CONTINENTAL OVERHAUL MANUAL FOR AIRCRAFT …

1 CONTINENTALOVERHAUL MANUALFOR AIRCRAFT ENGINEMODELSC75, C85, C90 & O-2002 FOREWORDThis MANUAL is published for the guidance of all facilities engaged in operation, maintenance andoverhaul of four cylinder engines of the Teledyne CONTINENTAL C and 0-200 description is included in this MANUAL of the various models and special equipments of the series andphotographs selected to illustrate the major differences between models. The Table of Specificationsprovides more detailed information in regard to features and performance of the models. It should benoticed that such descriptive material is neither intended nor adequate to enable conversion of anymodel to another in instances in which such conversion is permissible. For detailed informationregarding application of parts and their interchangeability, refer to the Spare Parts Catalog.

2 For modeland series number conversion instructions, refer to the Teledyne CONTINENTAL Service Bulletin on maintenance instructions relative to accessories installed on Teledyne CONTINENTAL aircraftengines in our factory are reprinted herein by permission of the accessory manufacturers. Instructionsfor OVERHAUL of these accessories may be obtained direct from the manufacturers or through theirauthorized service descriptive and dimensional information and all instructions contained in this edition have beenrevised and extended to cover all four cylinder models of the Teledyne CONTINENTAL C Series in currentproduction. The parts catalog section is not included in this edition, since it is subject to frequentchange in MANUAL of this scope cannot be revised often enough to be kept up to date at all times, since it is ourpolicy to improve details of engine design in the interest of maximum safety and utility of our productswhenever the results of our continuous experimental and development program indicate the desirabilityof replacing the old with something even better.

3 For this reason we issue Service Bulletins to ourApproved Distributors to advise of important changes in parts, desirable inspections and precautionsfound necessary in operation and maintenance. These bulletins are available for reading at all TeledyneContinental Approved Service Stations. Those who need permanent copies of Service Bulletins mayobtain them by direct mail, as issued, from the factory Publications Department on an annualsubscription basis. A nominal charge is made to cover the cost of is suggested that a careful study of the text of this MANUAL will provide the reader with knowledge ofengine construction and of techniques for both operation and repair work which, if applied in practice,will promote safety in flight and long engine , in spite of the high quality of materials and the careful inspection and testing of these engines, anydefect is suspected, the question should be brought immediately to the attention of the nearestTeledyne CONTINENTAL Approved Service Station so that a diagnosis and any necessary correction maybe OF CONTENTSS ection& Para.

4 TitlePageIIntroduction..91-1 Model Designation..91-2 Definitions and Abbreviations..91-3 Measurement ..101-4 Cleanliness ..10II Table of Specifications..11 III General Description..163-1 Difference Between Model Groups..163-2 Significance of C Series DashNumbers and Letters..163-3 Model Conversions..163-4 Optional Equipment..173-5 Superseding Parts..173-6 Crankcase Construction..173-7 Crankshafts ..183-8 Nitrided Crankshafts..183-9 Crankshaft Gears..193-10 Connecting Rods..193-11 Camshafts ..193-12 Camshaft Gears ..193-13 Hydraulic Valve Lifters ..203-17 Pushrods and Housings..213-18 Piston Assemblies ..213-19 Cylinder Assemblies.

5 213-25 Crankcase Cover Assembly for-12, -14, -16 & 0-200 Models..223-26 Crankcase Cover Assembly for-8 Models. 23 3-27 Gear Train ..233-28 Carburetor Induction System..243-29 Oil Sumps..243-30 3-30 Ignition System ..243-36 Delco-Remy Starter..253-37 Prestolite Starter ..263-38 Generator and Drive..263-39 Side Mounted Fuel Pump..263-40 Duel Fuel Pump Equipment..263-41 Lubrication System..27IV Unpacking the engine ..294-1 Shipping Crates ..294-2 Method of Packing and Preservation..294-3 Removal of engine from Crate..304-4 Preparation for Installation..30V Storage of Engines ..315-1 General ..315-2 Flyable Storage ..315-3 Temporary Storage ..31 Section& Para. TitlePage5-4 Indefinite Storage ..325-5 Procedure For Return of A/C to Service.

6 335-6 Indefinite Storage Inspection..33VI Installation in Airplane & Removal..346-1 Mounting the engine ..346-2 Fuel Systems..386-3 Oil System ..386-4 Propeller Installation..386-5 engine Removal ..39 VII Operating Instruction..407-1 Procedure Preliminary to Starting..407-2 Starting Procedure..407-3 Warm-Up ..407-4 Ground Test ..407-5 Take-Off ..417-6 Climbing ..417-7 Level Flight ..4l7-8 Let-Down and Landing..427-9 Stopping the engine ..427-10 Lubricating Oil ..427-11 Viscosity..427-12 Oil Change Periods ..427-13 Oil Change Procedure..437-14 engine Fuel ..43 VIII engine Troubles and Service Repairs ..44IX Periodic Inspection and Maintenance..489-1 Daily Inspection.

7 489-2 First Fifty Hour Inspection..489-3 100-Hour Periodic Inspection..49X Adjustment and Minor Repair..5110-1 Carburetors..5110-7 Magnetos ..5310-18 Replacement of Ignition Cables..5710-24 Delco-Remy Starter..5910-30 Prestolite Starter..6010-38 Generator and Drive..6210-47 Hydraulic Valve Lifters..64XI Disassembly ..6711-1 Preliminary Operations..6711-10 Disassembly ..684 TABLE OF CONTENTS (Con t)Section& Para. TitlePageXII Cleaning ..7212-1 Materials and Processes..7212-6 Specific Parts ..72 XIII Inspection ..7413-1 Definitions ..7413-2 Inspection Tools ..7413-5 Inspection Methods ..7513-14 Inspection of Critical Parts..77 XIV Repair and Replacement..8114-1 General Repair.

8 8114-7 Repair and Replacement ofSpecific Parts ..8214-13A Crankcase Modification..8714-21 Protective Coatings..90XV Assembly of Subassemblies..9315-1 General Procedure..9315-4 Detailed Procedure ..93 Section& Para. Title .. PageXVI Final Assembly ..9716-1 General Procedure..9716-4 Detailed Procedure..97 XVII Testing after OVERHAUL ..10617-1 Testing Equipment ..10617-2 Test Stand ..10617-3 Instruments ..10617-4 Test Club ..10617-5 Test After OVERHAUL ..10617-6 Preservation..11117-7 Fuel and Lubricating Oil..11117-8 Testing Engines Installed in AIRCRAFT ..11117-9 Inspection ..111 XVIII Table of Limits ..114 LIST OF TABLESS ection& Para. TitlePageI Features Common to all Models..11II Type Certificate Numbers.

9 11 III Features Peculiar to EachModel Group ..11IV Dimensions Peculiar to Each Modelor Model Dash Number..11V Speed and Power Ratings..12VI Operating Temperature Limits..12 VII Operating Pressure Limits ..12 VIII Model or Model Dash NumberEquipment ..12IX General Ignition SystemSpecifications ..13X Ignition Timing ..13XI Valve Mechanism Specifications..13 XII Lubrication System Specifications..13 XIII Fuel Metering System Specifications ..14 Section& Para. TitlePageXIV Accessory Drive Speed Ratiosand Rotation ..14XV Line and Instrument Connections..14 XVI Weights of Standard EngineEquipment..15 XVII Additional Weights of OptionalEquipment ..15 XVIII Recommended Oil Viscosity Grades ..43 XIX Magnflux Inspection Data..77XX Stud Identification Chart..81 XXI Test Operating Limits..109 XXII Test Schedule.

10 110 XXIII Oil Sump Capacity ..111 XXIV General Use -Tightening Torques..118 XXV Pipe Plugs ..1185 LIST OF ILLUSTRATIONSF igure Left Side View, Model C85-12F ..62. Three-Quarter Right Rear View, Model C85-12 ..63. Three-Quarter Left Front View, Model C90-16F ..74. Three-Quarter Right Rear View, Model C90-16F ..75. Right Front View, Model C-90 ..86. Left Front View, Model O-200 ..87. Cylinder Arrangement Diagram (Top View) ..108. Section Through Hydraulic Valve Lifter ..209. Crankcase Cover and Accessories of -12, -14, -16 and O-200 Models..2210. Gear Train of -12,-14,-16 and O-200 Models ..2411. Hoisting engine by Crankshaft Lifting Eye ..2912. Typical Installation Diagram for -12,-14 & -16 Models, Side View ..3513. Installation Drawing for -12, -14 & -16 Models, Front View..3514. Installation Drawing for -12, -14 & -16 Models, Rear View.