FI-2

CONTINENTAL® AIRCRAFT ENGINE

POSITION TUNED FUEL

INJECTOR NOZZLES
Printing Instructions CLOSE
To print this document in its intended booklet format:
1. From the File menu, select Print.

2. Select the Printer Name to send the output to from the available options. If the
printer Installation
automatically printsand
duplexMaintenance
(both sides of the paper), select that option
Manual
from the printer Properties dialog box.
3. Click All option in the Print Range group.
4. In the Page Handling group, select the number of copies to print. Change Page
Scaling to Booklet Printing and Booklet subset to Both sides with Binding on
the Left side.
5. Click the OK button at the bottom right to commence printing.

Publication FI-2
©
2011 CONTINENTAL MOTORS, INC. AUGUST 2011
Supersedure Notice
This manual is a revision of the information contained in Publication Part No. FI-2, dated 30 Janu-
ary 2010. Previous editions are obsolete upon release of this manual.

Effective Changes for this Manual

0............... 31 August 2011

List of Effective Pages

Document Title:Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual
Publication Number: FI-2 Initial Publication Date: 31 August 2011
Page Change Page Change Page Change Page Change
Cover ..............................0
A......................................0
1 thru 12..........................0

Published and printed in the U.S.A. by Continental Motors, Inc.

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

Copyright © 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or
otherwise altered without the publisher's written permission. This manual is provided without express, statutory, or implied war-
ranties. The publisher will not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or mis-
interpretation of the contents. Content is subject to change without notice. Other products and companies mentioned herein
may be trademarks of the respective owners.

A Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011
 CONTENTS
A. Introduction.................................................................................1
B. Engine Optimization ...................................................................1
C. Fuel Management.......................................................................3
D. Fuel Injector Nozzle Descriptions ...............................................4
E. Installation Instructions ...............................................................6
F. Maintenance Instructions............................................................9

Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual 1

31 August 2011
A. Introduction
Continental Motors has made significant improvements in fuel system
quality and variation reduction through computer automation of the
fuel system manufacturing component calibration test stands.
Continental Motors Position Tuned Fuel Injector Nozzles match the
fuel flow to the air flow of each cylinder. During development, an
automated test cell process measures the aircraft exhaust system
contribution. The factory Position Tuned Fuel Injector Nozzle System
allows the pilot to lean the fuel flow within the Airplane Flight Manual
(AFM)/Pilot’s Operating Handbook (POH) requirements with optimum
results.
B. Engine Optimization
Continental Motors fuel nozzles have traditionally been matched to
provide equal fuel flow to each cylinder. On early fuel injection model
engines, airflow differed between cylinders due to induction system
design and engine speed. Our latest engine models (IO-360-ES, IO-
550-N, TSIO-550-B, C, E, G & K) feature balanced induction
systems. The airflow difference between engine cylinders is
dramatically reduced, although not totally eliminated (Figure 1). Due
to the minute cylinder-to-cylinder airflow differences, we developed
“position tuned” nozzle fuel systems to match injector fuel flow to the
individual cylinder airflow at specific cruise settings.
Our engineers developed a method to test the fuel mixture lean out
curve on an automated test cell to measure and evaluate the fuel flow
range between the first and the last cylinder EGT peaks as the
mixture is leaned from full rich at various operating conditions. These
state-of-the-art measurement capabilities ensure accurate and
consistent results. A full set of engine data is recorded. Because the
engine exhaust system can affect the cylinder-to-cylinder airflow;
some specific engine models are optimized with the aircraft exhaust
system installed.
Based on the actual fuel flow value at each cylinder's peak EGT,
individual fuel injector nozzle flows were changed to align the peaks
(Figure 2). This ensures each cylinder is operating at the same air/
fuel ratio at the cruise condition. EGT peak-to-peak fuel flow ranges
were also checked at other operating conditions.
NOTE: Figures 1, 2 & 3 depict controlled engine test
cell results. Individual engine peak EGT range
variations may vary in the field.

2 Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011
 Figure 1. Before Optimization

Figure 2. After Optimization

Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual 3

31 August 2011
C. Fuel Management
Engine fuel flow adjustments must be according to the engine
manufacturer's specifications, STC holder's specifications, or the
Aircraft Manufacturer's AFM/POH. Observe the engine
manufacturer's, the STC holder, or the aircraft manufacturer's turbine
inlet temperature (TIT) restrictions for turbocharged aircraft. Do not
alter specified leaning practices. Operation outside of established
specifications violates the manufacturer's type design data under
which the engine was originally certified and may cause severe
damage to the engine.
A typical 75% power plot (Figure 3) shows the fuel can be leaned
from a full rich fuel flow of 21.6 GPH to 18.0 GPH for best power (75
degrees rich of first cylinder to peak). For improved fuel economy the
fuel flow can be further leaned to 14.3 GPH (50 degrees lean of last
cylinder to peak). Note on this example, corrected brake horsepower
is reduced approximately 10% at Best Economy versus the Best
Power fuel flow setting. Position Tuned Fuel Injector Nozzles allow
the pilot to lean the fuel flow within POH recommendations with
optimum results.

Figure 3. Engine Performance After Optimization

4 Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011
D. Fuel Injector Nozzle Descriptions
In 2004, Continental Motors refined the fuel injector nozzle flow stand
measurement capability and automated the test classification
process. The best available flow measurement and pressure control
capabilities are now integrated into the test stand. This process flows
the fuel injector nozzle at three different fuel supply pressures,
creates an orifice flow equation from the data, and calculates the
equivalent flow at specific supply pressures. This equivalent flow
value is used to classify the fuel injector nozzle. With the capability to
manufacture and measure fuel injector nozzle flow very precisely, we
were able to decrease the fuel injector nozzle flow classification
tolerance 60%. This resulted in over 70 different fuel injector nozzle
flow classification sizes.
Our fuel injector nozzles have undergone three quality improvement
processes since origin. First generation fuel injector nozzles were
identified by three-character fuel injector nozzle size codes (Figure 4)
on the wrench flat.

Figure 4. First Generation Tuned Fuel Injector Nozzle

The second generation extended the identification to four-characters,
including the installed cylinder position at the left-most character
(Figure 5) in the identification.
Continental Motors fuel injector nozzles manufactured after Dec 2005
(third generation), etched on four faces of the wrench flats (see
Figure 6) are the only available replacement nozzles. To select the
proper replacement nozzles, you must first identify which generation
is installed. If the injectors to be replaced do not conform to the new
format, they have been superseded by the current number. A factory

Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual 5

31 August 2011
 service representative can help determine the correct replacement
once the faulty fuel injector nozzle is properly identified.

Figure 5. Second Generation Tuned Fuel Injector Nozzle

Observe the markings in Figure 6. A three digit numeric code used
during the manufacturing process is stamped on two faces of the fuel
injector nozzle's wrench flat - this code is the same for all fuel injector
nozzles in the set. Adjacent to the three digit number, four digits
indicating the cylinder position number and nozzle flow are stamped
on two faces of the wrench flat; use this 4 digit number when
assigning fuel injector nozzles to cylinders. When ordering
replacement fuel injector nozzles, specify the position number and
nozzle flow for each fuel injector nozzle required.

Figure 6. Second Generation Tuned Fuel Injector Nozzle

6 Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011
E. Installation Instructions
1. Remove cowling and any airframe accessories that may obstruct
access to the fuel injector nozzles in accordance with the airframe
manufacturer's instructions.
2. Turn aircraft fuel selector to the OFF position.
3. Loosen and remove the fuel injection lines from the existing fuel
injector nozzles. On turbocharged engine models, loosen fuel
injector nozzle sleeve assembly nuts from the upper deck
reference tubes and remove metal washer, rubber washer and
sleeve assemblies from each fuel injector nozzle. Discard the
rubber washers.
CAUTION: Clearance surrounding the injector nozzle
is limited on some engine models. Use an Ideal
Aviation Part No. 8165-IA Injector Remover/ Installer
to avoid injector or cylinder damage.
4. Loosen and remove the fuel injector nozzles from each cylinder.
NOTE: Return the removed nozzles to the authorized
Continental Motors Distributor you purchased the
replacement nozzles from for a core credit.
5. Remove new position tuned fuel injector nozzles from the
container and remove the protective covers from each fuel
injector nozzle.
6. Visually inspect the fuel injector nozzle jet orifice to verify it is free
of obstructions or contamination. If cleaning is required, follow the
“Maintenance Instructions” in Section F.
7. On fuel injector nozzles equipped with O-rings, install new O-
rings on each fuel injector nozzle. Sparingly apply Dow Corning
No. 4 lubricant to the O-rings.
8. Apply a thin film of anti-seize compound (P/N 646943) to the
(Figure 7) fuel injector nozzle threads.

Figure 7. Position Tuned Fuel Injector Nozzle

Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual 7

31 August 2011
 CAUTION: Failure to match the fuel injector nozzle to
the correct engine cylinder may cause abnormal
engine operation or engine damage.
9. Match the position tuned fuel injector nozzle to the cylinder
position number (Figure 6) stamped on the wrench flat. Install the
nozzles in the cylinder nozzle ports; finger-tighten the nozzles to
prevent cross-threading. Refer to Figure 8 for engine crankcase
cylinder arrangement.

Figure 8. Cylinder to Crankcase Arrangement

10. Torque each fuel injector nozzle to a value of 55 to 65 inch
pounds using a calibrated torque wrench.

8 Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011
 Figure 9. Turbocharged Fuel Injector Assembly
11. For turbocharged engines, reinstall air reference sleeve
assemblies on the nozzles. Connect the deck reference pressure
tube to the sleeve with a new seal. Tighten the nut to upper deck
reference tube finger-tight to set seal between nut and male
connector; tighten an additional ¾ to 1 turn.
12. Install a new rubber washer and the previously removed metal
washer on each fuel injector nozzle (Figure 9).
CAUTION: Do not apply any type of thread lubricant
or sealant to the fuel injection line to fuel injector
nozzle junction.
13. Reconnect each fuel injection line to the appropriate fuel injector
nozzle and tighten to a torque value of 40 to 45 inch pounds.
14. Turn the aircraft fuel selector to the ON position.
15. Perform a complete fuel system leak check in accordance with
the aircraft manufacturer's or STC holder's instructions prior to
engine operation.

Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual 9

31 August 2011
 16. Check the engine fuel injection system to verify proper fuel flow
parameters in accordance with the aircraft manufacturer's or STC
holder's instructions and the latest revision of Service Document
SID97-3 or SID07-3, depending on engine model.
17. Reinstall all airframe-supplied accessories and cowling in
accordance with the airframe manufacturer's instructions.
F. Maintenance Instructions
Remove fuel injector nozzles annually or every 300 hours of engine
operation (whichever occurs first) and clean as follows:
1. Remove cowling and airframe accessories that may obstruct
access to the fuel injector nozzles according to the airframe
manufacturer's instructions.
2. Turn aircraft fuel selector to the OFF position.
3. Loosen and remove the fuel lines from the fuel injector nozzles.
For turbocharged engine models, loosen fuel injector nozzle
sleeve assembly nuts from the upper deck reference tubes and
remove metal washer, rubber washer and sleeve assemblies
from each fuel injector nozzle. Discard rubber washers.
CAUTION: Clearance surrounding the injector nozzle
is limited on some engine models. Use an Ideal
Aviation Part No. 8165-IA Injector Remover/ Installer
to avoid injector or cylinder damage.
4. Loosen and remove the fuel injector nozzles from each cylinder.
Remove and discard o-rings, if the configuration uses them, from
the fuel injector nozzles.
CAUTION: Use only approved fuel injector nozzle
solvent. Unapproved solvents may erode the brass fuel
injector nozzles.
5. Clean each fuel injector nozzle in an ultrasonic cleanser bath
according to the instructions provided by the manufacturer of the
ultrasonic cleanser. If an ultrasonic cleanser is not available, soak
the nozzles in lacquer thinner, methyl ethyl ketone (MEK) or
acetone for several hours. Wipe the exterior of the fuel injector
nozzle clean with a lint-free cloth. Dry the fuel injector nozzle
interior with dry compressed air. Visually inspect the nozzle jet
orifice to verify it is open and there are no obstructions.
CAUTION: Never attempt to clear or clean a fuel
injector nozzle jet orifice restriction using a sharp
object, reamer or a blasting medium. Replace fuel
injector nozzles which cannot be satisfactorily cleaned.

10 Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011
 6. If a nozzle jet orifice is obstructed and cannot be cleaned with
solvent, replace the nozzle.
7. Once each fuel injector nozzle is clean and free of any restriction,
reinstall fuel injector nozzles:
8. On fuel injector nozzles equipped with O-rings, install new O-
rings on each fuel injector nozzle. Sparingly apply Dow Corning
No. 4 lubricant to the O-rings.
9. Apply a thin film of anti-seize compound (Part No. 646943) to
tapered fuel injector nozzle (Figure 7) threads.
CAUTION: Failure to match the fuel injector nozzle to
the correct engine cylinder may cause abnormal
engine operation or engine damage.
10. Match the position tuned fuel injector nozzle to the cylinder
position number (Figure 6) stamped on the wrench flat. Install the
nozzles in the cylinder nozzle port; finger-tighten the nozzles to
prevent cross-threading. Refer to Figure 8 for engine crankcase
cylinder arrangement.
11. Torque each fuel injector nozzle to a torque value of 55 to 65 inch
pounds using a calibrated torque wrench.
12. For turbocharged engine models, reinstall fuel injector nozzle
sleeve assemblies and tighten nut to upper deck reference tube
finger tight to set the seal between the nut and male connector;
tighten an additional ¾ to 1 turn.
13. Install a new rubber washer and previously removed metal
washer on each fuel injector nozzle (see Figure 9).
CAUTION: Do not apply any type of thread lubricant
or sealant to the fuel injection line to fuel injector
nozzle junction.
14. Reinstall each fuel injection line to the appropriate fuel injector
nozzle and torque to a value of 40 to 45 inch pounds.
15. Turn aircraft fuel selector to the ON position.
16. Check the engine fuel injection system to verify proper fuel flow
parameters in accordance with the aircraft manufacturer's or STC
holder's instructions and the latest revision of Service Document
SID97-3 or SID07-3, depending on engine model.
17. Reinstall all airframe-supplied accessories and cowling in
accordance with the airframe manufacturer's instructions.

Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual 11

31 August 2011
 NOTES

12 Position Tuned Fuel Injector Nozzle Installation and Maintenance Manual

31 August 2011