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<ul><li><p>Publication X306072011 CONTINENTAL MOTORS, INC. AUG 2011</p><p>IO-550-DIO-550-EIO-550-FIO-550-L</p><p>CONTINENTAL AIRCRAFT ENGINE</p><p>SANDCAST SERIES ENGINE</p><p> OVERHAUL</p><p>MANUAL</p><p>TECHNICAL CONTENT ACCEPTED BY THE FAA </p></li><li><p>ii IO-550 Sandcast Series Engine Overhaul Manual31 August 2011</p><p>Supersedure Notice</p><p>This manual revision replaces the front cover and list of effective pages for Publication Part No. X30607, datedSeptember 1992. Previous editions are obsolete upon release of this manual.</p><p>Effective Changes for this Manual0 ..... September 19921 ...... 31 August 2011</p><p>List of Effective Pages</p><p>Document Title: IO-550 Sandcast Series Engine Overhaul ManualPublication Number: X30607 Initial Publication Date: September 1992Page Change Page Change Page Change Page ChangeCover.............. 1 70-50-01 thru 70-50-06.0 74-50-01 thru 74-50-02 0ii.................. 1 72-00-01 thru 72-00-16.0 75-00-01 thru 75-00-04 0iii thru xx ............ 0 72-10-01 thru 72-10-40.0 76-00-01 thru 76-00-26 01-00-01 thru 1-00-06 .. 0 72-20-01 thru 72-20-20 77-00-01 thru 77-00-04 01-10-01 thru 1-10-10 .. 0 72-30-01 thru 72-30-20.0 77-10-01 thru 77-10-02 01-20-01 thru 1-20-40 .. 0 72-40-01 thru 72-40-18.0 77-20-01 thru 77-20-06 01-30-01 thru 1-30-04 .. 0 72-50-01 thru 72-50-20.0 78-00-01 thru 78-00-04 04-00-01 thru 4-00-04 .. 0 72-60-01 thru 72-60-22.0 79-00-01 thru 79-00-04 05-00-01 thru 5-00-04 .. 0 72-70-01 thru 72-70-10.0 79-10-01 thru 79-10-02 05-10-01 thru 5-10-02 .. 0 72-80-01 thru 72-80-06.0 79-20-01 thru 79-20-02 05-20-01 thru 5-20-04 .. 0 73-00-01 thru 73-00-03.0 80-00-01 thru 80-00-09 05-30-01 thru 5-30-02 .. 0 73-10-01 thru 73-10-04.0 80-10-00 thru 80-10-04 070-00-01 thru 70-00-04 0 74-00-01 thru 74-00-03.0 80-20-01 thru 80-20-04 070-10-01 thru 70-10-02 0 74-10-00 thru 74-10-01.0 81-00-01 thru 81-00-02 070-20-01 thru 70-20-02 0 74-20-00 thru 74-20-01.070-30-01 thru 70-30-02 0 74-30-00 ............070-40-01 thru 70-40-02 0 74-40-01 thru 74-40-02.0</p><p>Published and printed in the U.S.A. by Continental Motors, Inc.</p><p>Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601</p><p>Copyright 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwisealtered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher willnot be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content issubject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.</p></li><li><p>WARNING (Please note the following statements from FAA Advisory Circular 20-62C entitled 'ELIGIBILITY, QUALITY, AND IDENTIFICATION OF APPROVED REPLACEMENT PARTS'): </p><p>3. BACKG ROUND. An increasing amount of replacement parts (including standard parts), materials, appliances, and instruments are offered for sale as being of aircraft quality when actually the quality and origin of these units are unknown. Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use on certificated aircraft. Frequently such units are deceptively advertised or presented as 'unused,' 'like new,' or 'remanufactured.' This implies that the quality of such units is equal to an original or appropriately repaired or overhauled unit. </p><p>The performance rules for replacement of parts and materials used in the maintenance and alteration of U.S. certificated aircraft are specified in Federal Aviation Regulations (FAR) 43.13 and FAR 145.57. The responsibility for the continued airworthiness of the aircraft, which includes the replacement of parts, is the responsibility of the owner/operator as outlined in FAR 91.163, FAR 121.363, FAR 123.45, FAR 127.131 and FAR 135.143 (a). </p><p>4. IDENTIFICATION OF THE APPROVED PARTS. Approved serviceable replacement parts are identified as follows: </p><p>a. By an FAA Form 8130-3 (Formerly FAA Form 186), Airworthiness Approval Tag. An Airworthiness Approval Tag identifies a part or group of parts that have been approved by authorized FAA representatives. </p><p>b. By an FAA Technical Standard Order (TSO) number and identification mark that indicates the part or appliance has been manufactured under the requirements of FAR 37. </p><p>c. By an FAAIPMA symbol, together with the manufacturer's name, trademark or symbol, part number, and the make and model of the type certificated product on which the part is eligible for installation, stamped on the part. An FAA Parts Manufacturer Approval (FAAIPMA) is issued under FAR 21.305. The make and model information may be on a tag attached to the part. </p><p>d. By shipping ticket, invoice, or other document which provides evidence that the part was produced by a manufacturer holding an FAA Approved Production Inspection System issued under FAR 21, Subpart F, or by a manufacturer holding an FAA Production Certificate issued under FAR 21 , Subpart G. </p><p>e. By a certificate of airworthiness for export issued by a foreign govemment under the provisions of FAR 21, Subpart N. </p><p>11. KNOW YOUR SUPPLIER. It has come to our attention that many reproduced parts and components, particularly instruments which have been manufactured by persons other than the original manufacturer, are available for purchase and installation on U.S. certificated aircraft. Often, an original part is used as a sample to produce duplicates. The reproduced parts appear to be as good as the original part; however, there are many unknown factors to be considered that may not be readily apparent to the purchaser, i.e., heat treating, plating, inspections, tests and calibrations. All too often the faulty part is not discovered until a malfunction or an accident occurs. </p><p>12. SUMMARY. In accordance with FAR's, certification of materials, parts, and appliances for return to service, for use on aircraft, Is the responsibility of the person or agency who signs the approval. The owner/operator, as denoted in paragraph 3 of this adviSOry circular, is responsible for the continued airworthiness of the aircraft. To assure continued safety in aircraft operation, it is essential that great care be used when inspecting, testing, and determining the acceptability of all parts and materials. Particular caution should be exercised when the identity of materials, parts, and appliances cannot be established or when their origin is in doubt. </p><p>III </p></li><li><p>iv </p><p>OVERHAUL MANUAL FOR </p><p>10-550 SANDCAST SERIES AIRCRAFT ENGINE </p><p> NOTICE-</p><p>The overhauler must comply with all the instructions contained in this manual in order to assure safe and reliable engine performance. Failure to comply will be deemed misuse, thereby relieving the engine manufacturer of responsibility under its warranty. </p><p>This manual contains no warranties, either expressed or implied. The information and procedures contained herein provide the overhauler with technical information and instructions applicable to proper overhaul procedures. </p><p>Prior to overhaul, the mechanic must meet requirements of Federal Aviation Regulation 65 and must follow FAR parts 43, 91, and 145, as applicable. This manual must be used in conjunction </p><p>. with the FAA Advisory Circular 43-13-1A, Acceptable Methods, Techniques and Practices-Aircraft Inspection and Repair, as well as Teledyne Continental Motors' 10-550 Series Parts Catalog X30606A. </p><p>CHAPTER </p><p>1 - Introduction 4- Airworthiness Limitations 5- Time Umits/Maintenance Checks 70 - Standard Practices 72 - Engine Reciprocating 73 - Engine Fuel System 74 - Ignition 75 - Air 76 - Engine Controls 77 - Engine Indicating 78 - Exhaust 79 - Oil 80 - Starting </p></li><li><p>INTRODUCTION </p><p>This Teledyne Continental Motors Overhaul Manual is prepared in accordance with the GAMA (General Aviation Manufacturers Association) format. The manual is divided into groups which enable a broad separation of contents, (Chapters) within each group. The chapters are broken down into major systems, Engine - Reciprocating, Exhaust, Starting, etc. The System Chapters are arranged numerically. All System Chapters are assigned a number which becomes the first element of a standardized numbering system. The element '72' of the number series 72-00-00 refers to the System Chapter on 'Engine Reciprocating.' All information pertaining to the engine will be covered in this System Chapter. </p><p>The major System Chapters are then broken down into Sub-System Sections. These sections are identified by the second element of the standardized numbering system. The number '1 0' of the basic number series '72-10-00' is for the 'disassembly' of the engine. </p><p>The Subsection is the third element of the standardized numbering system '72-10-12.' This number is the final breakdown of the Chapter. Number '12' is for 'Starter and Starter Drive Adapter,' that is 'Disassembled' from the 'Engine.' </p><p>EXAMPLE: </p><p>- Chapter - - Section - - Subsection -'Engine Reciprocating' 'Disassembly' 'Starter and Starter Drive Adapter' </p><p>il.-______ 72 - 110 12 ______ --1J </p><p>In producing this publication, considerable effort has been put forth to provide grammatically clear and accurate information. Teledyne Continental Motors solicits the users assistance in providing information for review on changes that the user may suggest. </p><p>v </p></li><li><p>vi </p><p>TABLE OF CONTENTS </p><p>Section Page </p><p>ii Current Status of Pages ................ ii iii Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii iv Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv v Introduction .................... v vi Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi xiv List of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv xix List of Charts ................... xix </p><p>CHAPTER 1 INTRODUCTION </p><p>1-00-00 SCOPE................... 1-00-03 1-00-01 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-00-03 1-00-02 Service Bulletins .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-00-04 1-00-03 Service Reports And Inquiries . . . . . . . . . . . . . . . . . . . . . . . . 1-00-04 1-00-04 100% Replacement Parts ............. 1-00-05 </p><p>1-10-00 DEFINITIONS &amp; ABBREVIATIONS ........... 1-10-01 1-10-01 Abbreviation / Symbols .............. 1-10-01 1-10-02 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10-02 1-10-03 Description Of Engine Model Code ....... . . . . . . . . 1-10-06 1-10-04 Basic Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10-07 </p><p>1-20-00 TOOLS................... 1-20-01 1-20-01 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20-01 </p><p>1-30-00 APPLICATION CHART SEALANTS/LUBRICANTS ....... 1-30-01 1-30-01 Product List ................. 1-30-01 </p><p>CHAPTER 4 AIRWORTHINESS LIMITATIONS </p><p>4-00-00 AIRWORTHINESS LIMITATIONS ............ 4-00-01 </p><p>CHAPTER 5 TIME LIMITS/MAINTENANCE </p><p>CHECK </p><p>5-00-00 GENERAL .................. 5-00-03 5-10-00 TIME LIMITS/INSPECTION PROGRAM . . . . . . . . . . . . . . . . . . . . 5-10-01 5-20-00 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 5-20-01 5-20-01 Preflight Inspection ............... 5-20-01 5-20-02 50 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20-01 5-20-03 100 Hour Inspection .............. 5-20-01 5-30-00 UNSCHEDULED MAINTENANCE ............ 5-30-01 </p></li><li><p>TABLE OF CONTENTS (Cont'd) Section </p><p>CHAPTER 70 STANDARD PRACTICES </p><p>70-00-00 GENERAL .................. 70-00-03 70-10-00 LOCKWIRE PROCEDURE ............. 70-10-01 70-20-00 CRANKCASE SEALANT AND THREADING PROCEDURE ..... 70-20-01 70-30-00 APPLICATION OF ADHESIVES ............ 70-30-01 70-40-00 INSTALLATION OF GASKETS ............ 70-40-01 70-50-00 CYLINDER LEAKAGE CHECK ............ 70-50-01 70-50-01 Leakage Checks ............... 70-50-02 70-50-02 Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-02 70-50-03 Performing The Check .............. 70-50-03 70-50-04 Dynamic Seal Check .............. 70-50-05 </p><p>72-00-00 72-00-01 72-00-02 72-00-03 72-00-04 72-00-05 72-00-06 72-00-07 72-00-08 72-00-09 72-00-10 72-00-11 72-00-12 72-00-13 72-00-14 </p><p>CHAPTER 72 ENGINE RECIPROCATING </p><p>GENERAL ................. . 72-00-03 Introduction ................. 72-00-06 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-06 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-06 Connecting Rods ............... 72-00-07 Camshaft ................. 72-00-08 Pistons' .................. 72-00-08 Hydraulic Valve Tappets ............. 72-00-08 Cylinders ................. 72-00-08 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-09 Lubrication System ............... 72-00-11 Valve Mechanism ............... 72-00-13 Induction System ............... 72-00-13 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-14 Ignition System ................ 72-00-14 </p><p>CHAPTER 7210 DISASSEMBL Y </p><p>72-10-00 GENERAL .................. 72-10-03 72-10-01 72-10-02 72-10-03 72-10-04 72-10-05A 72-10-058 72-10-06A 72-10-068 72-10-06C 72-10-07 72-10-08A </p><p>Engine Removal Instructions ............ 72-10-03 Extent of Disassembly .............. 72-10-04 Parts to be Discarded .............. 72-10-04 Preliminary Cleaning .............. 72-10-04 Ignition System (10-550-D,E &amp; L) ........... 72-10-04 Ignition System 10-550-F) ............. 72-10-06 Fuel Injection System (10-550-D) ........... 72-10-08 Fuel Injection System (10-550-E) ........... 72-10-10 Fuel Injection System (10-550-F &amp; L) .......... 72-10-12 Magneto and Accessory Drives . . . . . . . . . . . . . . . . . . . . . . . 72-10-14 Induction System (10-550-D) ............ 72-10-14 </p><p>vii </p></li><li><p>viii </p><p>TABLE OF CONTENTS (Cont'd) Section </p><p>72-10-088 Induction System (10-550-E). . . . . . . . . . . . . . . . . . . . . . . 72-10-16 72-10-08C Induction System (10-550-F &amp; L) ........... 72-10-18 72-10-09A Oil Sump (10-550-D,E &amp; F) ............ 72-10-20 72-10-098 Oil Sump (10-550-L) . . . . . . . . . . . . . . . . . . . . . . . . . . 72-10-21 72-10-10 Oil Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . ..</p></li></ul>