Description
Continental IO-550 A B C G N P R Permold Series Engine Maintenance and Overhaul Manual M-16 (2011)
This is the complete Continental IO-550 A B C G N P R Permold Series Engine Maintenance and Overhaul Manual M-16, the 2011 edition published by Continental Motors, Inc. It provides maintenance and overhaul instructions for the IO-550-A, IO-550-B, IO-550-C, IO-550-G, IO-550-N, IO-550-P, and IO-550-R aircraft engines built with the Permold crankcase design. Whether you are performing a routine inspection, troubleshooting a fuel injection issue, or conducting a full engine overhaul, this Continental IO-550 manual delivers the manufacturer’s procedures, service limits, and dimensional specifications in a single PDF.
File Details
- Manual Type: Maintenance and Overhaul Manual
- Brand: Continental Motors
- Engine Series: IO-550 Permold Series
- Models Covered: IO-550-A, IO-550-B, IO-550-C, IO-550-G, IO-550-N, IO-550-P, IO-550-R
- Publication Number: M-16
- Publication Date: 31 August 2011
- Language: English
- Page Count: 824
- File Format: PDF
Chapters Covered in the Continental IO-550 Permold Series Manual M-16
- Chapter 1: Introduction — Scope and purpose, effectivity symbols, advisories, compliance, order of precedence, publications, contact information
- Chapter 2: Engine Description — General engine description, model number definition, cylinder number designations, detailed engine description including crankcase, engine drive train, crankshaft, connecting rods, camshaft, idler gear, cylinders, pistons, hydraulic valve tappets, lubrication system, oil pump, oil sumps, oil cooler and temperature control valve, fuel system, fuel pump, fuel injectors, starter assembly, alternator, ignition system, engine cooling, induction system, exhaust system, specifications, and performance data
- Chapter 3: Special Tools and Supplies — Special tools list, vendor contact information, mechanic’s tools, lubricants, sealants, adhesives, engine oil specifications, oil change intervals, additives
- Chapter 4: Airworthiness Limitations — Mandatory replacement times, mandatory inspection intervals, other related procedures, distribution of changes
- Chapter 5: Engine Removal and Installation — Engine removal, engine installation, materials required, engine receipt and handling, uncrating, crating for shipping, acceptance inspection, engine transport, installation procedures, pre-oiling methods, fuel injection system purge, installation inspection, preflight and run-up, engine installation drawings for all models
- Chapter 6: Engine Inspection and Service — Inspection program introduction, inspection and maintenance schedule, scheduled inspections including 25-hour, 50-hour, 100-hour, 500-hour inspections, visual inspection, engine operational check, oil pump operational check, fuel system operational check, magneto RPM drop check, engine shutdown, engine oil servicing, oil change, oil sample collection, oil trend monitoring, ignition system maintenance, magneto timing, spark plug maintenance, ignition harness maintenance, engine adjustments, oil pressure adjustment, fuel system adjustment, auto leaning schedule adjustments, belt tension check, cylinder inspections including visual, differential pressure test, borescope inspection, crankcase inspection, engine mount inspection, induction system inspection, ignition system inspection, engine gauge inspection, fuel system inspection, engine control linkage inspection, induction or cylinder drain inspection, exhaust system inspection, alternator inspection, unscheduled maintenance including propeller strike, hydraulic lock, overspeed inspections, lightning strike, contaminated fuel system, foreign object contamination, inspection checklists
- Chapter 7: Engine Operation — Flight prerequisites, oil change interval, engine fuel requirements, flight check and break-in, engine break-in, standard fuel system flight check, altitude compensating fuel system flight check, flight check limits, normal operation, pre-operational requirements, engine start, cold start, flooded engine, hot start, ground run-up, engine shutdown, engine operation in abnormal environments, extreme cold, engine preheating, hot weather, high density altitude
- Chapter 8: Troubleshooting — General troubleshooting, engine runs rough, engine will not run, engine indication malfunctions, engine performance malfunctions, induction system, fuel injection system, fuel injector operational check, charging system, starting system, ignition system, ignition harness and spark plug diagnostics, lubrication system, engine cylinders, crankcase, excess crankcase pressure, exhaust system
- Chapter 9: Engine Preservation and Storage — Preserving and storing an engine, preservation checklist, new or unused engine storage, temporary storage, indefinite storage, return an engine to service after storage
- Chapter 10: Non-Overhaul Repair and Replacement — Parts replacement, fuel pump replacement, fuel injector replacement, nozzle identification, starter motor and adapter replacement, alternator replacement, direct drive alternator removal and installation, belt driven alternator removal and installation, magneto replacement, lubrication system repair, oil filter adapter stud replacement, oil pump repair, oil sump and suction tube repair, oil cooler repair, oil pressure relief valve repair, oil temperature control valve inspection, engine cylinder maintenance, rocker arm removal, hydraulic tappet removal, cylinder removal and installation, cylinder torque, hydraulic tappet installation, rocker arm installation, crankshaft nose oil seal replacement, crankcase repair, exhaust system repairs, engine preservation and storage
- Chapter 11: Engine Overhaul Introduction — Engine overhaul, overhaul schedule, overhaul sequence, overhaul checklists including engine removal and disassembly checklist, engine overhaul visual inspection checklist, fluorescent penetrant inspection checklist, magnetic particle inspection checklist, ultrasonic inspection checklist, dimensional inspection checklist, engine cylinder overhaul inspection checklist, engine drive train inspection checklist, replacement parts inventory
- Chapter 12: Engine Disassembly — Engine disassembly sequence, ignition system removal and disassembly, accessory drive adapter removal, fuel injection system removal for all models, induction system removal for all models, exhaust system removal, oil cooler removal, oil pump removal, alternator removal, compressor mounting assembly removal, starter and adapter removal, oil sump removal for all models, engine cylinder removal for all models, inter-cylinder baffle removal, engine mount removal
- Chapter 13: Component Disassembly — Ignition system, fuel injection system, starter and adapter disassembly, basic starter and starter adapter disassembly, starter adapter with accessory drive disassembly, engine cylinder disassembly for all models, accessory drive pad disassembly, crankcase disassembly, crankcase studding disassembly, engine drive train disassembly, camshaft disassembly, crankshaft disassembly, compressor mounting kit disassembly
- Chapter 14: Engine Cleaning — Engine and component cleaning, cylinder cleaning, piston cleaning, cleaning exhaust parts, cleaning aluminum alloy parts, dry blasting, vapor blasting, protective coatings, alodine, aviation oil, paint
- Chapter 15: Overhaul Inspection and Repair — Engine overhaul inspection, engine overhaul inspection checklists, visual inspection, gear tooth inspection, fluorescent penetrant inspection, magnetic particle inspection, connecting rod magnetic particle inspection, ultrasonic inspections, ultrasonic inspection certification, crankshaft ultrasonic inspection, dimensional inspection, crankcase dimensional inspection, drive train dimensional inspection, connecting rod dimensional inspection, crankshaft counterweight inspection, engine cylinder dimensional inspection, starter adapter dimensional inspection, lubrication system dimensional inspection, alternator drive hub slippage inspection, throttle and mixture control lever inspection, exhaust system inspection, accessory drive adapter dimensional inspection, stud height dimensional inspection, freon compressor dimensional inspection, overhaul repair including fuel injection system, induction system, freon compressor mount, alternator overhaul, starter and starter adapter overhaul repair, ignition system overhaul, accessory drive adapter overhaul, exhaust system overhaul repair, lubrication system overhaul, oil cooler overhaul repair, oil pressure relief valve seat repair, oil filter adapter stud replacement, tachometer drive assembly replacement, engine cylinder overhaul repair, cylinder repair versus replacement guidelines, engine overhaul replacement parts, rocker shaft retention modification, new cylinder position numbers, cylinder head repair, cylinder fin tip repair, cylinder barrel repair, cylinder bore honing, valve seat removal and installation, valve guide removal and installation, valve guide bore reaming, valve seat machining, spark plug helical coil insert replacement, cylinder stud installation, piston ring replacement, cylinder protective coatings, rocker arm bushing replacement, rocker arm to retainer clearance, inter-cylinder baffle repair, crankcase overhaul repair, camshaft gear replacement, crankcase line boring, crankcase machining, crankcase welding, oil filler overhaul repair, crankcase cylinder deck stud helical coil installation, crankcase cylinder deck stud replacement, engine drive train overhaul, camshaft repair, crankshaft repair, oil control plug replacement, crankshaft counterweight bushing replacement, crankshaft hanger blade bushing replacement, crankshaft plating overhaul, connecting rod piston pin bushing replacement, piston pin bushing boring, connecting rod replacement
- Chapter 16: Component Assembly — Fuel injection system, fuel injector nozzles, alternator assembly, starter and starter adapter assembly, starter and starter adapter with scavenge pump assembly, basic starter and starter adapter assembly, exhaust system assembly, lubrication system assembly, oil pump assembly, basic oil pump assembly, oil pump assembly with mechanical tach drive adapter, oil pump with electric tach drive adapter assembly, oil cooler assembly, engine cylinder assembly, cylinder component preparation, cylinder baffle installation, piston ring gap adjustment, valve train installation, cylinder component assembly, crankcase assembly, oil filler installation, engine mount installation, engine drive train assembly, camshaft assembly, crankshaft assembly, connecting rod and bearing assembly, crankshaft nose oil seal assembly, compressor mounting kit assembly
- Chapter 17: Engine Assembly — Engine assembly sequence, component lubrication, crankcase assembly, drive train installation, crankcase hardware installation for all models, cylinder installation for all models, cylinder and crankcase torque, crankcase miscellaneous hardware installation, hydraulic valve tappet and pushrod installation for all models, rocker arm installation for all models, inter-cylinder baffle installation, oil sump and suction tube installation for all models, oil pump installation, accessory drive pad installation, starter and starter adapter installation, oil cooler installation for all models, alternator installation, direct drive alternator installation, optional belt driven alternator installation, induction system installation for all models, fuel injection system installation for all models, ignition system installation, Continental ignition system installation, Champion (Slick) ignition system installation, compressor mount installation
- Chapter 18: Post-Overhaul Test and Adjustments — Introduction, post-overhaul testing prerequisites, post-overhaul test operating limits, standard acceptance test, oil consumption test, drive belt tension check
- Appendix A: Glossary — Acronyms and definitions of terms used throughout the manual
- Appendix B: Torque Specifications — General information, torque tips, cylinder torque procedure, torque wrench and extension calculations, general torque specifications, tube fitting torque, hose fitting torque, component specific torque, specific torque for non-lubricated hardware
- Appendix C: Standard Practices — Handling parts, replacement parts, background, acceptable replacement parts, know your supplier, 100% parts replacement requirements, mandatory overhaul replacement parts, authorized oversize/undersize parts, torque, safety wiring hardware, tab washer installation, helical coil insert replacement, stud replacement, cotter pin installation, fuel system service, fuel system purge, gasket maker application, gasket installation, hose and tubing installation, harness routing
- Appendix D: Overhaul Dimensional Limits — Fuel injection system, starter and starter adapter, ignition system, lubrication system, engine cylinder overhaul dimensions, crankcase, engine drive train, crankshaft counterweight assemblies, counterweight pins, crankshaft hanger blade and counterweight bushing dimensions, connecting rod dimensions, stud height settings, crankcase plugs and fittings, crankcase stud height settings
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Continental IO-550 A B C G N P R Permold Series Engine Maintenance and Overhaul Manual M-16 2011” are as follows:
+Chapter 1 . Introductionp. 35
+1-1. Scope and Purpose of This Manualp. 35
1-1.1. Effectivity Symbolsp. 35
1-1.2. Advisoriesp. 36
+1-1.3. Using this Manualp. 36
Figure 1-1. Figure and Index Referencep. 37
1-1.4. Compliancep. 37
1-1.5. Order of Precedencep. 38
+1-2. Publicationsp. 39
1-2.1. Service Documentsp. 39
+1-2.2. Related Publicationsp. 40
Table 1-1. Related Publicationsp. 40
1-2.3. Publication Accessp. 41
+1-2.4. Publication Changesp. 41
+1-2.4.1. Update/Change Distributionp. 41
Figure 1-2. Change Page Identificationp. 42
Figure 1-3. List of Effective Pagesp. 43
1-2.4.2. Suggestions and Correctionsp. 43
1-3. Contact Informationp. 44
+Chapter 2 . Engine Descriptionp. 45
+2-1. General Engine Descriptionp. 45
+2-1.1. Engine Model Number Definitionp. 46
Figure 2-1. Engine Model Definitionp. 46
+2-1.2. Cylinder Number Designationsp. 46
Figure 2-2. Cylinder Number Designationp. 46
+2-2. Detailed Engine Descriptionp. 47
+2-2.1. Crankcasep. 47
Figure 2-3. Permold Crankcase Featuresp. 47
+2-2.2. Engine Drive Trainp. 48
Figure 2-4. Engine Drive Trainp. 48
+2-2.2.1. Crankshaftp. 49
Figure 2-5. Crankshaftp. 49
+2-2.2.2. Connecting Rodsp. 49
Figure 2-6. Connecting Rodp. 50
+2-2.2.3. Camshaftp. 50
Figure 2-7. Camshaftp. 50
2-2.2.4. Idler Gearp. 51
+2-2.3. Cylindersp. 51
2-2.3.1. Updraft Cylinder Designp. 51
+2-2.3.2. Cross-flow Cylinder Designp. 51
Figure 2-8. Updraft Cylinder Featuresp. 52
Figure 2-9. Crossflow Cylinder Featuresp. 52
+2-2.3.3. Pistonsp. 53
Figure 2-10. Piston Featuresp. 53
2-2.3.4. Hydraulic Valve Tappetsp. 53
+2-2.4. Lubrication Systemp. 53
Figure 2-11. Lubrication Schematicp. 54
+2-2.4.1. Oil Pumpp. 54
Figure 2-12. Oil Pumpp. 55
2-2.4.2. Oil Sumpsp. 55
+2-2.4.3. Oil Cooler and Oil Temperature Control Valvep. 56
Figure 2-13. Oil Coolerp. 56
+2-2.5. Fuel Systemp. 57
Figure 2-14. IO-550-G, N, P & R Fuel System Schematicp. 57
Figure 2-15. Altitude Compensating Fuel System Schematicp. 57
+2-2.5.1. Fuel Pumpp. 57
Table 2-1. Standard Fuel Pump Featuresp. 58
Figure 2-16. IO-550-A, B & C Standard Fuel Pumpp. 58
Figure 2-17. IO-550-G, N, P & R Standard Fuel Pumpp. 58
Table 2-2. Altitude Compensating Fuel Pump Featuresp. 59
Figure 2-18. IO-550-A&C Altitude Compensating Fuel Pumpp. 59
Figure 2-19. IO-550-B Altitude Compensating Fuel Pumpp. 59
+2-2.5.2. Fuel Injectorsp. 60
Figure 2-20. IO-550-A, B & C Fuel Injector Nozzlep. 60
Figure 2-21. IO-550-G, N, P & R Fuel Injector Nozzlep. 60
+2-2.6. Starter Assemblyp. 61
Figure 2-22. Starting Systemp. 61
2-2.7. Alternatorp. 61
+2-2.8. Ignition Systemp. 62
Figure 2-23. Continental Motors Magneto Part Number Definitionp. 62
Figure 2-24. Continental Motors Ignition System Schematicp. 63
Figure 2-25. Slick Ignition System Schematicp. 63
+2-2.9. Engine Coolingp. 64
Figure 2-26. Engine Coolingp. 64
+2-2.10. Induction Systemp. 64
Figure 2-27. Typical Updraft Induction Systemp. 65
Figure 2-28. Typical Cross-flow Induction Systemp. 65
2-2.11. Exhaust Systemp. 66
+2-3. Engine Specificationsp. 66
+2-3.1. IO-550-A Specificationsp. 66
Table 2-3. IO-550-A Specificationsp. 66
+2-3.2. IO-550-B Specificationsp. 68
Table 2-4. IO-550-B Specificationsp. 68
+2-3.3. IO-550-C Specificationsp. 70
Table 2-5. IO-550-C Specificationsp. 70
+2-3.4. IO-550-G Specificationsp. 72
Table 2-6. IO-550-G Specificationsp. 72
+2-3.5. IO-550-N Specificationsp. 74
Table 2-7. IO-550-N Specificationsp. 74
+2-3.6. IO-550-P Specificationsp. 76
Table 2-8. IO-550-P Specificationsp. 76
+2-3.7. IO-550-R Specificationsp. 78
Table 2-9. IO-550-R Specificationsp. 78
+2-3.8. IO-550-Accessory Drive Ratiosp. 80
Table 2-10. Accessory Drive Ratiosp. 80
2-3.8.1. Accessory Drive Padp. 80
2-3.9. Oil Specificationsp. 80
+2-3.10. Performance Datap. 81
+2-3.10.1. IO-550-A Performance Chartsp. 82
Figure 2-29. IO-550-A Fuel Flow vs. Brake Horsepowerp. 82
Figure 2-30. IO-550-A Sea Level Performancep. 83
+2-3.10.2. IO-550-B Performance Chartsp. 84
Figure 2-31. IO-550-B Fuel Flow vs. Brake Horsepowerp. 84
Figure 2-32. IO-550-B Sea Level Performancep. 85
+2-3.10.3. IO-550-C Performance Chartsp. 86
Figure 2-33. IO-550-C Fuel Flow vs. Brake Horsepowerp. 86
Figure 2-34. IO-550-C Sea Level Performancep. 87
+2-3.10.4. IO-550-G Performance Chartsp. 88
Figure 2-35. IO-550-G Fuel Flow vs. Brake Horsepowerp. 88
Figure 2-36. IO-550-G Sea Level Performancep. 89
+2-3.10.5. IO-550-N, P & R Performance Chartsp. 90
Figure 2-37. IO-550-N, P & R Fuel Flow vs. Brake Horsepowerp. 90
Figure 2-38. IO-550-N, P & R Sea Level Performancep. 91
+Chapter 3 . Special Tools and Suppliesp. 93
+3-1. Special Toolsp. 93
Table 3-1. Special Tools Listp. 93
+3-1.1. Vendor Contact Informationp. 99
Table 3-2. Tool, Accessory and Supply Vendorsp. 99
Figure 3-1. Model E2M Differential Pressure Tester (built in Master Orifice Tool)p. 101
Figure 3-2. Borescope (Autoscope®)p. 101
Figure 3-3. Pulley Alignment Toolp. 102
Figure 3-4. Model 20 ATM-C Porta-Test Unitp. 102
Figure 3-5. Alternator Drive Hub Torque Toolp. 103
Figure 3-6. Worm Shaft Tool and Starter Adapter Disassembly Toolp. 104
Figure 3-7. Oil Control Plug Installation Toolp. 104
Figure 3-8. Oil Control Plug Leak Test Fixturep. 105
Figure 3-9. Needle Bearing Installation Tool -Part 1p. 106
Figure 3-10. Needle Bearing Installation Tool -Part 2p. 107
Figure 3-11. Bearing Installation Toolp. 108
Figure 3-12. Crankcase Needle Bearing Installation Toolp. 108
Figure 3-13. Valve Guide Seal Installation Toolp. 109
Figure 3-14. O-Ring Installation Toolp. 109
Figure 3-15. Oil Seal Toolp. 110
Figure 3-16. Helical Coil Extraction Toolp. 110
Figure 3-17. Helical Coil Insertion Toolp. 111
Figure 3-18. Helical Coil Expanding Toolp. 111
Figure 3-19. Rosan® Stud Removal Toolp. 112
Figure 3-20. Rosan Stud Removal Tool Installed on Studp. 112
3-1.2. Mechanic’s Toolsp. 113
+3-2. Lubricants, Sealants and Adhesivesp. 114
+3-2.1. Engine Oil Specificationsp. 114
Table 3-3. Qualified SAE J-1899 Ashless Dispersant Engine Oilp. 115
Table 3-4. Break-in Oilp. 115
Table 3-5. Preservative Oilp. 115
3-2.2. Oil Change Intervalsp. 116
+3-2.3. Additivesp. 116
Table 3-6. Lubricantsp. 117
Table 3-7. Sealantsp. 118
Table 3-8. Adhesivesp. 119
Table 3-9. Miscellaneousp. 120
+Chapter 4 . Airworthiness Limitationsp. 121
4-1. Mandatory Replacement Timesp. 121
4-2. Mandatory Inspection Intervalsp. 121
4-3. Other Related Proceduresp. 121
4-4. Distribution of Changes to Airworthiness Limitationsp. 121
+Chapter 5 . Engine Removal and Installationp. 123
5-1. Engine Removalp. 123
+5-2. Engine Installationp. 125
5-2.1. Materials Requiredp. 125
+5-2.2. Engine Receipt and Handlingp. 125
5-2.2.1. Uncrating the Enginep. 126
5-2.2.2. Crating an Engine for Shippingp. 126
5-2.2.3. Acceptance Inspectionp. 126
5-2.2.4. Engine Transportp. 127
+5-3. Installation Proceduresp. 128
5-3.1. Prepare the Airframe for Engine Installationp. 128
5-3.2. Prepare the Engine for Installationp. 128
5-3.3. Installation Sequencep. 130
+5-3.4. Engine Pre-oilingp. 131
5-3.4.1. Pre-oiling Method 1p. 131
5-3.4.2. Pre-oiling Method 2p. 132
5-3.5. Fuel Injection System Purgep. 132
5-3.6. Installation Inspectionp. 133
5-3.7. Preflight and Run-upp. 134
+5-4. Engine Installation Drawingsp. 135
+5-4.1. IO-550 Common Installation Drawingsp. 135
Figure 5-1. Exhaust Port Dimensionsp. 135
Figure 5-2. Propeller Flange Dimensionsp. 136
Figure 5-3. 60 Amp Continental Gear Driven Alternator Detailp. 137
Figure 5-4. 100 Amp Continental Gear Driven Alternator Detailp. 137
Figure 5-5. 100 Amp Continental Gear Driven Alternator Detailp. 137
Figure 5-6. 70-Amp Belt Driven Alternator Detailp. 138
Figure 5-7. 85 Amp Belt Driven Alternator Detailp. 138
+5-4.2. IO-550-A Installation Drawingsp. 139
Figure 5-8. IO-550-A Front & Rear Viewp. 139
Figure 5-9. IO-550-A Top & Side Viewp. 140
+5-4.3. IO-550-B Installation Drawingsp. 141
Figure 5-10. IO-550-B Front & Rear Viewp. 141
Figure 5-11. IO-550-B Top & Side Viewp. 142
+5-4.4. IO-550-C Installation Drawingsp. 143
Figure 5-12. IO-550-C Front & Rear Viewp. 143
Figure 5-13. IO-550-C Top & Side Viewp. 144
+5-4.5. IO-550-G & N Installation Drawingsp. 145
Figure 5-14. IO-550-G & N Front & Rear Viewp. 145
Figure 5-15. IO-550-G & N Top & Side Viewp. 146
+5-4.6. IO-550-P Installation Drawingsp. 147
Figure 5-16. IO-550-P Front & Rear Viewp. 147
Figure 5-17. IO-550-P Top & Side Viewp. 148
+5-4.7. IO-550-R Installation Drawingsp. 149
Figure 5-18. IO-550-R Front & Rear Viewp. 149
Figure 5-19. IO-550-R Top & Side Viewp. 150
+Chapter 6 . Engine Inspection and Servicep. 151
6-1. Inspection Program Introductionp. 151
6-2. Inspection and Maintenance Schedulep. 151
+6-3. Scheduled Inspectionsp. 151
Table 6-1. Engine Inspection and Maintenance Schedulep. 152
6-3.1. One Time Post – Installation Inspectionsp. 153
6-3.2. 25-Hour Initial Operation Inspectionp. 153
6-3.3. 50-Hour Engine Inspectionp. 155
6-3.4. 100-Hour (Annual) Engine Inspectionp. 156
6-3.5. 500-Hour Engine Inspectionp. 157
6-3.6. Visual Inspectionp. 158
+6-3.7. Engine Operational Checkp. 160
Table 6-2. Engine Operation Prerequisitesp. 160
+6-3.7.1. Engine Operating Limitsp. 161
Table 6-3. IO-550 Engine Operating Limitsp. 161
6-3.7.2. Maintenance Preflight Inspectionp. 162
6-3.7.3. Oil Pump Operational Checkp. 164
+6-3.7.4. Fuel System Operational Checkp. 164
Table 6-4. Static Ground Setup Compensation Tablep. 165
+6-3.7.4.1. Fuel System Operational Checkout with the Port-Test Unitp. 166
Figure 6-1. Porta-Test Connections to Integral Throttle Body/Metering Unitp. 167
Figure 6-2. Porta-Test Connections to Fuel Control Unitp. 167
+6-3.7.4.2. Fuel System Operational Checkout with Calibrated Gaugesp. 168
Figure 6-3. Calibrated Gauge Connections to Integral Throttle Body/Metering Unitp. 169
Figure 6-4. Calibrated Gauge Connections to Fuel Control Unitp. 169
+6-3.7.4.3. Fuel System Operational Checkout Procedurep. 170
Figure 6-5. IO-550-A, B & C Throttle Body Adjustmentsp. 171
Figure 6-6. IO-550-G, N, P & R Throttle Body Adjustmentsp. 171
6-3.7.5. Magneto RPM Drop Checkp. 173
6-3.7.6. Engine Shutdownp. 174
+6-3.8. Engine Oil Servicingp. 175
+6-3.8.1. Check and Replenish Engine Oil Levelp. 175
Figure 6-7. IO-550-A, B & C Oil Servicing Pointsp. 176
Figure 6-8. IO-550-G & N Oil Servicing Pointsp. 177
Figure 6-9. IO-550-P Oil Servicing Pointsp. 178
Figure 6-10. IO-550-R Oil Servicing Pointsp. 179
6-3.8.2. Oil Changep. 180
6-3.8.3. Check for Oil Leaksp. 181
6-3.8.4. Oil Sample Collectionp. 181
6-3.8.5. Oil Trend Monitoring and Spectrographic Oil Analysisp. 182
+6-3.9. Ignition System Maintenancep. 182
+6-3.9.1. Magneto Timingp. 182
+6-3.9.1.1. Crankshaft Top Dead Center Alignmentp. 183
Figure 6-11. Timing Disk and TDC Locator Installedp. 183
Figure 6-12. No. 1 Cylinder Positioned at Top of Intake Strokep. 184
Figure 6-13. Crankshaft Positioned at TDCp. 184
Figure 6-14. Cylinder No. 1 Top of Compression Strokep. 185
Figure 6-15. No. 1 Cylinder Full Advance Firing Positionp. 185
6-3.9.1.2. Magneto to Engine Timingp. 186
+6-3.9.2. Spark Plug Maintenancep. 187
Figure 6-16. Spark Plug Inspection Criteriap. 187
Table 6-5. TSIO-550 Approved Spark Plug Listp. 188
Figure 6-17. Spark Plug Rotation Chartp. 188
+6-3.9.3. Ignition Harness Maintenancep. 189
Figure 6-18. Lubricate Ignition Wire with MS-122ADp. 189
Figure 6-19. Champion (Slick) Ignition Harness Routingp. 190
Figure 6-20. Continental Motors Ignition Harness Routingp. 191
+6-3.10. Engine Adjustmentsp. 192
+6-3.10.1. Oil Pressure Adjustmentp. 193
Figure 6-21. Oil Pressure Relief Valve Adjustment Screwp. 193
+6-3.10.2. Fuel System Adjustmentp. 194
Figure 6-22. Fuel Pump Adjustmentsp. 194
6-3.10.3. Auto Leaning Schedule Adjustmentsp. 198
+6-3.10.4. Belt Tension Check and Adjustmentp. 200
+6-3.10.4.1. Freon Compressor Drive Belt Tension Check and Adjustmentp. 200
Figure 6-23. Freon Compressor Belt Tensioningp. 200
+6-3.10.4.2. Alternator Drive Belt Tension Check and Adjustmentp. 201
Figure 6-24. Alternator Belt Tensioningp. 201
+6-3.11. Cylinder Inspectionsp. 202
Table 6-6. Cylinder Inspection Tasks and Referencesp. 202
+6-3.11.1. Cylinder Visual Inspectionsp. 202
Figure 6-25. Cylinder Power Stroke Areasp. 203
+6-3.11.2. Differential Pressure Testp. 204
+6-3.11.2.1. Differential Pressure Tester E2M Setupp. 206
Figure 6-26. Model E2M Differential Pressure Testerp. 207
6-3.11.2.2. Differential Pressure Tester Reliability Checkp. 207
+6-3.11.2.3. Cylinder Differential Pressure Testp. 207
Figure 6-27. Differential Pressure Test Equipment Usagep. 208
Table 6-7. Differential Pressure Test Resultsp. 210
+6-3.11.3. Cylinder Borescope Inspectionp. 212
Table 6-8. Borescope Inspection Objectives and Corrective Actionsp. 213
Figure 6-28. Normal Combustion Chamberp. 214
Figure 6-29. Burned Exhaust Valvep. 214
Figure 6-30. Phosphate-Coated Cylinder w/ Revised Hone Patternp. 214
Figure 6-31. Phosphated Cylinder Borep. 214
Figure 6-32. Cylinder Barrel Scoring and Piston Rubp. 215
Figure 6-33. Typical Wear in Upper Ring Travelp. 215
Figure 6-34. Typical Cylinder Wearp. 215
6-3.11.4. Cylinder to Crankcase Mounting Deck Inspectionp. 216
+6-3.11.5. Baffle Inspectionp. 217
Figure 6-35. Improperly Positioned Baffle Sealsp. 218
Figure 6-36. Improperly Positioned Baffle Sealsp. 218
Figure 6-37. Improperly Positioned Aft and Side Peripheral Baffle Sealsp. 219
Figure 6-38. Improperly Positioned Aft and Side Peripheral Baffle Sealsp. 219
Figure 6-39. Aft and Side Baffles with Air Gapsp. 220
Figure 6-40. Cooling Loss Due to Gaps in Baffle Sealsp. 220
Figure 6-41. Cooling Loss Due to Gaps in Baffle Sealsp. 221
6-3.11.6. Cowling Inspectionp. 222
+6-3.12. Crankcase Inspectionp. 223
Figure 6-42. Crankcase Critical (white) and Non-critical (Shaded) Areap. 224
+6-3.12.1. Crankcase Inspection with Freon Compressorp. 224
Figure 6-43. Mount Boss with Thick Ribp. 225
Figure 6-44. Mount Boss with Thin Ribp. 225
Figure 6-45. General Inspection Areap. 225
Figure 6-46. Suspect Crack Indicationp. 226
6-3.13. Engine Mount Inspectionp. 227
+6-3.14. Induction System Inspectionp. 227
Figure 6-47. Induction Tube Bead Locationp. 228
Figure 6-48. Properly Installed Induction Tube, Hose and Clampsp. 228
+6-3.15. Ignition System Inspectionp. 229
6-3.15.1. Impulse Coupling Functional Checkp. 230
6-3.15.2. Starting Vibrator Functional Checkp. 231
6-3.15.3. Magneto Drive Coupling Inspectionp. 232
6-3.16. Engine Gauge Inspectionp. 232
6-3.17. Fuel System Inspectionp. 233
+6-3.18. Engine Control Linkage Inspectionp. 234
Figure 6-49. IO550-A, B & C Throttle Control Linkagep. 235
Figure 6-50. IO-550-G, N, P & R Throttle Control Linkagep. 235
6-3.19. Induction or Cylinder Drain Inspectionp. 236
6-3.20. Exhaust System Inspectionp. 237
+6-3.21. Alternator Inspectionp. 238
+6-3.21.1. Alternator Drive Hub Inspectionp. 238
Figure 6-51. Alternator Drive Hubp. 239
+6-3.21.2. Hartzell (Kelly) ES10024 Series Alternator Inspectionp. 239
Figure 6-52. ES10024 Alternatorp. 240
+6-4. Unscheduled Maintenancep. 242
+6-4.1. Propeller Strikep. 242
6-4.1.1. Propeller Strike Inspectionp. 242
6-4.2. Hydraulic Lock Inspectionp. 243
+6-4.3. Engine Overspeed Inspectionsp. 244
Table 6-9. Overspeed Categoriesp. 244
6-4.3.1. Category I Overspeed Inspectionp. 244
6-4.3.2. Category II Overspeed Inspectionp. 245
6-4.3.3. Category III Overspeed Inspectionp. 245
6-4.4. Lightning Strike Inspectionp. 245
6-4.5. Contaminated Fuel System Inspectionp. 246
6-4.6. Foreign Object Contamination Inspectionp. 247
+6-5. Inspection Checklistsp. 248
Table 6-10. Engine Operational Checklistp. 249
Table 6-11. 25-Hour Initial Operation Inspection Checklistp. 251
Table 6-12. 50-Hour Engine Inspection Checklistp. 253
Table 6-13. 100-Hour Engine Inspection Checklistp. 255
Table 6-14. 500-Hour Engine Inspection Checklistp. 257
Table 6-15. Cylinder Inspection Checklistp. 259
+Chapter 7 . Engine Operationp. 263
7-1. Introductionp. 263
+7-2. Flight Prerequisitesp. 263
7-2.1. Oil Change Intervalp. 263
7-2.2. Engine Fuel Requirementsp. 264
+7-2.3. Flight Check and Break-Inp. 264
7-2.3.1. Engine Break-Inp. 265
7-2.3.2. IO-550 Standard Fuel System Flight Checkp. 266
7-2.3.3. IO-550 Altitude Compensating Fuel System Flight Checkp. 266
+7-2.3.4. Flight Check Limitsp. 267
Table 7-1. IO-550 Engine Operating Limitsp. 267
Figure 7-1. IO-550-A Altitude Leaning Chartp. 268
Figure 7-2. IO-550-B Altitude Leaning Chartp. 268
Figure 7-3. IO-550-C Altitude Leaning Chartp. 269
+7-3. Normal Operationp. 270
7-3.1. Pre-operational Requirementsp. 270
+7-3.2. Engine Startp. 271
7-3.2.1. Cold Startp. 272
7-3.2.2. Flooded Enginep. 272
7-3.2.3. Hot Startp. 273
7-3.3. Ground Run-upp. 273
7-3.4. Engine Shutdownp. 275
+7-4. Engine Operation in Abnormal Environmentsp. 276
+7-4.1. Engine Operation in Extreme Coldp. 276
+7-4.1.1. Engine Preheatingp. 277
7-4.1.1.1. Engine Preheat with a Combustion Heaterp. 277
7-4.1.1.2. Engine Preheat with an Engine-Mounted Preheaterp. 279
7-4.1.1.3. Cold Weather Starting Without Preheatingp. 280
+7-4.2. Engine Operation in Hot Weatherp. 282
7-4.2.1. Cooling an Engine in Hot Weatherp. 283
7-4.2.2. Engine Restart in Hot Weatherp. 283
7-4.3. Ground Operation at High Density Altitudep. 283
+Chapter 8 . Troubleshootingp. 285
+8-1. General Troubleshootingp. 286
8-1.1. Engine Runs Roughp. 287
8-1.2. Engine Will Not Runp. 288
8-1.3. Engine Indication Malfunctionsp. 289
8-1.4. Engine Performance Malfunctionsp. 289
+8-2. Induction Systemp. 290
8-2.1. Engine Will Not Startp. 290
8-2.2. Engine Will Not Runp. 291
8-2.3. Engine Lacks Power/Manifold Pressure Lowp. 291
+8-3. Fuel Injection Systemp. 292
8-3.1. Fuel Injector Operational Checkp. 294
8-4. Charging Systemp. 296
8-5. Starting Systemp. 296
+8-6. Ignition Systemp. 297
8-6.1. Ignition Harness and Spark Plug Diagnosticsp. 298
8-7. Lubrication Systemp. 299
8-8. Engine Cylindersp. 301
+8-9. Crankcasep. 302
8-9.1. Excess Crankcase Pressurep. 303
8-10. Exhaust Systemp. 303
+Chapter 9 . Engine Preservation and Storagep. 305
+9-1. Preserving and Storing an Enginep. 305
9-1.1. Engine Preservation Checklistp. 305
9-1.2. New or Unused Engine Storagep. 305
9-1.3. Temporary Storagep. 305
9-1.4. Indefinite Storagep. 307
+9-1.5. Return an Engine to Service after Storagep. 308
Table 9-1. Engine Preservation Checklistp. 309
+Chapter 10 . Non-Overhaul Repair and Replacementp. 311
+10-1. Parts Replacementp. 311
Table 10-1. Non-Overhaul Parts Replacement Referencep. 312
Table 10-2. Parts Repair Referencep. 313
Table 10-3. Parts Handling Guidelinesp. 313
+10-2. Fuel Pump Replacementp. 314
+10-2.1. Fuel Pump Removalp. 314
Figure 10-1. IO-550 Fuel Pump Adjustments & Fittingsp. 315
+10-2.2. Fuel Pump Service Limitsp. 316
Figure 10-2. Fuel Pump Drive Coupling Fits and Limitsp. 316
Table 10-4. Fuel Pump Drive Coupling Dimensionsp. 316
+10-2.3. Fuel Pump Installationp. 316
Figure 10-3. Fuel Pump Assemblyp. 317
+10-3. Fuel Injector Replacementp. 318
+10-3.1. Nozzle Identificationp. 318
Figure 10-4. Original Fuel Injector Nozzlesp. 318
Figure 10-5. Position Tuned Fuel Injector Nozzlep. 318
Figure 10-6. Post-2005 Position Tuned Fuel Injector Nozzlep. 319
10-3.2. Fuel Injector Removalp. 319
+10-3.3. Fuel Injector Installationp. 320
Figure 10-7. Apply Anti-Seize To Fuel Injector Nozzlep. 320
Figure 10-8. Fuel Injector Assembliesp. 321
+10-4. Starter Motor and Adapter Replacementp. 322
10-4.1. Starter Motor Removalp. 322
+10-4.2. Starter Adapter Removalp. 322
Figure 10-9. Starter Motor and Starter Adapterp. 323
+10-4.3. Starter and Starter Adapter Service Limitsp. 324
Table 10-5. Basic Starter Adapter Dimensionsp. 324
Figure 10-10. Basic Starter Adapterp. 325
Figure 10-11. Shaft Gear Drum Dimensionsp. 325
Table 10-6. Shaft Gear Drum Service Limitsp. 325
Figure 10-12. Worm Wheel Drum Dimensionsp. 326
Table 10-7. Worm Wheel Drum Dimensionsp. 326
Figure 10-13. Starter Adapter with Scavenge Pumpp. 326
Table 10-8. Starter Adapter with Accessory Drive Service Limitsp. 327
10-4.4. Starter Adapter Installationp. 328
10-4.5. Starter Motor Installationp. 328
+10-5. Alternator Replacementp. 330
+10-5.1. Direct Drive Alternator Removalp. 330
+10-5.1.1. Direct Drive Alternator Drive Hub Removalp. 331
Figure 10-14. Gear Driven Alternator Assemblyp. 331
+10-5.1.2. Direct Drive Alternator Drive Hub Installationp. 332
Figure 10-15. Alternator Cotter Pin Installationp. 333
10-5.2. Direct Drive Alternator Installationp. 334
10-5.3. Belt Driven Alternator Removalp. 336
10-5.4. Belt Driven Alternator Installationp. 336
10-5.5. Alternator Drive Sheave Removalp. 336
+10-5.6. Alternator Drive Sheave Installationp. 336
Figure 10-16. Belt Driven Alternator Bracket Assemblyp. 337
+10-5.7. Belt Driven Alternator Bracket Replacementp. 338
Figure 10-17. Optional Alternator Bracket Assemblyp. 338
10-5.8. Belt Driven Alternator Bracket Installationp. 338
+10-6. Magneto Replacementp. 339
+10-6.1. Continental Motors’ Magneto Removalp. 340
Figure 10-18. Continental Motors Ignition Systemp. 341
+10-6.2. Champion (Slick) Magneto Removalp. 342
Figure 10-19. Slick Ignition Systemp. 343
+10-6.3. Ignition System Service Limitsp. 344
Table 10-9. Ignition System Service Limitsp. 344
Figure 10-20. Accessory Drive Adapter Dimensionsp. 345
10-6.4. Continental Motors’ Magneto Installationp. 346
10-6.5. Champion (Slick) Magneto Installationp. 348
+10-6.6. Accessory Drive Adapter Replacementp. 350
Figure 10-21. Accessory Drive Assemblyp. 351
+10-7. Lubrication System Repairp. 352
10-7.1. Oil Filter Adapter Stud Replacementp. 352
10-7.2. Oil Pump or Tachometer Drive Repair and Replacementp. 352
10-7.3. Oil Sump and Oil Suction Tube Repair and Replacementp. 353
10-7.4. Oil Cooler Repair and Replacementp. 353
+10-7.5. Oil Pressure Relief Valve Repair and Replacementp. 354
Figure 10-22. Rear View of Enginep. 354
Figure 10-23. Oil Pressure Relief Valvep. 355
Figure 10-24. Valve Seat in the Oil Pump Housingp. 355
+10-7.6. Oil Temperature Control Valve Inspection and Replacementp. 356
Figure 10-25. Oil Temperature Control Valvep. 356
+10-7.7. Lubrication Component Service Limitsp. 358
Table 10-10. Lubrication System Component Service Limitsp. 358
Figure 10-26. Lubrication System Service Limitsp. 359
+10-8. Engine Cylinder Maintenancep. 360
+10-8.1. IO-550-A, B & C Rocker Arm Removalp. 360
Figure 10-27. Updraft Cylinder Assemblyp. 361
+10-8.2. IO-550-G, N, P & R Rocker Arm Removalp. 362
Figure 10-28. Crossflow Cylinder Assemblyp. 363
+10-8.3. Updraft Cylinder Hydraulic Tappet Removalp. 364
Figure 10-29. Updraft Cylinder Pushrod Tube Assemblyp. 365
+10-8.4. Crossflow Cylinder Hydraulic Tappet Removalp. 366
Figure 10-30. Crossflow Cylinder Pushrod Tube Assemblyp. 367
+10-8.5. IO-550-A, B & C Cylinder Removalp. 368
Figure 10-31. Packing Installed to Stabilize Connecting Rodsp. 369
Figure 10-32. Piston, Piston Pin and Piston Ringsp. 370
Figure 10-33. Static Sealp. 371
10-8.6. IO-550 G, N, P & R Engine Cylinder Removalp. 372
+10-8.7. Engine Cylinder Dimensional Inspectionp. 375
Figure 10-34. Pushrod Dimensionsp. 377
+10-8.7.1. IO-550-A, B & C Series Engines Cylinders Service Limitsp. 380
Table 10-11. IO-550-A, B & C Cylinder Assembly Service Limitsp. 380
Figure 10-35. IO-550-A, B & C Cylinder Assemblyp. 382
+10-8.7.2. IO-550-G, N, P & R Cylinder Service Limitsp. 383
Table 10-12. IO-550-G, N, P & R Cylinder Assembly Service Limitsp. 383
Figure 10-36. IO-550-G, N, P & R Cylinder Assembly Service Limitsp. 385
Figure 10-37. Cylinder Service Limitsp. 386
Table 10-13. Cylinder Barrel Service Limitsp. 387
Figure 10-38. Intake Valve Seat Dimensionsp. 388
Figure 10-39. Exhaust Valve Seat Dimensionsp. 388
Figure 10-40. Valve Dimensionsp. 389
10-8.8. IO-550-A, B & C Engine Cylinder Installationp. 390
10-8.9. IO-550-G, N, P & R Cylinder Installationp. 394
+10-8.10. Cylinder Torquep. 397
Figure 10-41. Single Cylinder Torque Sequencep. 397
+10-8.11. Updraft Cylinder Hydraulic Tappet Installationp. 398
Figure 10-42. Pushrod Spring Compressorp. 399
10-8.12. Crossflow Cylinder Hydraulic Tappet Installationp. 400
+10-8.13. Updraft Cylinder Rocker Arm Installationp. 402
Figure 10-43. Updraft Cylinder Rocker Arm Side Clearancep. 402
Figure 10-44. Rocker Arm to Retainer Clearancep. 403
+10-8.14. Crossflow Cylinder Rocker Arm Installationp. 404
Figure 10-45. Rocker Arm Side Clearancep. 405
+10-9. Crankshaft Nose Oil Seal Replacementp. 406
+10-9.1. Crankshaft Nose Oil Seal Removalp. 406
Figure 10-46. Retainer Plate and Screws on Front of Crankcasep. 406
Figure 10-47. Crankshaft Nose Oil Seal Partsp. 407
Figure 10-48. Crankshaft Plated Areap. 407
10-9.2. Crankshaft Nose Oil Seal Installationp. 408
10-10. Crankcase Repairp. 409
10-11. Exhaust System Repairsp. 409
10-12. Engine Preservation and Storagep. 409
+Chapter 11 . Engine Overhaul Introductionp. 411
11-1. Engine Overhaulp. 411
11-2. Overhaul Schedulep. 411
+11-3. Overhaul Sequencep. 412
Table 11-1. Overhaul Sequencep. 412
+11-4. Overhaul Checklistsp. 412
Table 11-2. Engine Removal and Disassembly Checklistp. 414
Table 11-3. Engine Overhaul Visual Inspection Checklistp. 415
Table 11-4. Fluorescent Penetrant Inspection Checklistp. 422
Table 11-5. Magnetic Particle Inspection Checklistp. 424
Table 11-6. Ultrasonic Inspection Checklistp. 425
Table 11-7. Dimensional Inspection Checklistp. 426
Table 11-8. Engine Cylinder Overhaul Inspection Checklistp. 435
Table 11-9. Engine Drive Train Inspection Checklistp. 436
Table 11-10. Replacement Parts Inventoryp. 438
+Chapter 12 . Engine Disassemblyp. 441
12-1. Engine Disassembly Sequencep. 441
+12-2. Ignition System Removal and Disassemblyp. 442
+12-2.1. Continental Motors Ignition System Removalp. 442
Figure 12-1. Magneto Tachometer Sensorp. 442
Figure 12-2. Continental Ignition Systemp. 443
+12-2.2. Champion (Slick) Ignition System Removalp. 444
Figure 12-3. Champion (Slick) Ignition Systemp. 444
+12-3. Accessory Drive Adapter Removalp. 445
Figure 12-4. Accessory Drive Adapter Assemblyp. 445
+12-4. Fuel Injection System Removalp. 446
+12-4.1. IO-550-A Fuel Injection System Removalp. 446
Figure 12-5. IO-550-A Fuel Injection Assemblyp. 447
+12-4.2. IO-550-B Fuel Injection System Removalp. 448
Figure 12-6. IO-550-B Fuel Injection Assemblyp. 449
+12-4.3. IO-550-C Fuel Injection System Removalp. 450
Figure 12-7. IO-550-C Fuel Injection Assemblyp. 451
+12-4.4. IO-550 G, N, P, R Fuel Injection System Removalp. 452
Figure 12-8. IO-550-G, N, P, & R Fuel Injection Assemblyp. 453
Figure 12-9. IO-550-G, N, P & R Throttle and Metering Assemblyp. 454
+12-5. Induction System Removalp. 456
+12-5.1. IO-550-A Induction System Removalp. 456
Figure 12-10. IO-550-A Induction Assemblyp. 457
+12-5.2. IO-550-B Induction System Removalp. 458
Figure 12-11. IO-550-B Induction Assemblyp. 458
+12-5.3. IO-550-C Induction System Removalp. 459
Figure 12-12. IO-550-C Induction Assemblyp. 459
+12-5.4. IO-550-G, N, P, & R Induction System Removalp. 460
Figure 12-13. IO-550-G, N, P, & R Induction Assemblyp. 461
12-6. Exhaust System Removalp. 462
+12-7. Oil Cooler Removalp. 462
Figure 12-14. IO-550-G, N, P & R Oil Coolerp. 462
Figure 12-15. IO-550-A, B & C Oil Coolerp. 463
+12-8. Oil Pump Removalp. 464
Figure 12-16. Oil Pump Assemblyp. 465
+12-9. Alternator Removalp. 468
+12-9.1. Direct Drive Alternator Removalp. 469
Figure 12-17. Direct Drive Alternatorp. 469
+12-9.2. Belt Driven Alternator Removalp. 470
Figure 12-18. Belt Driven Alternator Bracket Assemblyp. 470
+12-9.3. Belt Driven Alternator Bracket and Drive Sheave Removalp. 471
Figure 12-19. Optional Alternator Bracket Assemblyp. 471
+12-10. Compressor Mounting Assembly (Optional) Removalp. 472
Figure 12-20. Optional Freon Compressor Mount Assemblyp. 472
+12-11. Starter and Adapter Removalp. 473
Figure 12-21. Starter and Adapterp. 473
+12-12. Oil Sump Removalp. 474
+12-12.1. IO-550-A & C Oil Sump Removalp. 474
Figure 12-22. IO-550-A & C Oil Sumpp. 474
+12-12.2. IO-550-B & R Oil Sump Removalp. 475
Figure 12-23. IO-550-B & R Oil Sumpp. 475
+12-12.3. IO-550-G & N Oil Sump Removalp. 476
Figure 12-24. IO-550-G & N Oil Sumpp. 476
+12-12.4. IO-550-P Oil Sump Removalp. 477
Figure 12-25. IO-550-P Oil Sumpp. 477
+12-13. Engine Cylinder Removalp. 478
+12-13.1. IO-550-A, B & C Engine Cylinder Removalp. 478
Figure 12-26. IO-550-A, B & C Engine Cylinderp. 479
Figure 12-27. Piston Assemblyp. 480
Figure 12-28. Cylinder Base Packing support Connecting Rodsp. 480
+12-13.2. IO-550-G, N, P & R Inter-Cylinder Baffle Removalp. 482
Figure 12-29. Inter-Cylinder Baffle Assemblyp. 483
+12-13.3. IO-550-G, N, P & R Engine Cylinder Removalp. 484
Figure 12-30. Cylinder Drain Tube Fittingp. 484
Figure 12-31. IO-550-G, N, P & R Engine Cylinderp. 485
+12-14. Engine Mount Removalp. 487
+12-14.1. IO-550-A Engine Mount Removalp. 487
Figure 12-32. IO-550-A Engine Mountsp. 487
+12-14.2. IO-550-C Engine Mount Removalp. 488
Figure 12-33. IO-550-C Engine Mountsp. 488
+12-14.3. IO-550-G, N & P Engine Mount Removalp. 489
Figure 12-34. IO-550-G, N & P Engine Mountsp. 489
+Chapter 13 . Component Disassemblyp. 491
13-1. Ignition Systemp. 491
+13-2. Fuel Injection Systemp. 492
Figure 13-1. Fitting Orientation Guidep. 492
+13-3. Starter and Adapter Disassemblyp. 493
+13-3.1. Basic Starter and Starter Adapter Disassemblyp. 494
Figure 13-2. Starter and Adapterp. 495
+13-3.2. Starter Adapter with Accessory Drive Disassemblyp. 496
Figure 13-3. Starter and Adapter with Accessory Drivep. 497
+13-4. Engine Cylinder Disassemblyp. 500
+13-4.1. IO-550-A, B, & C Engine Cylinder Disassemblyp. 500
Figure 13-4. IO-550-A, B & C Cylinder Assemblyp. 501
+13-4.2. IO-550-G, N, P & R Cylinder Disassemblyp. 502
Figure 13-5. IO-550-G, N, P & R Cylinder Assemblyp. 503
+13-5. Accessory Drive Pad Disassemblyp. 504
Figure 13-6. Accessory Drive Assemblyp. 504
+13-6. Crankcase Disassemblyp. 505
+13-6.1. Miscellaneous Crankcase Accessory Removalp. 505
Figure 13-7. Oil Filler, Idler Support Pin and Camshaft Coverp. 505
Figure 13-8. Oil Seal Retainer Plates and Governor Coverp. 506
Figure 13-9. Crankcase Fastener Locationsp. 506
13-6.2. Crankcase Studding Disassemblyp. 508
+13-7. Engine Drive Train Disassemblyp. 509
+13-7.1. Camshaft Disassemblyp. 509
Figure 13-10. Keyed Camshaftp. 509
Figure 13-11. Camshaft Assemblyp. 509
+13-7.2. Crankshaft Disassemblyp. 510
Figure 13-12. Crankshaft Assemblyp. 511
+13-8. Compressor Mounting Kit Disassemblyp. 512
Figure 13-13. Freon Compressor Mounting Kitp. 512
+Chapter 14 . Engine Cleaningp. 513
+14-1. Engine and Component Cleaningp. 513
Table 14-1. Aircraft Engine Parts Cleaning Guidelinesp. 514
Table 14-2. Cleaning Tipsp. 517
14-1.1. Cylinder Cleaningp. 518
14-1.2. Piston Cleaningp. 519
14-1.3. Cleaning Exhaust Partsp. 520
14-1.4. Cleaning Aluminum Alloy Partsp. 520
14-2. Dry Blastingp. 521
14-3. Vapor Blastingp. 521
+14-4. Protective Coatingsp. 522
14-4.1. Alodinep. 522
14-4.2. Aviation Oilp. 522
+14-4.3. Paintp. 522
Table 14-3. Painting External Partsp. 522
+Chapter 15 . Overhaul Inspection and Repairp. 523
15-1. Engine Overhaul Inspectionp. 523
15-2. Engine Overhaul Inspection Checklistsp. 523
+15-3. Visual Inspectionp. 523
+15-3.1. Gear Tooth Inspectionp. 524
Figure 15-1. Gear Inspection Criteriap. 524
+15-4. Fluorescent Penetrant Inspectionp. 525
Table 15-1. Parts requiring Fluorescent Penetrant Inspectionp. 525
+15-5. Magnetic Particle Inspectionp. 526
Table 15-2. Magnetic Particle Inspection Referencep. 527
+15-5.1. Connecting Rod Magnetic Particle Inspectionp. 528
Table 15-3. Connecting Rod Magnetic Particle Inspection Criteriap. 528
+15-6. Ultrasonic Inspectionsp. 528
15-6.1. Ultrasonic Inspection Certificationp. 528
+15-6.2. Crankshaft Ultrasonic Inspectionp. 529
Table 15-4. Crankshaft Ultrasonic Inspection Pass/Fail Actionp. 529
Figure 15-2. Crankshaft Ultrasonic Inspection Method Locationp. 529
+15-7. Dimensional Inspectionp. 530
+15-7.1. Crankcase Dimensional Inspectionp. 531
Figure 15-3. Crankcase Critical (White) Stress Areasp. 532
Figure 15-4. Crankcase Dimensional Inspection Torque Sequencep. 534
+15-7.2. Drive Train Dimensional Inspectionp. 535
Figure 15-5. Crankshaft Journalsp. 535
15-7.2.1. Connecting Rod Dimensional Inspectionp. 536
+15-7.2.2. Crankshaft Counterweight Inspectionp. 537
Figure 15-6. Crankshaft Counterweight Bump Surface Inspectionp. 537
15-7.2.2.1. Crankshaft Counterweight Bushing Bore Inspectionp. 538
15-7.3. Engine Cylinder Dimensional Inspectionp. 539
15-7.4. Starter Adapter Dimensional Inspectionp. 540
15-7.5. Lubrication System Dimensional Inspectionp. 540
+15-7.6. Alternator Drive Hub Slippage Inspectionp. 541
Table 15-5. Alternator Drive Hub Slippagep. 541
+15-7.7. Throttle and Mixture Control Lever Inspectionp. 541
Figure 15-7. Serviceable Throttle/Mixture Control Lever & Shaft Splinesp. 542
Figure 15-8. Worn Throttle and Mixture Control Lever & Shaft Splinesp. 542
15-7.8. Exhaust System Inspectionp. 543
15-7.9. Accessory Drive Adapter Dimensional Inspectionp. 543
+15-7.10. Stud Height Dimensional Inspectionp. 543
Table 15-6. Stud Height Settingsp. 543
+15-7.11. Freon Compressor Dimensional Inspectionp. 544
Figure 15-9. Freon Compressor Sheavep. 544
+15-8. Overhaul Repairp. 545
15-8.1. Fuel Injection System Overhaul Repairp. 545
+15-8.2. Induction System Overhaul Repairp. 546
+15-8.2.1. IO-550-G, N, P & R Induction Manifold Overhaul Repairp. 546
Figure 15-10. Induction Manifold Fittingsp. 546
15-8.3. Freon Compressor Mount Overhaul Repairp. 547
15-8.4. Alternator Overhaulp. 547
+15-8.5. Starter and Starter Adapter Overhaul Repairp. 547
+15-8.5.1. Starter Adapter Housing Worm Shaft Needle Bearing Replacementp. 548
Figure 15-11. Starter and Adapter with Accessory Drivep. 548
+15-8.6. Ignition System Overhaulp. 548
+15-8.6.1. Accessory Drive Adapter Overhaulp. 549
Figure 15-12. Accessory Drive Adapter Bushing Installation Detailp. 549
15-8.7. Exhaust System Overhaul Repairp. 550
+15-8.8. Lubrication System Overhaulp. 550
15-8.8.1. Oil Cooler Overhaul Repairp. 551
+15-8.8.2. Oil Pressure Relief Valve Seat Repairp. 551
Figure 15-13. Oil Pressure Relief Valvep. 551
+15-8.8.3. Oil Filter Adapter Stud Replacementp. 551
Figure 15-14. Oil Filter Adapter Studp. 552
Figure 15-15. Identification of Oil Filter Adapter Stud Modificationp. 552
15-8.8.4. Tachometer Drive Assembly Replacementp. 552
+15-8.9. Engine Cylinder Overhaul Repairp. 553
+15-8.9.1. Cylinder Repair versus Replacement Guidelinesp. 554
Table 15-7. Cylinder Repair vs. Replacement Guidelinesp. 554
+15-8.9.2. Engine Overhaul Replacement Partsp. 555
Table 15-8. Mandatory Cylinder Overhaul Replacement Partsp. 555
+15-8.9.3. Rocker Shaft Retention Modificationp. 555
Figure 15-16. M92-6 Compliance Stampp. 555
Figure 15-17. Part No. 8181 Drill Guidep. 556
+15-8.9.4. New Cylinder Position Numbersp. 557
Figure 15-18. Cylinder Position Numberp. 557
15-8.9.5. Cylinder Head Repairp. 557
15-8.9.6. Cylinder Fin Tip Repairp. 558
15-8.9.7. Cylinder Barrel Repairp. 558
+15-8.9.8. Cylinder Bore Honingp. 558
Table 15-9. Cylinder Bore Surface FInish Specificationsp. 559
15-8.9.9. Valve Seat Removalp. 560
15-8.9.10. Valve Seat Installationp. 561
15-8.9.11. Valve Guide Removalp. 562
15-8.9.12. Valve Guide Installationp. 563
15-8.9.13. Valve Guide Bore Reamingp. 564
15-8.9.14. Valve Seat Machiningp. 564
15-8.9.15. Spark Plug Helical Coil Insert Replacementp. 565
15-8.9.16. Cylinder Stud Installationp. 566
15-8.9.17. Piston Ring Replacementp. 566
15-8.9.18. Cylinder Protective Coatingsp. 566
+15-8.9.19. Rocker Arm Bushing Replacementp. 567
+15-8.9.19.1. Rocker Arm (Dual) Bushing Replacementp. 567
Figure 15-19. Rocker Arm Bushing (Dual Bushing Type) Replacementp. 568
+15-8.9.19.2. Rocker Arm (Single) Bushing Replacementp. 569
Figure 15-20. Rocker Arm Single Bushing Replacementp. 570
+15-8.9.20. Rocker Arm-to-Retainer Clearancep. 571
Figure 15-21. Rocker Arm to Retainer Clearancep. 571
15-8.10. Inter-Cylinder Baffle Repairp. 572
+15-8.11. Crankcase Overhaul Repairp. 572
+15-8.11.1. Camshaft Gear Replacementp. 573
Figure 15-22. Distance from Camshaft to Centerline of Starter Bushingp. 573
Figure 15-23. Radius Cut Depthp. 573
15-8.11.2. Crankcase Line Boringp. 574
15-8.11.3. Crankcase Machiningp. 574
15-8.11.4. Crankcase Weldingp. 574
15-8.11.5. Oil Filler Overhaul Repairp. 574
+15-8.11.6. Crankcase Cylinder Deck Stud Helical Coil Installationp. 575
Figure 15-24. Cylinder Deck Stud Helical Coil Repair Instructionsp. 575
15-8.11.7. Crankcase Cylinder Deck Stud Replacementp. 576
+15-8.12. Engine Drive Train Overhaulp. 577
Table 15-10. Engine Drive Train Parts Replacementp. 577
15-8.12.1. Camshaft Repairp. 578
+15-8.12.2. Crankshaft Repairp. 578
+15-8.12.2.1. Oil Control Plug Replacementp. 579
Figure 15-25. Oil Control Plug/Crankshaft Pressure Testp. 580
+15-8.12.2.2. Crankshaft Counterweight Bushing Replacementp. 581
Figure 15-26. Counterweight Inspection, Repair and Installationp. 582
+15-8.12.2.3. Crankshaft Hanger Blade Bushing Replacementp. 583
Figure 15-27. Crankshaft Hanger Blade Bushing Replacementp. 584
+15-8.12.2.4. Crankshaft Plating Overhaulp. 585
Figure 15-28. Crankshaft Helix Patternp. 585
+15-8.12.2.5. Connecting Rod Piston Pin Bushing Replacementp. 586
Figure 15-29. Connecting Rod Assemblyp. 587
15-8.12.2.6. Piston Pin Bushing Boringp. 588
15-8.12.2.7. Connecting Rod Replacementp. 588
+Chapter 16 . Component Assemblyp. 589
+16-1. Fuel Injection Systemp. 589
16-1.1. Fuel Injection System Component Assemblyp. 589
16-1.2. Fuel Injector Nozzlesp. 589
+16-2. Alternator Assemblyp. 590
Figure 16-1. Direct Drive Alternatorp. 591
Figure 16-2. Alternator Cotter Pin Installationp. 591
+16-3. Starter & Starter Adapter Assemblyp. 591
+16-3.1. Starter & Starter Adapter with Scavenge Pump Assemblyp. 592
Figure 16-3. Worm Wheel Gear Installation Toolp. 592
Figure 16-4. Starter with Accessory Drivep. 593
Figure 16-5. Scavenge Pump Housing Silk Thread Patternp. 595
Figure 16-6. Starter w/Accessory Drive Adapter Oil Seal Positionp. 596
Figure 16-7. Oil Seal Retainer Clip Positionp. 597
+16-3.2. Basic Starter & Starter Adapter Assemblyp. 598
Figure 16-8. Basic Starter and Starter Adapter Assemblyp. 599
16-4. Exhaust System Assemblyp. 601
+16-5. Lubrication System Assemblyp. 602
+16-5.1. Oil Pump Assemblyp. 602
+16-5.1.1. Basic Oil Pump Assemblyp. 602
Figure 16-9. Oil Pump Housing Silk Thread Patternp. 602
Figure 16-10. Oil Pump Assemblyp. 603
+16-5.1.2. Oil Pump Assembly w/Mechanical Tach Drive Adapterp. 604
Figure 16-11. Oil Pump with Mechanical Tach Drive Assemblyp. 605
+16-5.1.3. Oil Pump with Electric Tach Drive Adapter Assemblyp. 606
Figure 16-12. Oil Pump Assembly with Electrical Tach Drive Adapterp. 607
16-5.2. Oil Cooler Assemblyp. 608
+16-6. Engine Cylinder Assemblyp. 608
16-6.1. Cylinder Component Preparationp. 608
+16-6.2. Cylinder Baffle Installationp. 609
Figure 16-13. Cylinder Baffle Installationp. 609
Figure 16-14. Secure Baffle with Springp. 609
+16-6.3. Piston Ring Gap Adjustmentp. 610
Figure 16-15. Piston Ring Installation Orderp. 610
Figure 16-16. Pistons, Piston Rings and Piston Pin Assemblyp. 611
+16-6.4. Valve Train Installationp. 612
Figure 16-17. Updraft Cylinder Assemblyp. 613
Figure 16-18. Crossflow Cylinder Assemblyp. 613
Figure 16-19. Valve and Spring Installationp. 614
+16-6.5. Cylinder Component Assemblyp. 615
Figure 16-20. Updraft Cylinder Pushrod Tube Assemblyp. 615
Figure 16-21. Crossflow Cylinder Pushrod Tube Assemblyp. 615
+16-7. Crankcase Assemblyp. 616
+16-7.1. Oil Filler Installationp. 617
Figure 16-22. Oil Filler, Idler Support Pin and Camshaft Coverp. 617
+16-8. Engine Mount Installationp. 618
+16-8.1. IO-550-A Engine Mount Installationp. 618
Figure 16-23. IO-550-A Engine Mounting Bracketsp. 618
+16-8.2. IO-550-C Engine Mount Installationp. 619
Figure 16-24. IO-550-C Engine Mounting Bracketsp. 619
+16-8.3. IO-550-G, N & P Engine Mount Installationp. 620
Figure 16-25. IO-550-G, N, P & R Engine Mounting Bracketsp. 620
+16-9. Engine Drive Train Assemblyp. 621
+16-9.1. Camshaft Assemblyp. 621
Figure 16-26. Camshaft Assemblyp. 621
+16-9.2. Crankshaft Assemblyp. 622
Figure 16-27. Crankshaft Assemblyp. 623
Figure 16-28. Counterweight Inspection, Repair and Installationp. 625
+16-9.3. Connecting Rod and Bearing Assemblyp. 626
Figure 16-29. Connecting Rod Position Numberp. 626
+16-9.4. Crankshaft Nose Oil Seal Assemblyp. 627
Figure 16-30. Crankshaft Nose Oil Seal Partsp. 627
+16-10. Compressor Mounting Kit Assemblyp. 628
Figure 16-31. Freon Compressor Mounting Assemblyp. 628
+Chapter 17 . Engine Assemblyp. 629
+17-1. Engine Assembly Sequencep. 629
17-1.1. Component Lubricationp. 629
+17-2. Crankcase Assemblyp. 630
+17-2.1. Drive Train Installationp. 630
Figure 17-1. Crankcase Sealant and Threadingp. 631
Figure 17-2. Crankshaft Assemblyp. 633
Figure 17-3. Camshaft Assemblyp. 634
Figure 17-4. Timing Mark Alignmentp. 634
Figure 17-5. Oil Filler, Support Pin, and Camshaft Coverp. 635
Figure 17-6. Left Crankcase Assembled on Standp. 636
Figure 17-7. Cylinder Base O-ring supporting the Connecting Rodsp. 637
+17-2.2. Crankcase Hardware Installationp. 638
+17-2.2.1. IO-550-A, B & C Crankcase Assemblyp. 638
Figure 17-8. Crankcase Fastener Locationsp. 638
Figure 17-9. Permold Crankcase Fastenersp. 639
17-2.2.2. IO-550-G, N, P & R Crankcase Assemblyp. 640
+17-3. Cylinder Installationp. 642
+17-3.1. IO-550-A, B & C Cylinder Installationp. 642
Figure 17-10. Updraft Cylinder Assemblyp. 643
+17-3.2. IO-550-G, N, P & R Cylinder Installationp. 644
Figure 17-11. Piston, Piston Rings & Piston Pinp. 644
Figure 17-12. Crossflow Cylinder Assemblyp. 645
Figure 17-13. Cylinder Drain Fittingp. 646
+17-3.3. Cylinder and Crankcase Torquep. 648
Figure 17-14. Permold Crankcase Torque Sequencep. 649
+17-3.4. Crankcase Miscellaneous Hardware Installationp. 650
Figure 17-15. Oil Seal Retainer Plates and Governor Coverp. 650
+17-3.5. Hydraulic Valve Tappet and Pushrod Installationp. 652
+17-3.5.1. IO-550-A, B & C Valve Tappet and Pushrod Installationp. 652
Figure 17-16. Pushrod Housing Installationp. 652
17-3.5.2. IO-550-G, N, P & R Valve Tappet and Pushrod Installationp. 654
+17-3.6. Rocker Arm Installationp. 656
+17-3.6.1. IO-550-A, B & C Rocker Arm Installationp. 656
Figure 17-17. Updraft Cylinder Rocker Arm Side Clearancep. 656
Figure 17-18. Rocker Arm to Retainer Clearancep. 657
+17-3.6.2. IO-550-G, N, P & R Rocker Arm Installationp. 658
Figure 17-19. Crossflow Cylinder Rocker Arm Side Clearancep. 658
+17-3.7. Inter-Cylinder Baffle Installationp. 660
Figure 17-20. Inter-Cylinder Baffle Assemblyp. 661
+17-4. Oil Sump & Suction Tube Installationp. 662
Figure 17-21. Oil Sump Torque Sequencep. 662
+17-4.1. IO-550-A & C Oil Suction Tube & Sump Installationp. 662
Figure 17-22. IO-550-A & C Oil Sumpp. 663
+17-4.2. IO-550-B & R Oil Suction Tube & Sump Installationp. 664
Figure 17-23. IO-550-B & R Oil Sump Assemblyp. 665
+17-4.3. IO-550-G & N Oil Suction Tube & Sump Installationp. 666
Figure 17-24. IO-550-G & N Oil Sump Assemblyp. 667
+17-4.4. IO-550-P Oil Sump Installationp. 668
Figure 17-25. IO-550-P Oil Sump Assemblyp. 669
+17-5. Oil Pump Installationp. 670
Figure 17-26. Oil Pump Assemblyp. 671
+17-6. Accessory Drive Pad Installationp. 672
Figure 17-27. IO-550-C Throttle Support Bracketp. 672
Figure 17-28. Accessory Drive Adapter Assemblyp. 673
+17-7. Starter and Starter Adapter Installationp. 674
Figure 17-29. Starter and Adapter Assemblyp. 674
+17-8. Oil Cooler Installationp. 675
+17-8.1. IO-550-A, B & C Oil Cooler Installationp. 676
Figure 17-30. IO-550-A, B & C Oil Cooler Assemblyp. 677
+17-8.2. IO-550-G, N, P & R Oil Cooler Installationp. 678
Figure 17-31. IO-550-G, N, P & R Oil Cooler Assemblyp. 679
+17-9. Alternator Installationp. 680
+17-9.1. Direct Drive Alternator Installationp. 680
Figure 17-32. Direct Drive Alternatorp. 680
Figure 17-33. Alternator Drive End Housing Modificationp. 681
+17-9.2. Optional Belt Driven Alternator Installationp. 682
Figure 17-34. Belt-Driven Alternator Assembly (Optional)p. 683
+17-10. Induction System Installationp. 684
+17-10.1. IO-550-A Induction System Installationp. 684
Figure 17-35. IO-550-A Induction Assemblyp. 685
+17-10.2. IO-550-B Induction System Installationp. 686
Figure 17-36. IO-550-B Induction Assemblyp. 687
+17-10.3. IO-550-C Induction System Installationp. 688
Figure 17-37. IO-550-C Induction Assemblyp. 689
+17-10.4. IO-550-G, N, P & R Induction System Installationp. 690
Figure 17-38. IO-550-G, N, P & R Induction Assemblyp. 691
+17-11. Fuel Injection System Installationp. 692
+17-11.1. IO-550-A Fuel Injection System Installationp. 692
Figure 17-39. Anti-Seize Applicationp. 692
Figure 17-40. IO-550-A Fuel Injection Assemblyp. 693
+17-11.2. IO-550-B Fuel Injection System Installationp. 694
Figure 17-41. IO-550-B Fuel Injection Assemblyp. 695
+17-11.3. IO-550-C Fuel Injection System Installationp. 698
Figure 17-42. IO-550-C Fuel Injection Assemblyp. 699
+17-11.4. IO-550-G, N, P & R Fuel Injection System Installationp. 700
Figure 17-43. IO-550-G, N, P & R Fuel Injection Assemblyp. 701
+17-12. Ignition System Installationp. 702
+17-12.1. Continental Ignition System Installationp. 702
Figure 17-44. Continental Ignition Assemblyp. 703
Figure 17-45. Magneto Sensorp. 703
+17-12.2. Champion (Slick) Ignition System Installationp. 704
Figure 17-46. Slick Ignition Assemblyp. 705
+17-13. Compressor (Optional) Mount Installationp. 706
Figure 17-47. Freon Compressor Mounting Assemblyp. 707
Figure 17-48. Sheave Alignmentp. 708
Figure 17-49. Starter Adapter Belt Sheave Alignmentp. 709
Figure 17-50. Belt Tension Adjustmentp. 709
+Chapter 18 . Post-Overhaul Test and Adjustmentsp. 711
+18-1. Introductionp. 711
Table 18-1. Engine Operation Prerequisitesp. 711
18-2. Post-Overhaul Testing Prerequisitesp. 711
18-3. Post-Overhaul Test Operating Limitsp. 713
+18-4. Standard Acceptance Testp. 713
Table 18-2. Standard Acceptance Test Requirementsp. 713
+18-5. Oil Consumption Testp. 714
Table 18-3. Oil Consumption Test Requirementsp. 714
18-6. Drive Belt Tension Checkp. 714
+Appendix A . Glossaryp. 715
A-1. Acronymsp. 715
A-2. Glossaryp. 716
+Appendix B . Torque Specificationsp. 719
+B-1. General Informationp. 719
B-2. Cylinder Torque Procedurep. 721
+B-3. Torque Wrench and Extension Calculationsp. 722
Figure B-1. Torque Wrenchp. 722
Figure B-2. Drive extensionsp. 722
Figure B-3. Extension increases applied torquep. 723
Figure B-4. Extension decreases applied torquep. 723
Table B-1. General Torque Specificationp. 724
Table B-2. Tube Fitting Torque Specificationsp. 725
Table B-3. Hose Fitting (“B” Nut) Torque Specificationp. 725
Table B-4. Component Specific Torque Specificationsp. 726
Table B-5. Specific Torque for Non-Lubricated Hardwarep. 730
+Appendix C . Standard Practicesp. 731
C-1. Handling Partsp. 731
+C-2. Replacement Partsp. 732
C-2.1. Backgroundp. 732
+C-2.2. Acceptable Replacement Partsp. 732
C-2.2.1. Know Your Supplierp. 733
C-2.3. 100% Parts Replacement Requirementsp. 733
C-2.4. Mandatory Overhaul Replacement Partsp. 734
C-2.5. Authorized Oversize/Undersize Partsp. 734
C-3. Torquep. 734
+C-4. Safety Wiring Hardwarep. 735
Figure C-1. Right-hand-thread safety wire installationp. 735
Figure C-2. Safety wire Patterns for Right-Hand Threadsp. 736
+C-5. Tab Washer Installationp. 737
Figure C-3. Tab Washer Installationp. 737
+C-6. Helical Coil Insert Replacementp. 738
+C-6.1. Helical Coil Removalp. 739
Figure C-4. Helical Coil Extraction Toolp. 739
+C-6.2. Helical Coil Insertionp. 740
Figure C-5. Installing a Helical Coil Insertp. 740
+C-7. Stud Replacementp. 741
+C-7.1. Stud Removalp. 741
+C-7.1.1. Size-on-Size Rosan® Stud Removalp. 742
Table C-1. Rosan® Stud Primary & Secondary Bore Specificationsp. 742
+C-7.1.2. Step-Type Rosan® Stud Removalp. 742
+C-7.1.2.1. Step-Type Rosan® Stud Removal Method 1p. 742
Figure C-6. Rosan® Stud Removal Toolp. 743
Figure C-7. Rosan® Stud Removal Tool Installed on Studp. 743
C-7.1.2.2. Step-Type Rosan® Stud Removal Method 2p. 743
+C-7.2. Stud Installationp. 744
Figure C-8. Stud Sizesp. 744
Figure C-9. Minimum Material Thickness for Helical Coil insertionp. 745
+C-7.2.1. Rosan® Stud Installationp. 745
Figure C-10. Rosan® Stud Installation Dimensionsp. 745
+C-8. Cotter Pin Installationp. 746
Figure C-11. Cotter Pin Installationp. 746
+C-9. Fuel System Servicep. 747
C-9.1. Fuel System Purgep. 747
C-10. Gasket Maker® Applicationp. 748
C-11. Gasket Installationp. 749
+C-12. Hose and Tubing Installationp. 750
Figure C-12. Installing Hoses and Fittingsp. 750
C-13. Harness Routingp. 751
+Appendix D . Overhaul Dimensional Limitsp. 753
D-1. Overhaul Dimensional Limits=New Part Dimensionsp. 753
+D-2. Fuel Injection Systemp. 754
Figure D-1. Fuel Pump Drive Coupling Fits & Limitsp. 754
Table D-1. Fuel Pump Drive Coupling Dimensionsp. 754
D-2.1. Throttle Leverp. 755
+D-3. Starter and Starter Adapterp. 756
Figure D-2. Basic Starter Adapterp. 756
Table D-2. Basic Starter Adapter Overhaul Dimensionsp. 757
Figure D-3. Starter and Starter Adapter with Scavenge Pump Dimensionsp. 758
Table D-3. Starter/Starter Adapter with Scavenge Pump Dimensionsp. 759
Figure D-4. Worm Wheel Drum Dimensionsp. 760
Table D-4. Worm Wheel Drum Dimensionsp. 760
Figure D-5. Shaft Gear Drum Dimensionsp. 760
Table D-5. Shaft Gear Drum Fits & Limitsp. 760
+D-4. Ignition Systemp. 761
Table D-6. Ignition System Dimensionalp. 761
Figure D-6. Accessory Drive Adapter Dimensionsp. 761
+D-5. Lubrication Systemp. 762
Table D-7. Lubrication System Dimensionsp. 762
Table D-8. Lubrication System Components Dimensionsp. 763
Figure D-7. Oil Pump Dimensionsp. 763
+D-6. Engine Cylinder Overhaul Dimensionsp. 764
Table D-9. Cylinder Assembly Dimensionsp. 764
Figure D-8. IO-550-A, B & C Updraft Cylinder Dimensionsp. 765
Table D-10. Updraft Engine Cylinder Assembly Dimensionsp. 766
Figure D-9. Cylinder Assembly Dimensionsp. 768
Table D-11. Crossflow Cylinder Assembly Dimensionsp. 769
Table D-12. Cylinder Assembly Dimensionsp. 770
Figure D-10. Cylinder Barrel Dimensionsp. 771
Table D-13. Cylinder Barrel Dimensionsp. 771
Figure D-11. Intake Valve Seat Dimensionsp. 772
Figure D-12. Exhaust Valve Seat Dimensionsp. 773
Figure D-13. New Intake Valve Dimensionsp. 774
Figure D-14. New Exhaust Valve Dimensionsp. 774
+D-7. Crankcasep. 775
Table D-14. Additional Crankcase Dimensionsp. 775
Figure D-15. Crankcase Main Bearing Oil Feed Hole Chamferp. 775
Figure D-16. Crankcase Dimensionsp. 776
Table D-15. Crankcase Dimensionsp. 776
+D-8. Engine Drive Trainp. 777
Table D-16. Additional Engine Drive Train Dimensionsp. 777
Figure D-17. Engine Drive Train Dimensionsp. 777
Table D-17. Engine Drive Train Dimensionsp. 778
Figure D-18. Crankshaft, Camshaft, and Idler Gear Backlashp. 779
Table D-18. Crankshaft, Camshaft, and Idler Gear Backlashp. 779
Figure D-19. Pushrod Dimensionsp. 779
+D-8.1. Crankshaft Counterweight Assembliesp. 780
Figure D-20. Counterweight Assemblyp. 780
+D-8.2. Counterweight Pinsp. 780
Table D-19. Counterweight Pin Part Numbersp. 780
+D-8.3. Crankshaft Hanger Blade and Counterweight Bushing Dimensionsp. 781
Table D-20. Crankshaft Counterweight Blade Bushing Dimensionsp. 781
Figure D-21. Crankshaft Counterweight Bushing Bore Dimensionsp. 781
Figure D-22. Crankshaft Counterweight Bushing Dimensionsp. 781
Figure D-23. Crankshaft Hanger Blade Bushing Borep. 782
Figure D-24. Crankshaft Hanger Blade Bushingp. 782
+D-8.4. Connecting Rod Dimensionsp. 783
Figure D-25. Connecting Rod Dimensionsp. 783
+D-9. Stud Height Settingsp. 784
+D-9.1. Starter Adapter Stud Height Settingsp. 784
Figure D-26. Basic Starter Adapter Studsp. 784
Table D-21. Basic Starter Adapter Stud Heightsp. 784
Figure D-27. Starter Adapter with Accessory Drive Studsp. 785
Table D-22. Starter Adapter with Accessory Drive Stud Heightsp. 785
+D-9.2. Lubrication System Stud Height Settingsp. 786
Figure D-28. Lubrication System Stud Height Settingsp. 786
Figure D-29. IO-550-B & -R Oil SUmp Stud Height Settingp. 786
+D-9.3. Accessory Drive Adapter Stud Heightp. 787
Figure D-30. Accessory Drive Adapterp. 787
+D-9.4. Cylinder Stud Height Settingsp. 788
Figure D-31. Cylinder Stud Heightsp. 788
Table D-23. Cylinder Stud Heightsp. 788
+D-9.5. Oil Control Collar Stud Height Settingsp. 789
Figure D-32. Oil Control Collar Stud Height Settingsp. 789
+D-9.6. Crankcase Plugs and Fittingsp. 789
Table D-24. Crankcase Plugsp. 789
+D-9.7. Crankcase Stud Height Settingsp. 790
Table D-25. 656619-1 & -5 Crankcase Stud Heightsp. 790
Figure D-33. Crankcase Stud Detailp. 791
Table D-26. 656619-2 and -6 Crankcase Stud Heightsp. 792
Table D-27. 656619-3 Crankcase Stud Heightsp. 794
Table D-28. 656619-4 Crankcase Stud Heightsp. 796
Table D-29. 656619-7 Crankcase Stud Heightsp. 798
Table D-30. 656619-8 Crankcase Stud Heightsp. 800
Table D-31. 656619-9 Crankcase Stud Heightsp. 802
Figure D-34. 656619-9 Crankcase Stud Detailp. 803
Table D-32. 656619-10 Crankcase Stud Heightsp. 804
Figure D-35. 656619-10 Crankcase Stud Detailp. 805
Table D-33. 656619-11 Crankcase Stud Heightsp. 806
Table D-34. 656619-12 Crankcase Stud Heightsp. 808
Table D-35. 656619-13 Crankcase Stud Heightsp. 810
Table D-36. 656619-14 Crankcase Stud Heightsp. 812
Table D-37. 656619-15 Crankcase Stud Heightsp. 814
Figure D-36. 656619-15, -17 & -24 Crankcase Stud Detailp. 815
Table D-38. 656619-16 Crankcase Stud Heightsp. 816
Figure D-37. 656619-16 & -18 Crankcase Stud Detailp. 817
Table D-39. 656619-17 Crankcase Stud Heightsp. 818
Table D-40. 656619-18 Crankcase Stud Heightsp. 820
This Continental IO-550 Permold Series maintenance and overhaul manual M-16 is arranged in a sequential order that takes you from engine removal and disassembly through cleaning, inspection, repair, assembly, installation, and post-overhaul testing. The depth of coverage means you are not just getting a tune-up guide; you are getting the complete manufacturer’s overhaul protocol for seven engine models in one document.
What This Continental IO-550 Manual Enables You to Do
With this manual, you can perform the full range of maintenance and overhaul tasks on IO-550-A, B, C, G, N, P and R engines. That includes engine removal and installation, cylinder removal and replacement, hydraulic tappet service, rocker arm adjustment, fuel injector replacement, fuel pump service, magneto timing, alternator replacement, starter adapter repair, oil pump service, oil cooler installation, induction system repair, and complete engine disassembly and reassembly. The troubleshooting chapter helps you diagnose rough running, low power, high oil consumption, abnormal indications, and starting problems. The overhaul chapters guide you through inspection, dimensional checking, repair, and assembly with the manufacturer’s service limits and torque values.
Because this is the 2011 edition of the M-16 manual, it incorporates service documents and updates issued up to that date, including references to service bulletins, service information letters, and mandatory replacement parts. The appendices give you the torque specifications, standard practices, and overhaul dimensional limits you need to work confidently. The engine specifications chapter covers each model’s rated power, compression ratio, firing order, bore, stroke, displacement, oil capacity, fuel grades, temperatures, pressures, and performance data.
Engine Coverage and Model Details
The manual covers seven engine models in the IO-550 Permold Series: IO-550-A, IO-550-B, IO-550-C, IO-550-G, IO-550-N, IO-550-P, and IO-550-R. The IO-550-A, B and C models use updraft cylinders with a single rocker cover per cylinder. The IO-550-G, N, P and R models use crossflow cylinders with separate intake and exhaust rocker covers. The manual identifies these differences and provides model-specific instructions throughout. Engine specifications tables give you the rated maximum continuous operation, recommended cruise, fuel consumption, ignition timing, spark plug gap, cylinder head temperature limits, oil pressure limits, oil temperature limits, oil sump capacity, usable oil, recommended oil grades, weight, and dimensions for each model.
This manual was published by Continental Motors, Inc. and is intended for FAA-licensed mechanics or FAA-certified repair station employees working under supervision. It assumes the user has the knowledge, training, and experience commensurate with FAA license and certification requirements. Installation of aftermarket parts is a deviation from the approved type design, and Continental Motors does not provide product manufacturing specifications to aftermarket parts manufacturers.
Get the Continental IO-550 Permold Series Engine Manual M-16 in PDF
This Continental IO-550 A B C G N P R Permold Series Engine Maintenance and Overhaul Manual M-16 is delivered as an instant PDF download after payment. There is no shipping, no waiting, and no physical product to handle. You can open it on any device that reads PDFs, search through the text, print the pages you need for the shop, and keep the file on your computer or tablet for quick reference. The 824-page document is the complete manual, not a partial scan or a collection of excerpts. If you maintain, repair, or overhaul Continental IO-550 Permold Series engines, this manual gives you the manufacturer’s procedures, specifications, and service limits in one convenient file.
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