08 - Cylinder Installation

Instructional Series for Aviation Mechanics
Continental® Engine
Cylinder Installation
Ready Reference Guide
Form No. X30653 Rev. 3
© 2007, Teledyne Continental Motors, Inc.

Continental® Engine Cylinder Installation
Instructional Series for Aviation Mechanics
OBJECTIVE
This Ready Reference Guide is provided to assist you in performing the correct procedures for
cylinder removal and installation for Continental engines. Service information is subject to
revision/deletion. Insure that the data used in the Maintenance / Overhaul Manuals and TCM
Service bulletins are current. The information in this booklet is derived from TCM Service
Documentation. This information is subject to change and therefore can only be used as a
reference companion to the training video. Do not use this reference guide on the job!
Do not perform any maintenance, preventive maintenance or alterations on certificated aircraft
and engines unless you meet the educational, experience and licensing requirements mandated
by the FAA or equivalent aviation authority.
INTRODUCTION
This guide details the recommended tools and equipment you will need to remove and replace
cylinder assemblies on the engine. Additionally, diagrams are provided to illustrate the
location for measuring cylinder bore, piston ring gap and piston to cylinder clearance and
photographs showing installation techniques. Dimensional limits are provided as tabular data.
Always insure the data listed in the tables are current and has not been superseded!
CONTENTS
SECTION PAGE
Tools & Equipment Required ................................................. 2
Special Tool Procurement Sources ......................................... 3
Special Tools........................................................................... 4
Sealants, Lubricants & Adhesives .......................................... 7
Cylinder Reference Diagrams................................................. 9
Cylinder Bore & Piston Fit Specifications.............................. 14
Table 1 Piston to Engine Reference........................................ 26
Torque Limits.......................................................................... 28
Cylinder Base Nut & Through Bolt Torque Values ............... 31
Cylinder Torque Procedure..................................................... 32
Torque Sequence Diagrams .................................................... 33
Cylinder Installation Technique Photographs......................... 41
-1-
WARNING
The material provided in this Ready Reference Guide is

intended to assist the technician regarding Teledyne
Continental Motors cylinders installed on engines that
have not been modified from their original type design.
CAUTION:
Engine performance, service life and reliability will be
compromised if the engine’s cylinders are neglected.
CAUTION:
It is imperative that you view the instructional video in its
entirety before performing any of the procedures. Pay
close attention to the Warning and Notice statements that
occur. Insure that you heed these warnings. They are for
your safety!
Tools & Equipment Required

The mechanic should be equipped with a complete set of tools that include the following:
1. Wrenches - 1/4” through 1-1/4”
2. Common and Philips Head Screwdrivers
3. Pliers - Common Diagonal Cutters, Needle Nose, Duck Bill, Snap Ring.
4. Ratchets 1/4”, 3/8” and 1/2” Drive
5. 1/4” Drive Sockets - 5/32” through 1/2”
6. 3/8” Drive Sockets - 3/8” through 1”
7. 1/2” Drive Sockets - 7/16” through 1-1/2”
8. 1/2” Drive Deep well Sockets - 7/16” through 1”
9. Feeler Gauges
10. Leather or Soft Plastic Mallet
11. Calibrated Torque Wrenchesc - 0 through 1000 In. Lbs. or - 0 through 100 Ft. Lbs.
12. Micrometers*
13. Slide Hammer
14. Pullers
15. Thickness Gauges
16. Vernier Calipers*
17. Small Hole Gauges
c Must be currently calibrated, and the calibration must be traceable to the National
Institute for Standards and Technology.
-2-
Special Tool Procurement Sources
All tools in the Special Tools list are for reference only, and not for the purpose of promoting
or suggesting tools to be purchased from the indicated sources. The following information is
given as an aid for procuring special purpose tools.
COMPANY GENERAL PRODUCT SUMMARY
ALCOR Instruments for Light Powered
Box 32516 Aircraft
10130 Jones Maltsberger Rd. Special Tools
San Antonio TX, 78284
(512) 349-3771
KENT - MOORE Precision Instruments
29784 Little Mack Measuring Instruments
Roseville, MI 48066-2298 Precision Tools
(800) 253-0138 Special Tools
CHAMPION SPARK PLUG CO. Spark Plugs, Oil Filters
PO Box 686 1230 Old Norris Rd. Special Tools
Liberty SC 29657
(864) 843-5301
FEDERAL TOOL SUPPLY CO., INC. Precision Inspection Instruments
1144 Eddy St. Special Tools
Providence Rhode Island 02940
(800) 343-2050
AIRCRAFT TOOL SUPPLY Precision Tools
PO Box 4525, 2840 Breard St. Special Tools
Monroe LA 71201
(507) 451- 5310
McMASTER-CARR SUPPLY CO. Precision Tools
PO Box 4355 Special Tools
Chicago Illinois 60680
(312) 833-0300
SNAP ON TOOLS Precision Tools
2611 Commerce Blvd. Special Tools
Birmingham Alabama 35210
(205) 956-1722
KRAUTKRAMER-BRANSON, INC. Ultrasonic Test Equipment
PO Box 350
Lewiston PA 17044
(717) 242-0327
-3-
Special Tools
Specific Tools listed or equivalent tools marketed by other manufacturers are necessary for
overhaul and maintenance of the aircraft engine.
1. 3882 Cylinder Base Nut Wrenches.......................................................................................... Kent-Moore
3882 9/16” hex

3882-1 7/16” hex
3882-2 1/2” hex
3882-3 5/8” hex
3882-4 3/4” hex
2. 8079 Cylinder Base Nut Wrenches or equivalent ............................Borrough’s, Kent-Moore or equivalent
8079 9/16” hex

Modified from
3882 9/16” hex
3. 5203, 5204 & 8158A Cylinder Base Nut Wrenches ..................................................................Kent Moore
8158A
IO-550
-4-
4. 5203, 5204 & 8158A Cylinder Base Nut Wrenches ................................................................. Kent-Moore
5203
5/8”hex 5204
5/8”hex
5203a
9/16”hex
IO-470
IO-520
SERIES
5. 8121 Piston Pin Removers ...................................................................................................... Kent-Moore

6. 53602 Valve Spring Compressor ............................................................................................ Kent-Moore
7. 545-116 Dial Bore Gauges ...........................................................................Federal Tool Supply Co., Inc.
8. CFL10 Cylinder Hone ........................................................................................................ Snap On Tools
9. No. 1675 Valve Seat GrinderSet “Sioux Brand”........................................................... Aircraft Tool Supply
10. AEX 437 Valve Seat Grinder Pilot .437 Diameter........................................................ Aircraft Tool Supply
11. K106 Intake Valve Seat Grinding Stone Roughening 45° ........................................... Aircraft Tool Supply
12. K46 Intake Valve Seat Grinding Stone Finishing 45° .................................................. Aircraft Tool Supply
13. K95 Exhaust Valve Seat Grinding Stone Roughening 45° .......................................... Aircraft Tool Supply
14. K25 Exhaust Valve Seat Grinding Stone Finishing 45° ............................................... Aircraft Tool Supply
15. 5221A Holding Fixture Adapters..................................................... Borrough’s, Kent-Moore or equivalent
16. 5221B Cylinder Holding Fixture.......................................................Borrough’s, Kent-Moore or equivalent
17. 8156 Cylinder Heating Stand ..........................................................Borrough’s, Kent-Moore or equivalent
18. 8086 Valve Seat Insert Remover & Replacer .................................Borrough’s, Kent-Moore or equivalent
19. 4910 Valve Seat Insert Installer.......................................................Borrough’s, Kent-Moore or equivalent
20. 4956 Valve Seat Insert Installer......................................................Borrough’s, Kent-Moore or equivalent
21. 8116 Common Parts Kit ..................................................................Borrough’s, Kent-Moore or equivalent
22. 8116-1B through 15B Boring Bars...................................................Borrough’s, Kent-Moore or equivalent
23. 8116-1R through 15R Reamers.......................................................Borrough’s, Kent-Moore or equivalent
24. 8116-1 through 16 Expanding Guide Bodies...................................Borrough’s, Kent-Moore or equivalent
25. 4909 Valve Seat (Straight Side) Insert Cutters........................................................................ Kent-Moore
4954 Valve Seat (Straight Side) Insert Cutters........................................................................ Kent-Moore
-5-
26. 8135 Valve Seat (Step Side) Insert Cutters............................................................................. Kent-Moore
8136 Valve Seat (Step Side) Insert Cutters............................................................................. Kent-Moore
8138 Valve Seat (Step Side) Insert Cutters............................................................................. Kent-Moore
27. 8122A Common Drive Handle.........................................................Borrough’s, Kent-Moore or equivalent
28. 122 Valve Guide Cleaner ........................................................................................................ Kent-Moore
29. 2874 Valve Guide Remover .................................................................................................... Kent-Moore
30. 2842 Valve Guide Replacer..................................................................................................... Kent-Moore
31. 3170 Floating Holder ......................................................................Borrough’s, Kent-Moore or equivalent
32. 4981 Valve Guide Remover .................................................................................................... Kent-Moore
33. 8116-24 through 29 Valve Stem Hole Reamers ..............................Borrough’s, Kent-Moore or equivalent
34. 2847-2CP Reamer (Carbide Tipped)....................................................................................... Kent-Moore
2847-1CP Reamer (Carbide Tipped)....................................................................................... Kent-Moore
2847-2HP Reamer (High Speed Steel) ................................................................................... Kent-Moore
2847-1HP Reamer (High Speed Steel) ................................................................................... Kent-Moore
35. 2686 Reamer to Morse Taper Adapter (Square Shank) .......................................................... Kent-Moore
36. 2848-1 Plug Gauge for valve guide inspection ........................................................................ Kent-Moore
37. 4943-1HS through 5HS Reamers, Valve Guide Boss ............................................................. Kent-Moore
38. 4918 Spark Plug Insert Replacer.....................................................Borrough’s, Kent-Moore or equivalent
39. 504-1 Spark Plug Insert Tap............................................................Borrough’s, Kent-Moore or equivalent
40. 4919 Spark Plug Insert Remover.....................................................Borrough’s, Kent-Moore or equivalent
41. 445 18 mm Spark Plug Tap or equivalent for straightening out
damaged threads.............................................................................Borrough’s, Kent-Moore or equivalent
42. 2769A13 Rosan® Stud Remover ...................................................................McMaster-Carr Supply Co.
Rosan® is a registered trademark of Fairchild Aerospace Fastener Division
43. 8074 Rosan® Lock Ring Installer ........................................................................................... Kent-Moore
44. 8118 Rocker Arm Bushing Remover/Installer.......................................................................... Kent-Moore
45. 7232 Reamer Rocker Arm Bushing ......................................................................................... Kent-Moore
46. 8181-1 Drill Guide for improved rocker shaft retention ............................................................ Kent-Moore
47. 8181-2 Drill Guide for improved rocker shaft retention ............................................................ Kent-Moore
48. 8165 Fuel Injector Nozzle Remover and Installer ............................Borrough’s, Kent-Moore or equivalent
49. 2839 Ring Compressor............................................................................................................ Kent-Moore
50. 68-3 Push Rod Spring Compressor......................................................................................... Kent-Moore
-6-
Sealants, Lubricants & Adhesives
Aviation Engine Oil Ashless Dispersant

Recommended Grade
Above 40°F ambient air, sea level SAE 50 or Multi Viscosity

Below 40°F ambient air, sea level SAE 30 or Multi Viscosity
Manufacturer Brand Name
BP Oil Corporation BP Aero Oil
Castrol Castrol Aero AD Oil
Castrol Limited (Australia) Castrol Aero AD Oil
Chevron U.S.A., Inc. Chevron Aero Oil
Continental Oil Conco Aero S
Delta Petroleum Company Delta Avoil Oil
Exxon Company, U.S.A. Exxon Elite
Exxon Company, U.S.A. Exxon Aviation Oil EE
Gulf Oil Company Gulfpride Aviation AD
Mobil Oil Company Mobil Aero Oil
NYCO S.A. TURBONYCOIL 3570
Pennzoil Company Pennzoil Aircraft Engine Oil
Phillips Petroleum Company Phillips 66 Aviation Oil, Type A
Phillips Petroleum Company X/C Aviation Multiviscosity Oil
SAE 20W50, SAE 20W60
Quaker State Oil & Refining Company Quaker State AD Aviation Engine Oil
Red Ram Limited (Canada) Red Ram X/C Aviation Oil 20W50
Shell Australia Aeroshell (R) W
Shell Canada Limited Aeroshell Oil W, 15W-50 Anti-Wear Formulation
Shell USA Aeroshell Oil W, 15W-50 Anti-Wear Formulation
Shell USA Aeroshell Oil W100 Plus, W80 Plus
Sinclair Oil Company Sinclair Avoil
Texaco Inc. Texaco Aircraft Engine Oil - Premium AD
Total France Total Aero DM 15W50
Union Oil Company of California Union Aircraft Engine Oil HD
-7-
Break-in Oil
SAE J 1966 – Aviation (replaces MIL-L-6082) non-dispersant mineral lubricating oil for piston aircraft engines.
MIL-C-6529 Type II Corrosion preventive mineral oil
NOTE . . . Mineral oil conforming with MIL-C-6529 Type II contains a corrosion preventive additive and must not be
used for more than 25 hours or six months, whichever occurs first. If oil consumption has not stabilized in this
time, drain and replenish the oil and replace the oil filter.
Preservative Oil
TYPE EQUIVALENT APPLICATION
MIL-P-46002 Grade 1 Oil, (NOX RUST VCI-105) For Temporary and Indefinite Storage
MIL-P-46002 Motorstor Engine Protectant For Temporary and Indefinite Storage
Refer to the most current version of service bulletin SIL99-2B for current listings of Sealant, Lubricants
and Adhesives to be used when removing and replacing components on the Continental Engine. Also
refer to the most current version of the Applicable Maintenance and Overhaul manuals for the engine
model you are working on.
WARNING
The use of any form of silicone RTV Sealant or other sealant applied
between the cylinder base flange and the crankcase mounting deck
will cause a loss of torque and can severely damage the crankcase,
possibly resulting in separation of the cylinder from the crankcase
causing sudden loss of engine oil and subsequent engine failure.
-8-
Cross Sectional Diagram showing interaction of cylinder,

crankcase and valve train components
CYLINDER
BARREL
CYLINDER CONNECTING
HEAD ROD
VALVE PISTON
ROCKER
ARM
CAM
LOBE
ROCKER
SHAFT PUSHROD
PUSHROD
HOUSING TUBE HYDRAULIC
LIFTER
Cylinder Combustion
Chamber Sectional
-9-
Exploded Parts View for C Series, O200, 300 & O300 Series
Engines
Refer to most current version of SIL97-14 for Cylinder replacement options on C-75, C-
85, C-90, O200, O300 and GO300 Series engines.
INTAKE
VALVE MECHANICAL
TAPPET
CYLINDER
PUSHROD
EXHAUST
VALVE
ROCKER
ARM
VALVE
SPRINGS
PUSHROD PUSHROD ROCKER

HOUSING HOUSING COVER
-10-
Exploded Parts view of all “Updraft” style cylinders
CYLINDER VALVE
“O” RING INTAKE
SEATS VALVE
CYLINDER
BARREL
INNER VALVE
VALVE GUIDE EXHAUST
SPRING CYLINDER VALVE
HEAD
OUTER
VALVE
SPRING
PUSHROD
ROTOCOIL
PUSHROD
HOUSING &
ROCKER ARM ATTACHING
& BUSHING HARDWARE
ROCKER GASKET
COVER
-11-
Exploded Part view of all “Cross Flow” style cylinders
EXHAUST
VALVE INTAKE
CYLINDER BARREL
VALVE
CYLINDER HEAD
VALVE GUIDES
INNER SPRING
OUTER SPRING
ROTOCOIL
PUSHROD PUSHRODS
ROCKER HOUSING
SHAFTS TUBES
ROCKER ARMS
ROCKER COVERS
AND GASKETS
-12-
Photo view of typical cylinder features
ROCKER
SHAFT BOSS
INTAKE VALVE
SPRING & RETAINER
UPDRAFT
INTAKE
PORT
EXHAUST
CYLINDER
PORT CHT BAYONET MOUNT FLANGE
THERMOCOUPLE
BOSS
-13-
Cylinder Bore & Piston Fit Specifications
This section provides the following information:
1. Cylinder bore dimensions - New minimum / maximum , Service Limits (for continuing
cylinders in service between major overhauls) and Oversize Service Limits.
2. Piston to cylinder clearance specifications for graphite coated and non-graphite coated
pistons.
3. Piston ring gaps and location in cylinder to check ring gaps.
4. Piston diameters, piston skirt diameters and pin to dome height dimensions.
The “New Limits MIN & MAX” dimensions are given for D, X & Y so the cylinder barrel can
be ground to a specific configuration for standard or oversized barrels.
Only the D and the X diameters are used to determine the serviceability of the cylinder barrel.
No wear limit is given for Y diameter because it is used as a machining reference only.
New or oversize cylinder bore dimensions must be used at engine overhaul. Oversize
dimensions and service limits may be used to return cylinders to service on engines that have
not reached their published TBO. Do not return to service any cylinder exceeding the limits
specified in the most current revision of service bulletin SID97-4 and applicable overhaul
manuals.
Piston ring gaps and cylinder dimensions must be maintained within the specifications
provided in this bulletin.
The Piston information is presented in table form (Table 1) as an aid for cross reference.
Columns from left to right are: Engine Model, Manganese Phosphate Graphite Coated Piston
P/N, Uncoated Piston P/N, Graphite Coated Piston P/N, Piston Diameter, Skirt Diameter, & Pin
to Dome Height.
CAUTION:
Verify that all rings, piston and cylinder part numbers are the correct
part number for the specific installation. Installation of incorrect part
will cause engine damage and engine malfunction.
-14-
4.50”
CHOKE
4.00”
LENGTH FOR “D” DIA.
“D”
DIA.
6.50”
“Y”
DIA.
5.75”
“X”
DIA.
FIGURE 1. 5.25 INCH CYLINDER

ALL IO-520, IO-550, TSIO-520 except as listed in the following.
Refer to Figure 1
CYLINDER DIAMETER DIMENSIONS
“D” “X” “Y”
SIZE “D” DIAMETER “X” DIAMETER DIAMETER “Y” DIAMETER DIAMETER
DIAMETER SERVICE NEW SERVICE NEW SERVICE
NEW LIMITS LIMITS LIMITS
MIN. MAX. MAX. MIN. MAX. MAX. MIN. MAX. MAX.
STD 5.251 5.253 5.256 5.248 5.250 5.257 5.245 5.247 N/A
.005 5.256 5.258 5.261 5.253 5.255 5.262 5.250 5.252 N/A
.010 5.261 5.263 5.266 5.258 5.260 5.267 5.255 5.257 N/A
.015 5.266 5.268 5.271 5.263 5.265 5.272 5.260 5.262 N/A
CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .002 AT MEASURED DIAMETERS. SERVICE
LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.
-15-
IO-550-G, N, TSIO-520-BE, GTSIO-520-H, K, L, M & N
Refer to Figure 1
“D” “D” “X” DIAMETER “X” “Y” DIAMETER “Y”
SIZE DIAMETER DIAMETER NEW DIAMETER NEW DIAMETER
NEW SERVICE SERVICE SERVICE
LIMITS LIMITS LIMITS
STD 5.251 5.253 5.256 5.248 5.250 5.257 5.245 5.247 N/A
.005 5.256 5.258 5.261 5.253 5.255 5.262 5.250 5.252 N/A
.010 5.261 5.263 5.266 5.258 5.260 5.267 5.255 5.257 N/A
c
c APPLIES TO CYLINDER PART NUMBERS 653452, 653454 OR LATER REVISIONS ONLY.
TSIO-550-A, B, C, & E
Refer to Figure 1

“D” “X” “Y”
SIZE “D” DIAMETER “X” DIAMETER DIAMETER “Y” DIAMETER DIAMETER
DIAMETER SERVICE NEW SERVICE NEW SERVICE
NEW LIMITS LIMITS LIMITS
STD 5.252 5.254 5.257 5.249 5.251 5.258 5.246 5.248 N/A
.005 5.257 5.259 5.262 5.254 5.256 5.263 5.251 5.253 N/A
ALL IO-520, IO-550, TSIO-520 & GTSIO-520

Refer to Figure 1
PISTON TO CYLINDER CLEARANCE
5.25” PISTON PISTON IN CYLINDER
MEASURED BELOW 4th RING
GROOVE
ALL NON GRAPHITE COATED .008 - .011 LOOSE
GRAPHITE COATED .006 - .010 LOOSE
Measure clearance perpendicular to pin bore and at “D” Diameter.
-16-
TSIOL-550-A & B
Refer to Figure 1
“D” “X” “Y”
SIZ “D” DIAMETER DIAMETER “X” DIAMETER DIAMETER “Y” DIAMETER DIAMETER
E NEW SERVICE NEW SERVICE NEW SERVICE
STD 5.251 5.253 5.256 5.248 5.250 5.257 5.245 5.247 N/A
.005 5.256 5.258 5.261 5.253 5.255 5.262 5.250 5.252 N/A
.010 5.261 5.263 5.266 5.258 5.260 5.267 5.255 5.257 N/A
.015 5.266 5.268 5.271 5.263 5.265 5.272 5.260 5.262 N/A
TSIOL-550-A & B
Refer to Figure 1
5.25” PISTON PISTON IN CYLINDER
MEASURED BELOW 4th RING
GROOVE
-17-
5.25 CYLINDER ALL 520’s & ALL 550’s
RING GAP
1 INCH
± .50
FIGURE 2. RING GAP LOCATION
5.25 CYLINDER ALL 520’s & ALL 550’s
RING GAP SPECIFICATIONS

Refer to Figure 2
Measure 1.00 ± .50 into bore. ⊥
RING PART NUMBER GAPS
RING SET 654716A1 N/A
Top 648005 .028 - .044
2nd 654719 c .034 - .050
Oil Control d 654717 .020 - .036
4th/Skirt 648008 .015 - .031
c Gap for 2nd ring must be at least .006 larger than gap for top ring.
d P/N 654717 consists of P/N 654718 Expander and 649250-1 ring.
-18-
4.50”
CHOKE
4.00”
LENGTH FOR “D” DIA.
“D”
DIA.
6.50”
“Y”
DIA.
5.75”
“X”
DIA.

E SERIES, ALL O-470, IO-470, TSIO-470

“D” “X” “Y”
SIZE “D” DIAMETER DIAMETER “X” DIAMETER DIAMETER “Y” DIAMETER DIAMETER
NEW SERVICE NEW SERVICE NEW SERVICE
STD 5.001 5.003 5.006 4.998 5.000 5.007 4.995 4.997 N/A
.005 5.006 5.008 5.011 5.003 5.005 5.012 5.000 5.002 N/A
.010 5.011 5.013 5.016 5.008 5.010 5.017 5.005 5.007 N/A
.015 5.016 5.018 5.021 5.013 5.015 5.022 5.010 5.012 N/A
-19-
ALL 470’S EXCEPT O470 K, L, R, S & TSIO-470-B, C, & D

Refer to Figure 3
5” PISTON PISTON IN CYLINDER
MEASURED AT THE BOTTOM
OF THE PISTON SKIRT
E SERIES, O-470-K, L, R, S & TSIO-470-B, C, & D
Refer to Figure 3
5” PISTON PISTON IN CYLINDER
MEASURED AT THE BOTTOM
OF THE PISTON SKIRT
-20-
RING GAP
1 INCH
± .50
5.00 CYLINDER ALL 470’s

E SERIES, ALL O-470, IO-470, TSIO-470

Refer to Figure 4
Top 648009 .026 - .042
2nd 648010 c .032 - .048
Oil Control 648011 .018 - .034
4th/Skirt 648012 .015 - .031
-21-
4.875 ± .25
STRAIGHT
“D”
DIA.
6.375 REF
“Y”
DIA.
5.625 REF
“X”
DIA.

2.31
CLASSIFY “D” AT THIS POINT

ALL IO-240, IO-360, TSIO-360, LTSIO-360
Refer to Figure 5

“D” “X” “Y”
SIZE “D” DIAMETER DIAMETER “X” DIAMETER “Y” DIAMETER
NEW SERVICE DIAMETER SERVICE DIAMETER SERVICE
LIMITS NEW LIMITS NEW LIMITS
STD 4.437 4.439 4.442 4.434 4.436 4.443 4.431 4.433 N/A
.005 4.442 4.444 4.447 4.439 4.441 4.448 4.436 4.438 N/A
.015 4.452 4.454 4.457 4.449 4.451 4.458 4.446 4.448 N/A
-22-

Refer to Figure 5
4.44” PISTON PISTON BOTTOM OF SKIRT IN
CYLINDER
4.44 CYLINDER ALL 240’s & 360’s
RING GAP
1 INCH
± .50

Refer to Figure 6.
RING PART GAPS
NUMBER
Top 648039 .026 - .042
2nd 648040 c .032 - .048
Oil Control 648041 .019 - .035
4th/Skirt 648042 .015 - .031
-23-
O .001 O .002
OUT OF ROUND IN X
NOT TO EXCEED 0.001”
“X”
DIA. OUT OF ROUND
IN THIS AREA NOT
TO EXCEED 0.002”

C SERIES, ALL O-200, O-300, GO-300
Refer to Figure 7
“X” DIAMETER NEW “X” DIAMETER
SIZE SERVICE LIMITS
MIN. MAX. MAX. STRAIGHT BARREL
STD. 4.0615 4.0635 4.0665 NO CHOKE
.005 4.0665 4.0685 4.0715
.015 4.0765 4.0785 4.0815
CYLINDER BORE - OUT OF ROUND: NEW NOT TO EXCEED .001 AT X DIAMETERS.
SERVICE LIMIT NOT TO EXCEED .003 AT MEASURED DIAMETERS.
-24-
C SERIES, ALL O-200, O-300, GO-300
Refer to Figure 7.
4.06” PISTON PISTON IN CYLINDER MEASURED
ABOVE 4th RING GROOVE
RING GAP
1 INCH
± .50
4.06 CYLINDER C SERIES, ALL O-200’s & O-300’s

Refer to Figure 8.

Top 649632 .023 - .036
2nd 638110 .015 - .028
3rd 638110 .015 - .028
Oil Control 638111 .015 - .028
-25-
MEASURE RING
GAP AT 1 INCH
FROM OPEN END
OF CYLINDER
-26-
TABLE 1. Piston to Engine Reference

Manganese
Engine Model Phosphate Uncoated Graphite Piston Skirt Diameter Pin to
Graphite Coated Diameter Dome
Coated Height
GTSIO520C, D, H, 654840 648044 654724 5.25" 5.2420-5.2430 1.835-1.839
K, L, M, N,
TSIO520AF, B, BB,
BE,
C, CE, D, DB, E, 654840P010 648044P010 654724P010 5.26" 5.2520-5.2530
EB, G, H, J, JB, K,
KB, L, LB, M, N,
NB, P, R, T, UB, 654840P015 648044P015 654724P015 5.265" 5.2570-5.2580
VB, WB
IO520A, B, BA, BB, 654850 648045 5.25 5.2420-5.2430 1.617-1.621

C, CB,
D, E, F, J, K, L, M, 654850P010 648045P010 5.26" 5.2520-5.2530
MB, N,
NB, 654850P015 648045P015 5.265" 5.2570-5.2580
IO550A, B, C, D, E, 654857 648046 654726 5.25" 5.2420-5.2430 1.775-1.779

F, G, L,
N, 654857P010 648046P010 654726P010 5.26" 5.2520-5.2530
654857P015 648046P015 654726P015 5.265" 5.2570-5.2580
IO346A, TSIO550A, 654867 649805 654731 5.25" 5.2432-5.2442 1.775-1.779

B, C, E,
TSIOL550A, B, C
IO520P, 654836 648037 654723 5.25" 5.2420-5.2430 1.775-1.779

LTSIO520AE,
LIO520P, 654836P010 648037P010 654723P010 5.26" 5.2520-5.2530
TSIO520AE
654836P015 648037P015 654723P015 5.265" 5.2570-5.2580
IO470C, O470G, 654829 648028 654721 5.00" 4.9887-4.9897 2.0157-

O470GCI, O470M 2.0197
IO470D, E, F, H, L, 654832 648029 654722 5.00" 4.9887-4.9897 2.0665-

M, N, S, 2.0705
U, V, O470U
654832P015 648029P015 654722P015 5.015" 5.0037-5.0047
IO470K, J 654862 649044 654729 5.00" 4.9887-4.9897 1.7689-

1.7729
654862P015 649044P015 654729P015 5.015" 5.0037-5.0047
-27-
TABLE 1. Piston to Engine Reference
Manganese
Engine Model Phosphate Uncoated Graphite Piston Skirt Diameter Pin to
Graphite Coated Diameter Dome
Coated Height
O470K, L, R, S 654833 646263 654744 5.00" 4.9907-4.9922 1.977-1.981

654833P015 646263P015 654744P015 5.015 5.0057-5.0072
LTSIO360E, EB, 654859 648048 654727 4.44" 4.4270-4.4280 1.598-1.602

KB, RB,
TSIO360A, AB, C, 654859P015 648048P015 654727P015 4.455" 4.4420-4.4430
CB, D,
DB, E, EB, F, FB,
GB, H,
HB, JB, KB, LB,
MB, RB, SB
IO240A, B, IO360A, 654861 648049 654728 4.44" 4.4270-4.4280 1.591-1.595

AB, C,
CB, D, DB, G, GB, 654861P015 648049P015 654728P015 4.455" 4.4420-4.4430
H, HB, J,
JB, K, KB, LB
O200A, B, O300A, 654853 646255 654749 4.06" 4.0517-4.0532 1.591-1.596

C, D,
654853P015 646255P015 654749P015 4.075" 4.0667-4.0682
GO300 654858 646279 4.06" 4.0517-4.0532 1.611-1.616

654858P015 646279P015 4.075" 4.0667-4.0682
C75 654841 646287 4.06" 4.0514-4.0524 1.698-1.708

654841P015 646287P015 4.075" 4.0664-4.0674
NOTE: This information is subject to change. Always refer to the most current version of
the TCM part numbers by accessing the electronic illustrated parts catalogs at
www.tcmlink.com This information can be accessed through FBO Services (all models),
Information Services (all models), or Aviator Services (Engine Specific) or call your local
distributor. These parts catalogs provide access to “real time” parts information meaning
the parts data is up to date daily.
-28-
TORQUE LIMITS
Proper torquing practices cannot be over emphasized. Torque values are provided as a
convenient method of achieving correct pre-loading of highly stressed fasteners. If the
fasteners are not properly plated, the fastener threads are not clean and free of deformation or
are not properly lubricated, the correct fastener pre-load will not be achieved even though the
specified torque value is reached. For this reason, it is critical that all fasteners be inspected for
proper plating, thread form and correctly lubricated prior to torquing. Failure to verify a
fasteners serviceability or to correctly lubricate the fastener prior to assembly and torquing will
result in the fastener not being properly pre-loaded and subsequent failure of the fastener may
occur.
The torque values provided must be used for the specific application. If an application is not
listed, then the general torque must be used. TORQUE VALUES LISTED ARE FOR USE
WITH CLEAN 50 WEIGHT AVIATION ENGINE OIL APPLIED TO THE THREADS,
UNLESS OTHERWISE SPECIFIED. Refer to appropriate manufacturer’s accessory overhaul
manuals for specified torque on accessories.
If cotter pin holes must be aligned, set torque wrench at low limit and torque nut to first hole
beyond this torque, but do not exceed the maximum torque limit specified. This torquing
procedure must be followed for all applications requiring cotter pin hole alignment except for
connecting rod nuts. Special instructions for connecting rods are provided in “ NOTE 1.”
-29-
NOTE: When you see the text notation - AR it refers to “As
Required.”
WARNING
THE USE OF MATERIALS OTHER THAN THOSE SPECIFIED BY
TCM ON MATING THREADS AND BETWEEN MATING
SURFACES CAN CAUSE INCORRECT FASTENER PRE-LOAD
AND SUBSEQUENT ENGINE DAMAGE OR FAILURE.
Table 1. General Use - Torque’s
BOLTS, NUTS & SCREWS DRIVING STUDS

SIZE IN. LBS. FT. LBS. IN. LBS. FT. LBS.
8 - 32 17.5 - 22.5 1.5 - 1.9 - -
10 - 24 21.0 - 25.0 1.7 - 2.0 - -
10 - 32 36.0 - 50.0 3.0 - 4.2 - -
1/4 - 20 75.0 - 85.0 6.3 - 7.1 50.0 - 70.0 4.2 - 5.8
1/4 - 28 90.0 - 110 7.5 - 9.2 - -
5/16 - 18 155 - 175 12.9 - 14.6 100 - 150 8.3 - 12.5
5/16 - 24 180 - 220 15.0 - 18.3 - -
3/8 - 16 220 - 260 18.3 - 21.7 200 - 275 16.7 - 22.9
3/8 - 24 275 - 325 22.9 - 27.1 - -
7/16 - 14 - - 300 - 425 25.0 - 35.4
7/16 - 20 400 - 450 33.3 - 37.5 - -
1/2 - 20 550 - 600 45.8 - 50.0 - -
-30-
Table 2. Driving Studs
SIZE TORQUE
Dec. In. Across IN/LBS FT/LBS
Flats
.25 - 20 1/4 7/16 50 - 70 4.2 - 5.8
.3125 - 5/16-18 1/2 100 - 150 8.3 - 12.5
18
.375 - 16 3/8-16 9/16 200 - 275 16.7 - 22.9
.44 - 14 7/16-14 5/8 300 - 425 25.0 - 35.4
Table 3. Pipe Plugs
SIZE TORQUE
Dec. In. Across IN/LBS FT/LBS
Flats
.062 - 27 1/16-27 30 - 40 2.5 - 3.3
.125 - 27 1/8-27 60 - 80 5.0 - 6.7
.250 - 18 1/4-18 7/16 130 - 150 10.8 - 12.5
.375 - 18 3/8-18 9/16 185 - 215 15.4 - 18.0
.500 - 14 1/2-14 3/4 255 - 285 21.3 - 23.8
.750 - 14 3/4-14 1 1/8 310 - 350 25.8 - 29.2
-31-
Table 4. Cylinder Base Nut and Through Bolt Torque Values
SIZE TORQUE
Dec. In. Across CRANKCASE IN/LBS FT/LBS MODEL
Flats
.38 - 24 3/8-24 9/16 Nut-Cyl. to crankcase studs 410 - 430 34.2 – 35.8 O-200
O-300
GO-300
O-470
.38 - 24 3/8-24 1/2 Nut-Cylinder to crankcase 440 - 460 36.7 – 38.3 IO-240
studs IO-360
TSIO-360
.44 - 20 7/16-20 5/8 Nut-Cyl. to crankcase 400 - 450 33.3 – 37.5 A & C Series
through studs
.44 - 20 7/16-20 5/8 Nut-Cyl. to crankcase studs 490 - 510 40.8 - 42.5 All other models -
(includes 7th stud) (Except TSIOL-550)
.44 - 20 7/16-20 5/8 Nut-Cyl. to crankcase studs 590 - 610 49.2 – 50.8 TSIOL-550
(includes 7th stud)
.44 - 20 7/16-20 9/16 Nut-through bolt at cylinder 590 - 610 49.2 – 50.8 IO-240
flange IO-360
TSIO-360
.50 - 20 1/2-20 3/4 Nut-6 point through bolt at 690 - 710 57.5 – 59.2 IO-346, All 470, 520 &
cylinder flange (P/N 643505 550 (Except TSIOL-
.33 in. high) 550)
.50 - 20 1/2-20 5/8 Nut-12 point through bolt at 790 - 810 65.8 – 67.5 IO-346, All 470, 520 &
cylinder flange (P/N 652541) 550
.50 - 20 1/2-20 5/8 Nut-tall 6 point through bolt 790 - 810 65.8 – 67.5 TSIOL-550
at cylinder flange (P/N
649496 .43 in. high)
NOTE: The torque specific information in this table is derived from service bulletin SB96-
7C and is subject to change. Always refer to the most current version of the TCM service
bulletin SB96-7C and applicable Maintenance / Overhaul manuals at www.tcmlink.com
This information can be accessed through FBO Services (all models) and Information
Services (all models), or call your local distributor to purchase a hard copy of these service
bulletins and manuals. A free copy of the most current version of service bulletin SB96-7C
Torque Limits is available at the following location on our web site:
http://www.tcmlink.com/pdf2/SB96-7C.pdf
-32-
Cylinder Torque Procedures
1. The proper torque sequence for all cylinder applications requires a three step torque
process.
2. First, torque cylinder base nuts to 50% of the rated value using the sequence shown in the
applicable engine overhaul manual. Do not torque the cylinder through bolt nuts during
this initial torque sequence.
3. Second, torque the cylinder through bolt nuts and cylinder base nuts in the sequence shown
in the applicable engine overhaul manual. Torque to the maximum value rated for the
cylinder base nuts.
4. Third, torque the through bolt nuts to their maximum rated values in the applicable engine
overhaul manual. Torque 7th stud nut last as applicable.
5. Always refer to the applicable engine maintenance or overhaul manual to obtain the torque
values for the engine you are working on.
WARNING
LUBRICATE ALL CYLINDER DECK STUD AND

THROUGH BOLT THREADS WITH CLEAN 50 WEIGHT
AVIATION OIL. FAILURE TO LUBRICATE THREADS
WILL RESULT IN INCORRECT FASTENER PRE-
LOADING AND LOSS OF MAIN BEARING CRUSH,
ENGINE DAMAGE AND POSSIBLE FAILURE.
-33-
1 3
4 2
C-75, C-85, C-90, O-200, O-300 GO-300

Single Cylinder Torque Sequence
5 7
1 3
4 2
8 6
TORQUE 7TH STUD NUT

LAST AS APPLICABLE
240/360 & 470/520/550 Series

Single Cylinder Torque Sequence
-34-
11 5 17 5
7 9 1 3 13 15 1 3
CYL# 4 CYL# 2 CYL# 1 CYL# 3
12 6 18 6
10 8 4 2 16 14 4 2
-35-
O-200 LEFT CRANKCASE O-200 RIGHT CRANKCASE
DESIGNATES CRANKCASE THROUGH BOLTS - CRANKCASE THROUGH BOLT THREADS & NUTS
MUST BE LUBRICATED WITH CLEAN 50 WT AVIATION OIL AND TORQUED SIMULTANEOUSLY
O-200 SERIES CYLINDER TORQUE SEQUENCE

13 15 5 7 21 23 5 7
9 11 1 3 17 17 19 1 3 9
CYL# 4 CYL# 2 CYL# 1 CYL# 3
12 10 4 2 20 20 18 4 2 12
16 14 8 6 24 22 8 6
-36-
IO-240 LEFT CRANKCASE IO-240 RIGHT CRANKCASE
DESIGNATES CRANKCASE THROUGH BOLTS - CRANKCASE THROUGH BOLT THREADS & NUTS
MUST BE LUBRICATED WITH CLEAN 50 WT AVIATION OIL AND TORQUED SIMULTANEOUSLY
IO-240 SERIES CYLINDER TORQUE SEQUENCE

19 5 12
15 17 1 3 8 10 24
CYL# 6 CYL# 4 CYL# 2
18 16 4 2 11 9 27
20 6 13
O-300 LEFT CRANKCASE
28 12 5
24 26 8 10 1 3 15
27 25 11 9 4 2 18
29 13 6
O-300 RIGHT CRANKCASE
DESIGNATES CRANKCASE THROUGH BOLTS - CRANKCASE

THROUGH BOLT THREADS & NUTS MUST BE LUBRICATED WITH
CLEAN 50 WT AVIATION OIL AND TORQUED SIMULTANEOUSLY
O-300 & GO-300 SERIES CYLINDER TORQUE SEQUENCE
-37-
23 25 5 7 14 16
19 21 1 3 10 12
28 30
27 22 20 4 2 13 11 33
26 24 8 6 17 15
IO-360 LEFT CRANKCASE
34 36 14 16 5 7
30 32 10 12 1 3
19 28
33 31 13 11 4 2 22 27
37 35 17 15 8 6
IO-360 RIGHT CRANKCASE

THROUGH BOLT THREADS & NUTS MUST BE LUBRICATED WITH
CLEAN 50 WT AVIATION OIL AND TORQUED SIMULTANEOUSLY
IO-360 SERIES CYLINDER TORQUE SEQUENCE
-38-
23 25 5 7 14 16
19 21 1 3 10 12
30
* * *
22 20 4 2 13 11 33
26 24 8 6 17 15
LEFT CRANKCASE
34 36 14 16 5 7
30 32 10 12 1 3
19
* * *
33 31 13 11 4 2 22
37 35 17 15 8 6
RIGHT CRANKCASE

THROUGH BOLT THREADS & NUTS MUST BE LUBRICATED WITH * TORQUE
7TH STUD
CLEAN 50 WT AVIATION OIL AND TORQUED SIMULTANEOUSLY NUT LAST
470, 520 & 550 SANDCAST SERIES CYLINDER TORQUE SEQUENCE
-39-
21 23 5 7 13 15
17 19 1 3 9 11
27
* * *
20 18 4 2 12 10 30
24 22 8 6 16 14
LEFT CRANKCASE
31 33 13 15 5 7
27 29 9 11 1 3
17
CYL# 1 CYL# 3 CYL# 5 ALT.
* * *
4 2 20
30 28 12 10
34 32 16 14 8 6
RIGHT CRANKCASE
7TH STUD
520/550 PERMOLD & LIQUID COOLED CYLINDER TORQUE SEQUENCE
-40-
23 25 5 7 14 16
19 21 1 3 10 12
30
* * *
22 20 4 2 13 11 33
26 24 8 6 17 15
LEFT CRANKCASE
34 36 14 16 5 7
30 32 10 12 1 3
19
* * *
31 13 11 4 2 22
33
37 35 17 15 8 6
RIGHT CRANKCASE

7TH STUD
GTSIO-520 SERIES CYLINDER TORQUE SEQUENCE
-41-
Cylinder Installation Technique Photographs
Seating the cylinder base “O” Ring Piston ring land identification and Pin installed
Lubricating the deck studs & through bolts Installing Cylinder onto the Crankcase
Torquing both sides of the Through Bolt Nuts Installation of 7th Stud
-42-
Cylinder Installation Technique Photographs
Beveled rocker shaft installed with bevel Installing Pushrod Housing tubes
facing the Crankcase
- End of X30653 Rev 3 -
-43-
PO Box 90 Mobile Alabama 36601-0090 ● 251-438-3411

888-TCM-LINK ● 888-826-5465
www.tcmlink.com
Form No. X30653 Rev. 3

©2007 Teledyne Continental Motors, Inc.

08 - Cylinder Installation

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Instructional Series for Aviation Mechanics

Ready Reference Guide

Form No. X30653 Rev. 3

© 2007, Teledyne Continental Motors, Inc.

The material provided in this Ready Reference Guide is

Tools & Equipment Required

3882 9/16” hex

2. 8079 Cylinder Base Nut Wrenches or equivalent ............................Borrough’s, Kent-Moore or equivalent

8079 9/16” hex

5. 8121 Piston Pin Removers ...................................................................................................... Kent-Moore

Aviation Engine Oil Ashless Dispersant

Above 40°F ambient air, sea level SAE 50 or Multi Viscosity

Cross Sectional Diagram showing interaction of cylinder,

PUSHROD PUSHROD ROCKER

Exploded Parts view of all “Updraft” style cylinders

Exploded Part view of all “Cross Flow” style cylinders

Photo view of typical cylinder features

FIGURE 1. 5.25 INCH CYLINDER

CYLINDER DIAMETER DIMENSIONS

ALL IO-520, IO-550, TSIO-520 & GTSIO-520

FIGURE 2. RING GAP LOCATION

5.25 CYLINDER ALL 520’s & ALL 550’s

RING GAP SPECIFICATIONS

FIGURE 3. 5.00 INCH CYLINDER

CYLINDER DIAMETER DIMENSIONS

ALL 470’S EXCEPT O470 K, L, R, S & TSIO-470-B, C, & D

5.00 CYLINDER ALL 470’s

E SERIES, ALL O-470, IO-470, TSIO-470

CLASSIFY “D” AT THIS POINT

FIGURE 5. 4.44 INCH CYLINDER

CYLINDER DIAMETER DIMENSIONS

ALL IO-240, IO-360, TSIO-360, LTSIO-360

4.44 CYLINDER ALL 240’s & 360’s

FIGURE 6. RING GAP LOCATION

FIGURE 7. 4.06 INCH CYLINDER

4.06 CYLINDER C SERIES, ALL O-200’s & O-300’s

FIGURE 8. RING GAP LOCATION

Measure 1.00 ± .50 into bore. ⊥

TABLE 1. Piston to Engine Reference

IO520A, B, BA, BB, 654850 648045 5.25 5.2420-5.2430 1.617-1.621

IO550A, B, C, D, E, 654857 648046 654726 5.25" 5.2420-5.2430 1.775-1.779

IO346A, TSIO550A, 654867 649805 654731 5.25" 5.2432-5.2442 1.775-1.779

IO520P, 654836 648037 654723 5.25" 5.2420-5.2430 1.775-1.779

IO470C, O470G, 654829 648028 654721 5.00" 4.9887-4.9897 2.0157-

IO470D, E, F, H, L, 654832 648029 654722 5.00" 4.9887-4.9897 2.0665-

IO470K, J 654862 649044 654729 5.00" 4.9887-4.9897 1.7689-

O470K, L, R, S 654833 646263 654744 5.00" 4.9907-4.9922 1.977-1.981

LTSIO360E, EB, 654859 648048 654727 4.44" 4.4270-4.4280 1.598-1.602

IO240A, B, IO360A, 654861 648049 654728 4.44" 4.4270-4.4280 1.591-1.595

O200A, B, O300A, 654853 646255 654749 4.06" 4.0517-4.0532 1.591-1.596

GO300 654858 646279 4.06" 4.0517-4.0532 1.611-1.616

C75 654841 646287 4.06" 4.0514-4.0524 1.698-1.708

Table 1. General Use - Torque’s

BOLTS, NUTS & SCREWS DRIVING STUDS

Table 3. Pipe Plugs

LUBRICATE ALL CYLINDER DECK STUD AND

C-75, C-85, C-90, O-200, O-300 GO-300

TORQUE 7TH STUD NUT

240/360 & 470/520/550 Series

CYL# 4 CYL# 2 CYL# 1 CYL# 3

O-200 SERIES CYLINDER TORQUE SEQUENCE

CYL# 4 CYL# 2 CYL# 1 CYL# 3

IO-240 SERIES CYLINDER TORQUE SEQUENCE

CYL# 6 CYL# 4 CYL# 2

CLASSIFY “D” AT THIS POINT