MODELS C75, C85, C90 & 0-200 CONTINENTAL® AIRCRAFT ENGINE OVERHAUL MANUAL $e TELEDYNE CONTINENTAL MOTORS Aircraft Products Division FAA APPROVED FORM X-30010 FEBRUARY 1980FORM X-30010 OVERHAUL MANUAL FOR AIRCRAFT ENGINE MODELS C75,C85,C90 & 0-200 FAA APPROVED FEBRUARY 1980FOREWORD This manual is published for the guidance of all facilities engaged in operation, maintenance and overhaul of four cylinder engines of the Teledyne Continental C and 0-200 Series, A description is included in this manual of che various models and special equipments of the series and photographs selected co illustrate the major differences between models. The Table of Specifications provides more detailed information in regard to features and performance of the models. It should be noticed that such descriptive material is neither intended nor adequate to enable conversion of any model to another in instances in which such conversion is permissible. For detailed information regarding application of parts and their interchangeability, refer to the Spare Parts Catalog. For model and series number conversion instructions, refer to the Teledyne Continental Service Bulletin on that subject. Service maintenance instructions relative to accessories installed on Teledyne Continental aircraft engines in our factory are reprinted herein by permission of the accessory manufacturers. Instructions for overhaul of these acces- sories may be obtained direct from the manufacturers or through their authorized service facilities. All descriptive and dimensional information and all instructions contained in this edition have been revised and extended to cover all four cylinder models of the Teledyne Continental C Series in current production. The parts catalog section is not included in this edition, since it is subject to frequent change in details. A manual of this scope cannot be revised often enough to be kept up to date at all times, since it is our policy to improve details of engine design in the interest of maximum safety and utility of our products whenever the results of our continuous experimental and development program indicate the desirability of replacing the old with something even better. For this reason we issue Service Bulletins to our Approved Distributors to advise of imporeant changes in parts, desirable inspections and precautions found necessary in operation and maintenance. These bulletins are available for reading at all Teledyne Continental Approved Service Stations. Those who need permanent copies of Service Bulletins may obtain them by dizect mail, as issued, from the factory Publications Department on an annual subscription basis. A nominal charge is made to cover the cost of mailing. It is suggested that a careful study of the text of this manual will provide the reader with knowledge of engine construction and of techniques for both operation and repair work which, if applied in practice, will promote safety in flight and long engine life. If, in spite of the high quality of materials and the careful inspection and testing of these engines, any defect is suspected, che question should be brought immediately to the attention of the nearest Teledyne Continental Approved Service Station so that a diagnosis and any necessary correction may be made.TABLE OF CONTENTS ! Section Section San side age Pas ide age : aeeeepeceeeeeea aes esse geet ee cesses Lt Model Designation 9 Sa Fable storge a 12 Denton and Abbeeviaion 9 54 Temporary Stnge © 3 bree » - Cleanliness. - Ae: VI Installation in Airplane & Removal. 33 G4 Moondngthe Bogie sss cererslssc 32 1 Table ofpecitenions.... eee eae 7 5m Great Desiptoneeseeseeesseeee 16 $2 CBS RER x FL iene etreen oad Gouge.) ag GE Peper nwaeon - 32 Sigicance of Sees Dash sei eae eee 33 Model Conversions........... Flan vit ‘Operating Instruction. . see ge, ty 71 Procedure Prelminery 0 Stang 0.39 eee 17 72 Satghiocnius cs sseenl 36 ‘Crankcase Construction . pee Warm-Up... ....+ 9 a7 ‘Crankshafts 18 cis Ground Test, . 9 38 Nitrided Crankshafts 18 a Take-Off... . # Gad 39 ‘Crankshaft Gears. poset 19 abst ‘Climbing + bad 3-10 Connecting Rods... eo... 19 77 Level Flight . 40 cone 78 LerDown and Landing a 312 Camshaft Gears. . 19 ad ‘Stopping the Engine, . . . al 313 Hydraulic Valve Lifters. 20 ae Lubsicating Oil F F 41 347 Pushrods and Housings... . =. . 2 74 Engine Fuel sees 42 hie Pinon Asenbls a 319 Cylinder Assemblies cee 20 yt Engine Troubles and Service 325 Chankewe Cover Asebiy for pooner “12,14, 16 & 0200 Model. 2 aa Seen eee 3 Periodic Inspection and Maintenance, .,. 47 ee 2 51 allpinpectons 4 3-28, Carburetor Induction System. i 24 Pe pues Ey He Inspection = ae See re eee ee ey EEE ootine sess aseana CT Tee eee eae 33e ea 25 -X Adjustment and Minor Repairs... $0 337 Prestolite Starter........... 2008 260 (101 Carburetors sees 50 338 Generator and Drive... . 26 10-7 ‘Magnetos. seeeeee 52 3:39 Side Mounted Fuel Pump........... 26 10-18 Replacement of Ignition Cables... 56 sot ibsa pes pap Ease ce Tela, oor lioneomeny same Ties Perera i 1030 Premaliw Sumer, es soocollllole 9 1038 Generaorand Deve ets: Fe ere eevee 1A Shipping Cres eer 42 Nethodof Packing and Preservation 623 XLDisagembly eee eeeeeeeeesee 8 43 “Removal ofRngne fom Gute. 1.30 dtd—_raioary Operon 6 44 reparionforintaition = --.s.0. =. 30110. —‘Daerbly &Section & Para, xu 1 126 xm Ba 132 Bs Bat xv 1 7 Mea, 14.21 xv 15-1 4 Table No, " mn vl vit vit 1x XI xm xu TABLE OF CONTENTS (Con’t) Tine Cleaning Marerils and Processes, Specific Parts Inspection . Definitions. .. Inspection Tools Inspection Methods . Inspection of Critical Parts « Repair and Replacement. General Repair Repair and Replacement of Specific Parts Grankcase Modification Protective Coatings .....- Assembly of Subassemblies General Procedure... Detailed Procedure LIST Tide Peatures Common to all Models... ‘Type Certificate Numbers Features Peculiar to Bach Modet Group. ...... Dimensions Peculiar to Each Model ‘or Mode! Dash Number Speed and Power Ratings . ‘Operating Temperature Limits. . Operating Pressure Limits Model or Model Dash Number Equipment. General Ignition System Specifications. 7 Ignition Timing. ........- Valve Mechanism Specifications. Lubrication System Specifications . Fuel Metering System Specifications. .. . Section Page & Para. Tide TL -XVE_—_ Final Assembly 7! 361 General Procedures... sss. TL 16-4 Detailed Procedure : 73 XVII Testing after Overhasl . 73 WA Testing Equipment 73 472 TeseSTand, 74 473 nstruments 7% 174 Test Club, 175 Engine Test after Overhaul 80 17-7 Fuel and Lubricating Oil. : 80 17-8 Testing Engine Installed in Aircraft. 179 Inspection... on 86 XVII] Table of Limits 90 92 92 ey OF TABLES Table Page No. Tide 11 XIV. Accestory Drive Speed Ratios u and Rotation... eee XV Line and Instrument Connections. 11 XVI Weights of Standard Engine Equipment. TL —XVIT Additional Weights of Optional 2 Equipment 12 XVIM_ Recommended Oil Viscosity Grades - 22 XIX ——_-Magnflux laspeetion Data XX Stud Identification Chart 12 XXL Test Operating Limi... XXII Test Schedule 13 XXII Ol Somp Capacity... 13. XXIV. General Use- Tightening Torques.. 33 XXV Pipe Plags . B 1" Page 96 96 96 10s 105 103 105 105 105 108 108 108 au Page 4 cf 15 1s a2 7 80 106 107 108 116 116LIST OF ILLUSTRATIONS Left Side View, Model C85-12F. ‘Three-Quarcer Right Rear View, Model C85-12. ‘Three-Quarter Left Front View, Model C90-16F . . ‘Three-Quarter Right Rear View, Model C90-16F. . Right Front View, Model C90... 222.002. Left Front View, Model 0.200, ...... Cylinder Arrangement Diagram (Top View) Section Through fydraulie Valve Lifter, .. a ne ‘Crankcease Cover and Accessories of -12, -14,-16 and 0-200 Models . Gear Train of -12,-14, -16 and 0-200 Models... . Hoisting Engine by Crankshaft Lifting Eye, ‘Typical installation Diagram for-12, -14 & ~ 16 Modly Side View Installation Drawing for -12, -14 & -16 Models, Front View. Installation Drawing for -12, 14 & -16 Models, Rear View . . Installation Drawing for -12, -14 & -16 Models, Side and Top Views Engine Mounting Equipment of Models C90-14 & 16 and 0-200 Ignition Wiring Diagram ...... ceeeee Removal of Hydraulic Unit from Valve Lifter Body. . Compressing Valve Spring to Remove Locks. ‘Removing Plunger from Hydraulic Unit with Taped Pliers Installing Helical Coil Inseres eee Dimensions of Rocker Shaft Boss Bushings Daill Fixeure.. . aoe Drilling Hole in Bearing - Dailling Adapter Assembly Plug Detail. . Drill Fixture... Deill Fixture Installed, [Name Plate Change : ‘Tightening No. 1 Connecting Rod Bolts... Installing Crankshafe Bearing and Old Type Thrust Washer » Installing Crankshaft znd Connecting Rods. Installing Dowel Type Thrust Washers and Split Oil Seal... Installing Starter Pinion Pivot i Installing Crankease 1, 3 Side on 2, 4 Side Installing Crankease Cover on -12, -14, 16 and 0-200 Models Installing No. 3 Cylinder. . . Installing “O” Rings on Intake Manifold Studs - 102 Placing Crankshaft in Firing Position of No. 1 Piston... .. 103 Placing Flange Crankshaft in Firing Position of No. 1 Piston 103 109 Fuel Flow Limits vs. RP.M. at Propeller Load, Model C90... Fuel Plow Limits vs. RP.M, at Propeller Load, Models C75 and C85: 109 Fuel Flow Limits vs. RP.M, at Propeller Load, Madel 0-200 110 Limits and Lubrication Chart (Sheet 1 of 4) - Cross Section View... 47 Limits and Lubrication Charc (Sheet 2 of 4) - Longitudinal Section View a8 Limits and Lubrication Chart (Sheet $ of 4)- Rear View & Hotizontal Section -8 Models. a9 Limits and Lubrication Chare Sheet 4 of 4) - Rear View & Sections, “12, 14 and 0-200 Models . ce veeee neces 120