crankshaft.
13. Apply a translucent coat of Part No. 654663 Gasket Sealant on the outer diameter of
the oil seal.

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31 Jul 2017 CHANGE 4
Non-Overhaul Repair and Replacement
14. Using thumb pressure, work the seal and spring into the crankcase counterbore.
Ensure the seal is in the deepest part of the recess all the way around.

Figure 10-45. Split Nose Oil Seal Parts

15. After the seal is in place, wipe any remaining sealant from the seal and crankshaft.
16. Spray the exposed portion of the lightly scratched crisscross area with aluminum
paint and allow it to dry.
NOTE: The following steps apply only to engines utilizing oil seal
retainer plates.
17. Apply Part No. 653693, General Purpose Primer, to the crankcase oil seal retainer
screw holes.
18. Apply Part No. 646941, High Strength Adhesive Sealant, to the oil seal retainer
screws.
19. Install the crankshaft nose oil seal retainer plates and secure them with screws.
Torque the screws to the value specified in Appendix B.
20. Perform a normal “Engine Start” (Section 7-3.2) and “Ground Run-up” (Section 7-3.3).
Run the engine for a minimum of five minutes to reach normal operating temperatures.
Shut down the engine according to the “Engine Shutdown” (Section 7-3.4) instructions
and inspect the Crankcase Nose Oil Seal area for leaks.

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 Torque Specifications
Table B-2. Component Specific Torque Specifications
Torque Value
Models Affected (Non-standard, see
Size Fastener In.-Lbs. Ft.-Lbs. General Torque Specification)
.44-20 Nut, Cylinder to Crankcase 400-450 33.3-37.5 A Series, C-75, C-85 & C-90
Through Studs
.44-20 Nut, Front & Rear Crankcase 490-510 40.8-42.5 O-200
Bearing Through Studs
.44-20 Nut, Through Bolt at Cadmium 440-460 36.7-38.3 All Models (AR)
Plated Washer
.44-20 Nut, Through Bolt at Cylinder 490-510 40.8-42.5 All (AR) EXCEPT IO-240, IOF-240, & 360
Flange
.44-20 Nut, Through Bolt at Cylinder 590-610 49.2-50.8 All IO-240, IOF-240, & 360
Flange
.44-20 Nut, Through Bolt at Front 490-510 40.8-42.5 All Models (AR)
Mount Belt-Driven Alternator
.44-20 Nut, Tie Bolts at Nose and 340-360 28.3-30.0 GO-300
Prop Shaft Cages
.50-20 Nut, Crankcase Through Bolt 615-635 51.2-52.9 IO-346, O-470, IO-470, TSIO-470, 
at Cadmium Plated Washer GTSIO-520, IO-520, L/TSIO-520, IO-550,
IOF-550, TSIO-550, & TSIOF-550
.50-20 Nut, Crankcase Through Bolt 690-710 57.5-59.2 All IO-346, All 470, All 520 & All 550 
at Cylinder Flange, P/N EXCEPT TSIOL-550
634505 (6 point/0.33” tall)
.50-20 Nut, Crankcase Through Bolt 790-810 65.8-67.5 All IO-346, All 470, All 520 & All 550 
at Cylinder Flange, P/N EXCEPT TSIOL-550
652541 (12 point)
.50-20 Nut, Crankcase Through Bolt 790-810 65.8-67.5 TSIOL-550
at Cylinder Flange, P/N
649496 (6 point/0.43” tall)
.50-20 Nut, Crankcase-Nose Tie Bolts 640-660 53.3-55.0 All Models (AR)
.50-20 Nut, Through Bolt at Cadmium 690-710 57.5-59.2 TSIOL-550
Plated Washer
.62-18 Plug, (using crush washer) 190-210 15.8-17.5 All Models (AR)
Gears
.25-28 Bolt, Gear to Camshaft 140-160 11.7-13.3 A, C & E Series, O-200, O-300, O-470, 
IO-240, & IOF-240
.25-28 Bolt, Gear to Crankshaft  140-160 11.7-13.3 A, & C Series, O-200, O-300, GO-300, 
(P/N 22532)1 IO-240 & IOF-240
.25-28 Bolt, Gear to Crankshaft  170-175 14.2-14.6 E Series, O-470 Numerical, O-470-A & E
(P/N 534904)1
.31-24 Bolt, Gear to Camshaft 240-260 20.0-21.7 E Series, IO-360, L/TSIO-360, IO-346,
O-470, IO-470, TSIO-470, GTSIO-520, 
IO-520, L/TSIO-520, IO-550, IOF-550,
TSIO-550, TSIOF-550, & TSIOL-550
.31-24 Bolt, Gear to Crankshaft 240-260 20.0-21.7 E Series, IO-360, L/TSIO-360, IO-346
(Lower Hardness Identified
with Green Dykem)1

Standard Practice Maintenance Manual B-7

15 April 2016
Torque Specifications
Table B-2. Component Specific Torque Specifications
Torque Value
Models Affected (Non-standard, see
Size Fastener In.-Lbs. Ft.-Lbs. General Torque Specification)
.31-24 Bolt, Gear to Crankshaft (Bolt 380-420 31.7-35.0 O-470, IO-470, TSIO-470, IO-520, 
Hardness RC 38-42) 1 L/TSIO-520, GTSIO-520, IO-550, IOF-550,
TSIO-550, TSIOF-550, & TSIOL-550
.31-24 Bolt, Face Gear to Crankshaft 140-150 11.7-12.5 IO-346, GTSIO-520, IO-520, TSIO-520
(AR), IO-550, IOF-550, TSIO-550, &
TSIOL-550
.31-24 Nut, Generator or Alternator 175-200 14.6-16.7 A, C & E Series, O-200, IO-240, O-300,
Gear GO-300, IO-360, & L/TSIO-360
.31-24 Nut, Generator Gear (531231) 175-195 14.6-16.3 E Series
w/washer (401507)
.38-24 Bolt, Vacuum & Fuel Pump 275-325 22.9-27.1 IO-240 & IOF-240
Gear to Camshaft
.38-24 Nut, Slick Mag Gear to 120-180 10.0-15.0 O-200 & O-300
Magneto Shaft
Connecting Rods
.38-24 Nut, Connecting Rod  400-475 33.3-39.6 A & C Series, O-200, O-240, IO-240, 
(nuts 24804 or 626140  IOF-240, O-300, GO-300, IO-360 & 
w/bolt P/N 530213)2, 3, 4 L/TSIO-360
.38-24 Nut, Connecting Rod  400-475 33.3-39.6 E-Series O-470, IO-470, with 654796
(Spiralock nut P/N 654487 Connecting Rod
w/bolt P/N 655960)
.38-24 Nut, Connecting Rod  400-475 33.3-39.6 E-185, E-205, E-225, IO-346, O-470
(nut P/N 626140 w/bolt P/N Numbered and Lettered Engines IO-470,
35972)2, 3, 5 TSIO-470, with 628751 Connecting Rod
.38-24 Nut, Connecting Rod 490-510 40.8-42.5 O-200, O-240, IO-240, IOF-240, O-300,
(Spiralock nut P/N 654487  IO-360, L/TSIO-360, O-470, IO-470, 
w/bolt P/N 654693)5 TSIO-470
.38-24 Nut, Connecting Rod 490-510 40.8-42.5 O-200, O-240, IO-240, IOF-240, O-300,
(Spiralock nut P/N 654487  IO-360, L/TSIO-360, O-470, IO-470, 
w/bolt P/N 655959) TSIO-470
.44-20 Nut, Connecting Rod 550-600 45.8-50.0 O-470, IO-470, IO-520, L/TSIO-520-AE &
(Spiralock nut P/N 643215  CE, IO-550, IOF-550, TSIO-550, 
w/bolt P/N 643112) TSIOF-550 & TSIOL-550
.44-20 Nut, Connecting Rod 690-710 57.5-59.2 O-470, IO-470, GTSIO-520, IO-520, 
(Spiralock nut P/N 654490  L/TSIO-520, IO-550, IOF-550, TSIO-550,
w/bolts P/N 643112 or P/N TSIOF-550 & TSIOL-550
655958)
.44-28 Nut, Connecting Rod 475-525 39.6-43.8 IO-346, O-470, IO-470, TSIO-470, IO-520
(rod P/N 646476 w/bolts & TSIO-520 (EXCEPT L/TSIO-520-AE &
P/N 629340 and nut 628109)2 CE)
.44-28 Nut, Connecting Rod 550-575 45.8-47.9 GTSIO-520
(rod P/N 646474 w/bolts
P/N 631794 and nut 631554) 2

B-8 Standard Practice Maintenance Manual

CHANGE 4 31 Jul 2017
 Maintenance Standards
C-2.4. Mandatory Overhaul Replacement Parts
In addition to the items listed in Section C-2.3, mandatory replacement parts must be
discarded and replaced with new parts during engine overhaul.
Table C-1. Mandatory Overhaul Replacement Parts
MANDATORY
REPLACEMENT
SPECIAL 100% AT ENGINE
REPLACEMENT ITEMS CONDITIONS REPLACEMENT OVERHAUL
Replace On
Accessories, Engine Mounted1 Condition X
Replace On
Air-conditioning Drive Belts X
Condition
Alternators
• Drive Belts Replace On X
• Rubber Drive Bushings Condition X
Baffles (see Engine Baffles) Repairable X
Bearings: connecting rod, crankshaft main and thrust, needle, ball, and roller X
Bushings: used in bearing applications (subject to wear) - reference disassembly/
X
assembly instructions
Camshaft Gears:
• Replace P/Ns 535934, or 535660, or 656037 (O470J, K, L, R, S, U; IO346A; Design X
IO470J, K) with 656913, or subsequent part number, at overhaul. Change
• Replace P/Ns 537432 or 656038 (O470G, GCI, M; IO470C, D, E, F, H, L, M, N, S; Design
TSIO470B, C, D; GTSIO520C, D, H, K, L, M, N, R) with 656914, or subsequent part X
Change
number, at overhaul.
• Replace P/Ns 631845, or 655516, or 656031 (IO470U, V; IO520A, B, BA, BB, C,
CB, D, E, F, J, K, L, M, MB, N, NB, P, R; LIO520P; L/TSIO520ALL; IO550A, B, C, D, Design X
E, F, G, L, N, P, R; IOF550ALL; TSIO550A, B, C, E; TSIOL550A, B, C), or 655430 Change
(IO550A, B, C, D, E, F, G, L, N) with P/N 656818 or subsequent part number)
Camshaft Gear Bolts X
Cold Start Primer Diverter Valves X
Inspection
Connecting Rods (must be inspected for serviceable condition during Overhaul) Required
• Connecting Rods (P/N 626119, 646320, and 646321 must be replaced with current Design X
part number)2 See Section 10-9.1 for engine applicability Change
• Connecting Rods (with beam widths less than 0.625 inches must be replaced with Design X
current part number)2 Change
• Connecting Rod Bolts X
• Connecting Rod Nuts X
Cotter Pins X
Counterweight
Design
• Counterweights (P/N 631810 must be replaced with P/N 652833)3 X X
Change
• Counterweight Pins X
• Retainer Plates X
• Retaining (Snap) Rings X
Crankcase Through Bolts X
Crankshaft Gears
• Crankshaft Gear (P/Ns 536421 or 653631 must be replaced with P/N 657175, or Design X
subsequent)3 Change
• Crankshaft Cluster Gear (P/Ns 641906 or 656272 must be replaced with P/N Design X
656072, or subsequent)4 Change
• Crankshaft Gear, large (P/N 656991 Rev B must be replaced with P/N 656991 Design X
Rev.C, or subsequent)5 Change
• Crankshaft Gear Bolts X

Standard Practice Maintenance Manual C-5

31 Jul 2017 CHANGE 4
Maintenance Standards
Table C-1. Mandatory Overhaul Replacement Parts
MANDATORY
REPLACEMENT
SPECIAL 100% AT ENGINE
REPLACEMENT ITEMS CONDITIONS REPLACEMENT OVERHAUL
Crankshaft Gears, continued
• Crankshaft Alternator Face Gear Bolts X
• Crankshaft Alternator Face Gear Lock Plates X
Cylinder Deck Stud Nuts and Through Bolt Nuts X
Engine Baffles (see Baffles) Repairable X
Replace On
Engine Mounted Accessories1 Condition X
Exhaust Nuts X
Exhaust Valves and Rotocoils X
FADEC X
• Electronic Control Units X
• Engine Low Voltage Harness (including EGT and CHT sensors) X
• Fuel Filter X
• Fuel Injectors X
• Fuel Pressure Sensors X
• Manifold Air Pressure Sensors X
• Oil Pressure Sensor, if equipped X
• Oil Temperature Sensor, if equipped X
• Signal Conditioner, if equipped X
• Speed Sensor X
• Turbine Inlet Temperature Sensor(s), if equipped X
Replace On
Filters, replaceable (air, oil, fuel, magneto), if equipped X
Condition
Flexible Baffle Seal X
Fuel Systems X
Fuel Pump Drive Coupling (P/N 631263 must be replaced with P/N 653359, or
subsequent part number)6 on all IO520B, BA, BB, C, CB, M, MB, N, NB; TSIO520B, BB, Design X
BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB; IO550A, B, C, G, N, P, R; Change
TSIO550A, B, C, E; TSIOL550A, B, C
Gaskets X
Hoses Replace On X
Condition
Hydraulic Lifters (tappets) X
Ignition System Harness X
Replace On
Intake Valves Condition
Lock Washers X
Magnetos X
• Magneto Rubber Drive Bushings X
“O” Rings X
Design
Oil Pump Gears (O-300, IO-360, TSIO-360 and LTSIO-360 Series)7 Change X
Oil Suction Screens (360 series P/Ns 649470, 649471, 652669, 652670 must be Design X
replaced with current part number)7 Change
Oil Suction Screens (C-125, C-145 and O-300 series P/N 633272 must be replaced with Design
X
current part number)7 Change
Packings X
Pistons X
• Pins X
• Rings X

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 Maintenance Standards

C-9. Gasket Maker® Application

Gasket Maker is an easily workable tacky gel which can be applied onto one side of a
flange surface from a tube and evenly spread.
WARNING
Apply Gasket Maker only as directed. The improper use of
sealants may cause engine malfunction or failure. Do not apply
any form of sealant to the crankcase cylinder deck, chamfer,
cylinder mounting flange, cylinder base O-ring, main bearing
bosses, or cylinder fastener threads. The use of RTV, silicone,
Gasket Maker or any other sealant on the areas listed above
during engine assembly will cause a loss of cylinder deck stud
or through-bolt torque. Subsequent loss of cylinder attachment
load, loss of main bearing crush and/or fretting of the
crankcase parting surfaces will occur. The result will be
cylinder separation, main bearing movement, oil starvation and
catastrophic engine failure. USE ONLY CLEAN 50 WEIGHT
AVIATION ENGINE OIL ON SURFACES LISTED.
1. Verify the surface where the sealant will be applied is clean and free of nicks, burrs,
oil, and grit.
2. For the engine nose seal, apply Part No. 653692 General Purpose Primer to prepare
the sealant surface before applying Gasket Maker at the engine nose seal area.
3. Apply and spread a thin, translucent coat of Part No. 646942 Gasket Maker (not to
exceed 0.010 inches in thickness) to the surface directly from the tube. For small
parts, use a polyester urethane sponge or a short nap roller saturated with Gasket
Maker to apply the sealant to the part.
4. Once Gasket Maker has been applied, evenly torque the assembly into place.
5. Wipe away excess sealant with chlorinated solvent.
6. To remove Gasket Maker from your hands, apply waterless mechanics hand soap
followed by soap and water.

Standard Practice Maintenance Manual C-23

15 April 2016
Maintenance Standards
C-10. Gasket Installation
WARNING
Apply Gasket Maker only as directed. The improper use of
sealants may cause engine malfunction or failure. Do not apply
any form of sealant to the crankcase cylinder deck, chamfer,
cylinder mounting flange, cylinder base O-ring, main bearing
bosses, or cylinder fastener threads. The use of RTV, silicone,
Gasket Maker or any other sealant on the areas listed above
during engine assembly will cause a loss of cylinder deck stud
or through-bolt torque. Subsequent loss of cylinder attachment
load, loss of main bearing crush and/or fretting of the
crankcase parting surfaces will occur. The result will be
cylinder separation, main bearing movement, oil starvation and
catastrophic engine failure. USE ONLY CLEAN 50 WEIGHT
AVIATION ENGINE OIL ON SURFACES LISTED.
Gaskets and components must be properly positioned with the
hardware torqued and safety wired, as required, during
assembly to prevent oil loss.
Install only new gaskets. If the gasket material is age-sensitive (package or gasket is
stamped with a date code), verify the use by date has not passed. Inspect each gasket for
brittleness, cracks, wrinkles, damage, or deformities prior to installation. Do not use a
gasket with obvious defects, even if new; replace with a new manufacturer-specified
gasket. Verify that gasket surfaces are clean and free of nicks, burrs, oil, and grit.
CAUTION: Do not install brittle, dirty, cracked, or wrinkled gaskets.
Never reuse a gasket removed during disassembly.
1. Apply a thin coat of Part No. 642188 Gasket Sealant to both sides of the gasket
unless otherwise specified.
2. Install the gasket, following the contour of the mating surface.
3. Install the assembly and evenly torque the hardware to Appendix B specifications to
prevent damage to the gasket.
4. Safety wire the hardware where indicated.
C-10.1. Crush Washer Installation
Crush washers are commonly used at spark plug and oil sump plug bosses. The copper
material is soft and readily conforms to the two mating surfaces to form a tight seal.
1. Crush washers are one-time use items. Discard the crush washer during disassembly
and obtain a new crush washer for re-assembly.
2. If the crush washer exhibits a split line on one side, install the split line toward the
non-moving surface to avoid distortion. For example, at the oil sump, install the split
line against the oil sump boss rather than the plug.
3. Torque the fastener to the value specified in Appendix B; over-torquing risks
stripped threads.

C-24 Standard Practice Maintenance Manual

CHANGE 4 31 Jul 2017