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O-200-D

CONTINENTAL® AIRCRAFT ENGINE

ENGINE INSTALLATION AND OPERATION MANUAL

Publication OI-2
©

FAA APPROVED
MAY 2009

2009 TELEDYNE CONTINENTAL MOTORS INCORPORATED

TM

Supersedure Notice
This manual supports O-200-D and subsequent engine series installation, and operation instructions. This new publication affects no other publications previously released by Teledyne Continental Motors.

Effective Changes for this Manual
0 .................. 1 May 2009

List of Effective Pages
Document Title: O-200-D Series Installation & Operation Manual Publication Number: OI-2 Page Change Page Change Page Cover............................ 0 A................................... 0 i-ii.................................. 0 1-1 thu 1-8.................... 0 2-1 thu 2-10.................. 0 3-1 thu 3-22.................. 0 Initial Publication Date: 1 May 2009 Change Page Change

Published and printed in the U.S.A. by Teledyne Continental Motors. Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601 Copyright © 2009 by Teledyne Continental Motors. 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 warranties. The publisher will not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content is subject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.

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O-200-D Series Installation & Operation Manual 1 May 2009

TM

Table of Contents

TABLE OF CONTENTS LIST OF TABLES Table 1-1. Related Publications ....................................................................... 1-4 LIST OF ILLUSTRATIONS Figure 1-1. Figure and Index Reference ........................................................... 1-3 Figure 1-2. Change Page Identification ............................................................ 1-6 Figure 1-3. List of Effective Pages ................................................................... 1-7 Figure 2-1. Delco-Remy Starter ....................................................................... 2-5

Chapter 1. Introduction
1-1.Scope and Purpose of This Manual............................................................
1-1.1.Advisories................................................................................................................... 1-1.2.Using this Manual ......................................................................................................

1-1
1-1 1-2

1-2.Publications ................................................................................................

1-4

1-2.1.Related Publications................................................................................................... 1-4 1-2.2.Publication Access ..................................................................................................... 1-5 1-2.3.Publication Changes................................................................................................... 1-5 1-2.3.1.Update/Change Distribution ................................................................................1-5 1-2.3.2.Suggestions and Corrections................................................................................1-7

1-3.TCM Contact Information..........................................................................

1-8

Chapter 2.Engine Installation
2-1.Engine Installation ..................................................................................... 2-1
2-1.1.Common Tools and Consumable Supplies Required ................................................. 2-1 2-1.2.Engine Receipt and Handling..................................................................................... 2-1 2-1.2.1.Uncrating the Engine ...........................................................................................2-1 2-1.2.2.Crating an Engine for Shipping ...........................................................................2-2 2-1.2.3.Acceptance Inspection .........................................................................................2-2 2-1.3.Engine Transport ........................................................................................................ 2-2

2-2.Installation Procedures ...............................................................................

2-3

2-2.1.Prepare the Airframe for Engine Installation ............................................................. 2-3 2-2.2.Prepare the Engine for Installation............................................................................. 2-3 2-2.3.Installation Sequence.................................................................................................. 2-4 2-2.3.1.Engine Pre-oiling .................................................................................................2-6 2-2.3.2.Fuel Purge and Leak Check .................................................................................2-7 2-2.4.Installation Inspection ................................................................................................ 2-7 2-2.5.Preflight and Run-up ................................................................................................ 2-10

Chapter 3. Engine Operation
3-1.Introduction ................................................................................................ 3-2.Flight Prerequisites.....................................................................................
3-2.1.Oil Change Interval ....................................................................................................

3-1 3-1
3-2

O-200-D Series Installation & Operation Manual 1 May 2009

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Table of Contents
3-2.2.Engine Fuel Requirements ......................................................................................... 3-2 3-2.3.Flight Check and Break-In......................................................................................... 3-2 3-2.3.1.Engine Break-In................................................................................................... 3-3 3-2.3.2.Flight Check......................................................................................................... 3-3

TM

3-3.Normal Operation ......................................................................................

3-4

3-3.1.Pre-operational Requirements.................................................................................... 3-4 3-3.2.Engine Start................................................................................................................ 3-5 3-3.2.1.Cold Start ............................................................................................................. 3-6 3-3.2.2.Flooded Engine .................................................................................................... 3-6 3-3.2.3.Hot Start............................................................................................................... 3-6 3-3.3.Ground Run-up .......................................................................................................... 3-7 3-3.4.Taxi Preparation ......................................................................................................... 3-9 3-3.5.Power Control ............................................................................................................ 3-9 3-3.6.Take-Off ..................................................................................................................... 3-9 3-3.7.Cruise Climb ............................................................................................................ 3-10 3-3.8.Cruise ....................................................................................................................... 3-10 3-3.9.Descent..................................................................................................................... 3-11 3-3.10.Landing .................................................................................................................. 3-11 3-3.11.Engine Shutdown ................................................................................................... 3-11

3-4.Emergency Operation ..............................................................................
3-4.1.Engine Fire during Start ........................................................................................... 3-4.2.Engine Roughness.................................................................................................... 3-4.3.High Cylinder Head Temperature ............................................................................ 3-4.4.High Oil Temperature .............................................................................................. 3-4.5.Low Oil Pressure...................................................................................................... 3-4.6.In-Flight Restart ....................................................................................................... 3-4.7.Engine Fire In Flight ................................................................................................

3-13
3-13 3-13 3-13 3-14 3-14 3-14 3-14

3-5.Engine Operation in Abnormal Environments ........................................

3-15

3-5.1.Engine Operation in Extreme Cold.......................................................................... 3-15 3-5.1.1.Engine Preheating .............................................................................................. 3-16 3-5.2.Engine Operation in Hot Weather ............................................................................ 3-20 3-5.2.1.Cooling an Engine in Hot Weather.................................................................... 3-20 3-5.2.2.Engine Restart in Hot Weather .......................................................................... 3-21 3-5.2.3.Ground Operation in Hot Weather..................................................................... 3-21 3-5.2.4.Take-off and Initial Climb Out in Hot Weather ................................................ 3-21 3-5.3.Ground Operation at High Density Altitude ............................................................ 3-22

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O-200-D Series Installation & Operation Manual 1 May 2009

This manual provides airframe interface requirements. 1-1. refer to the appropriate manual. Introduction 1-1. Scope and Purpose of This Manual This manual is part of the interface control document for O-200-D Model engines. Warnings. engine accessories. Warnings and cautions precede the steps to which they apply. and operate the engine. test. efficiency. installation instructions and engine operating instructions. Chapter 3 provides supplemental information for the airplane flight manual (AFM) or pilot operating handbook (POH) in regards to specific engine operating procedures. CAUTION: Emphasizes certain information or instructions. including the O-200-A.TM Introduction Chapter 1. Advisories This manual utilizes three types of advisories. For information specific to other TCM engine series. notes are placed in the manner which provides the greatest clarity. could result in severe injury to personnel or equipment failure.1. or neglect of equipment can cause eventual engine malfunction or failure. or the airplane. which may facilitate performance of a procedure or operation of equipment. manufactured by Teledyne Continental Motors (TCM). Instructions in this manual are specific to the O-200-D engines. Abuse. which if disregarded. O-200-D Series Installation & Operation Manual 1 May 2009 1-1 . misuse. may result in damage to the engine or accessories. defined as follows: WARNING A warning emphasizes information which. Chapter 2 contains detailed engine installation instructions. if disregarded. and performance. B & C model engines. and notes do not impose undue restrictions. cautions. Advisories are inserted to ensure maximum safety. Failure to heed advisories will likely result in the undesirable or unsafe conditions the advisory was intended to prevent. NOTE: Provides special interest information. Chapters are arranged in sequential order to install.

Installation of non-TCM parts on a TCM engine must be performed using Instructions for Continued Airworthiness prepared by the manufacturer and approved by the FAA for the subject installation. testing. depicting the most prominent configuration in the engine series. Consult the illustrated parts breakdown in TCMLINK for your specific engine model and each subsystem. durability. longevity. separate instructions are prepared for each model. test.2. The first time instructions refer to an illustration. or certification of any non-TCM parts. illustrations in this manual are for reference only. Teledyne Continental Motors (TCM) provides Instructions for Continued Airworthiness based on the design. Using this Manual Except for the engine installation drawings. Exploded assembly illustrations accompany instructions throughout the manual. WARNING TCM Instructions for Continued Airworthiness are applicable only to TCM engines conforming to the approved. and certification of engines and parts for which TCM is the holder of the Type Certificate (TC) or Parts Manufacture Approval (PMA) issued by the Federal Aviation Administration (FAA). When significant variations exist between engine models. Do not use TCM ICAs for nonTCM parts. type certified engine model configuration. only the callout will be specified unless the referenced illustration changes. In subsequent parts references. the figure number is identified in parentheses. TCM has not participated in design.) are identified with numerical callouts (indexes). Parts in illustrations (Figure 1-1. TCM does not provide product manufacturing specifications to aftermarket parts manufacturers and accepts no liability for the suitability. or safety of such parts installed on TCM engines.TM Introduction 1-1. 1-2 O-200-D Series Installation & Operation Manual 1 May 2009 . followed by the callout. Installation of non-TCM parts on a TCM engine constitutes a deviation from TCM typedesign criteria. Corresponding parts listings follow the illustrations for reference.

Figure and Index Reference O-200-D Series Installation & Operation Manual 1 May 2009 1-3 .TM Introduction Figure 1-1.

source. Related Publications Supplied With Engine Order Internet via From TCMLINK1 TCM Yes Yes Yes Yes Yes Yes No Yes Available From Manufacturer N/A N/A N/A N/A 1-2. maintenance & overhaul. If you are a TCMLINK subscriber. 1-4 O-200-D Series Installation & Operation Manual 1 May 2009 . Using superseded information jeopardize engine airworthiness Table 1-1.TM Introduction 1-2. Related Publications Publication TCM Publications O-200-D Engine Maintenance and Overhaul Manual (M-2) Yes TCM Magneto Service Manual (X42002) No Illustrated Parts Catalog No Service Documents No 1. Publications The table below lists related publications. to confirm you have the latest revision of the manual. If you have not subscribed to TCMLINK and are using hardcopies. operation. contact TCM using the “TCM Contact Information” on page 8. TCMLINK Information Services® provides 24-hour-a-day access via the Internet.1. WARNING Use only the latest revision of all publications. you can access TCMLINK to confirm and review the latest revision of this manual. and accessibility relevant to O-200-D model engine installation.

and parts catalogs) via the Internet.3. This manual and other related publications noted herein constitute the Instructions for Continued Airworthiness (ICAs) prepared by Teledyne Continental Motors and accepted by the Federal Aviation Administration (FAA). WARNING New information may be contained in Teledyne Continental Motors service documents. Printed TCM publications may be ordered through Teledyne Continental Motors authorized distributors or via the Internet at TCMLINK. Printed publication subscribers receive printed changes and revisions as they are released. “TCM Contact Information” ). Such Service Documents represent a change to the published ICA until the individual publications incorporate the latest technical information. Aviator Services. Update/Change Distribution Document updates are available via TCMLINK upon notification of FAA document approval. and FBO Services programs provide an array of benefits including access to electronic versions of TCM technical publications (manuals. Contact a TCM distributor to discuss service subscription options and pricing or visit our website (See Section 1-3. Revisions replace the previous version of a publication from cover to cover.2. 1-2. Teledyne Continental Motors releases publication changes in the form of either change pages or complete publication revisions. Minor corrections are released as change pages to the original publication. Publication Access TCMLINK Alpha Services. Your TCM printed document purchase includes three years of updates at no extra charge. Service documents applicable to engines and accessories within the scope of this manual must be complied with as if they were contained in this document. FBO and Information Services are available with a paid subscription fee. service documents. Current TCMLINK service subscribers receive a complete publication library on CD delivered quarterly. Product or process improvements may trigger changes to existing product design specifications or procedures contained in publications. Aviator Services and Alpha Services memberships are free to TCM engine owners. Publication Changes The instructions in this manual represent the best and most complete information available at the time of publication.1. “TCM Contact Information” or our Internet website. Service Documents may supplement or replace technical information contained in one publication or an entire series of publications. depending upon the extent of change.3. See Section 1-3. 1-2. As new technical information becomes available. identified with O-200-D Series Installation & Operation Manual 1 May 2009 1-5 . Document revisions are released if the update changes more than 50% of the contents of a publication. Information Services.TM Introduction 1-2. TCM will make the information available to the customer.

). Information on the page that changed from the previous edition is identified by a vertical. six-point black line (Figure 1-2. Original pages are designated by a 0 in the List of Effective Pages “Change” column. If change pages are issued for the manual. with an effective date under the heading “Effective Changes for This Manual” on Page A. by change number.). 1-6 O-200-D Series Installation & Operation Manual 1 May 2009 . the change will be identified. itemizes the pages in each section. Change Page Identification Change Date Page A of the manual contains the original publication date and an itemized list of changes issued for the technical manual (Figure 1-3.TM Introduction a change number and effective change date in the page footer. A change page replaces only the previous edition of the affected page. Change Bar Change Number Figure 1-2. The list of effective pages. referred to as a “change bar” in the outside margin of the page.

Direct recommended changes or questions to the attention of “Publications” at the TCM address listed in Section 1-3 or you can send comments via email to TCM_pubs@teledyne. O-200-D Series Installation & Operation Manual 1 May 2009 1-7 . Suggestions and Corrections Teledyne Continental Motors solicits and encourages user comments regarding suggested changes to this manual. if you discover incorrect information which adversely affects safety.2.TM Introduction Effective Manual Changes and Change Dates Itemized List of Effective Pages Figure 1-3. using our toll-free number. Notify TCM Customer Service immediately.3. List of Effective Pages 1-2.com.

1-8 O-200-D Series Installation & Operation Manual 1 May 2009 .tcmlink.genuinecontinental. refer to the contact information below: Teledyne Continental Motors.TM Introduction 1-3.aero. parts. or service. AL 36601 TCM Customer Service: Toll free within the Continental United States: International: 1-888-826-5465 1-251-438-3411 TCMLINK on the Internet: www. TCM Contact Information Teledyne Continental Motors is available to answer technical questions and encourages suggestions regarding products. To contact TCM. Inc. they should contact their local TCM distributor or TCM field representative.com or www. P. Box 90 Mobile. O. If customers have an inquiry or require technical assistance.

MIL-P-46002. and engine usage influence susceptibility to corrosion. 100-LL Blue aviation fuel 6. 2. Bladder-type pressure pot (at least 1 gallon capacity) 10. 3. Lift the wooden cover and remove it. Oil conforming to SAE J-1966 (break-in oil.TM Engine Installation Chapter 2. In areas of high humidity. Spark plugs and copper gaskets 7. Ashless dispersant oil conforming to SAE J-1899 4.2. Type 1 flammable fuel container 11. 4. 2-1. Engine Installation 1. Common Tools and Consumable Supplies Required O-200-D Series Installation & Operation Manual 1 May 2009 2-1 . NOTE: The engine is preserved for long term storage at the factory.1.Engine Installation 2-1. Inspect the engine according to the “Acceptance Inspection” criteria in Section 21.3. Engine Receipt and Handling When the engine arrives.2. refer to the “Engine Preservation and Storage” instructions in Section 9 of the Engine Maintenance and Overhaul Manual (M-2) for ongoing corrosion protection instructions. non-dispersant mineral oil) MIL-C6529 Type II (Fly-away oil) 3. proceed to Section 2-1. Uncrating the Engine 1. Remove the lag screws attaching the wooden cover to the base. The owner/operator is responsible for recognizing the risk of corrosion and taking the appropriate precautions. if it is not immediately installed after acceptance. 2-1. inspect the crating for damage. MS 122 DF Spray (procured from Miller-Stephenson) 12.1. notify the freight shipping company for resolution. If the crating appears intact. Cable ties 9. Grade 1 oil 5. Spark Plug Manufacturer’s recommended spark plug thread lubricant 2-1. seasonal changes. Open the plastic bag wrapped around the engine. Safety Wire (. corrosion can occur within two days of uncrating the engine. If the engine crating appears damaged.2.2. Hoist 2.032”) 8.1. Environmental conditions (humidity).

remove the bolts from the shipping shock mounts. 2-1. Install and attach the container cover to the base. contact the supplier of the engine for disposition. Cover the engine with a plastic bag.Engine Installation TM 5. proceed with the instructions in Section 2-2. 2. 2. 3. 2-1. If the engine will be stored for any length of time. Acceptance Inspection CAUTION: If the hidden engine damage or corrosion is discovered. refer to the “Engine Preservation and Storage” instructions in Section 9 of the Engine Maintenance and Overhaul Manual (M-2). Engine Transport Refer to the “Engine Installation Drawings” for the engine lifting eye locations. CAUTION: Do not allow chains to become entangled on the engine or its hardware. 2-1. Crating an Engine for Shipping 1. sides or bottom of the engine to strike any obstructions as the extreme weight may damage the engine or its components. proceed with installation. rear. Attach a hoist to the engine lifting eyes located at the top of the crankcase backbone. 4.2. Attach the engine using shock mounts and bolts. 2-2 O-200-D Series Installation & Operation Manual 1 May 2009 . Lift the engine and install it on a transportation stand or dolly. 1. a. Inspect the engine for signs of damage or corrosion.2. 2. If the engine is to be installed within 30 days of unpacking.3.3. contact Teledyne Continental Motors (see “TCM Contact Information” in Section 1-3). Verify the engine serial number and model number on the engine nameplate are the same as specified in the engine logbook and the packing slip. 3. 1. “Prepare the Engine for Installation.2. Take up slack on the hoist prior to loosening the engine mount bolts. Do not install a damaged or corroded engine or place it in storage. Do not allow the front. If damage or corrosion is discovered. Do not install or place a damaged/ corroded engine in storage.” b. If the engine exhibits no sign of damage or corrosion. Be sure the area is clear when lifting the engine.2. Lower the engine onto the container base.

overhauled or stored engines prior to installation. 5. Installation Procedures 1. Failure to purge contamination may cause erratic engine operation. contact the supplier (If the engine was obtained from TCM. Catch the cylinder preservation oil draining out of the lower spark plug holes.2. 6. Inspect the paper filter for contamination. Replace all aircraft flexible oil and fuel hoses according to the aircraft manufacturer’s instructions prior to engine installation. proceed with engine installation. refer to the “Engine Preservation and Storage” instructions in Section 9 of the Engine Maintenance and Overhaul Manual (M-2). 2.1. Prepare the Engine for Installation Remove packing material. 2. Inspect the cylinder bores with a borescope for rust and contamination. Remove the AN-4060 protectors from the ignition leads. Follow the airframe manufacturer’s schedule interval for airframe mounted fuel and oil hoses. rebuilt. Remove the shipping plugs or dehydrator plugs from the spark plug holes. Turn the crankshaft through at least two complete revolutions to remove the cylinder preservation oil from the cylinders. 4. Hoses become brittle with age. Clean the aircraft fuel strainer and allow at least one quart of fuel to flow through the strainer and fuel supply line into a Type 1 fuel container through a paper filter. WARNING Purge the aircraft fuel tanks and lines to remove contamination prior to connecting the fuel supply to the engine. If contaminants are found in the fuel supply. if the fuel supply is free of contamination. it will burn off during the first engine start. The airframe fuel filter must be installed and in working order. 3. NOTE: If the engine won’t be installed immediately. TCM recommends hose replacement coincident with engine overhaul to avoid immediate contamination or failure at a later date. Prepare the Airframe for Engine Installation 2-2. and the preservative fluid from the oil sump of new. tags. 1. 2-2. 4. NOTE: A small amount of preservative oil remaining in the cylinder bore is acceptable. isolate and correct the source of contamination prior to connecting the aircraft fuel supply to the engine driven fuel pump.TM Engine Installation 2-2. O-200-D Series Installation & Operation Manual 1 May 2009 2-3 . 3. Place a basin under the engine to catch the cylinder preservation oil. NOTE: If corrosion or abnormal conditions are discovered during the borescope inspection. refer to “TCM Contact Information” in Section 1-3) for disposition instructions.

If gasket or accessory covers are not properly installed and torqued to M-2. 2.Engine Installation TM 7. Install all airframe manufacturer-required components according to the airframe manufacturer’s instructions. Other airframe manufacturer required item(s) 10. 9. torque the drain plug according to M-2. Install the engine in the sequence indicated in Section 2-2. 2-4 O-200-D Series Installation & Operation Manual 1 May 2009 . and connections.3. Hydraulic or vacuum pumps f. sides. Brackets d. Appendix B specifications. Drain plug locations are depicted in the “Engine Installation Drawings. Installation Sequence CAUTION: Do not allow chains to become entangled on the engine or its hardware. 3. Connect the aircraft fuel supply to the carburetor according to airframe manufacturer’s instructions. Cooling baffles b. may be installed in the accessory drive pads located on the upper rear portion of the crankcase. Connect the starter and alternator wiring according to airframe manufacturer’s instructions. 4. Remove the oil sump drain plug and drain the remaining cylinder preservation oil from the oil sump. Install the engine in the airframe mounts according to the airframe manufacturer’s instructions. oil leakage will occur. or bottom of the engine to strike any obstructions. Hoses and fittings c. NOTE: Optional accessories such as hydraulic pumps. Install the oil sump drain plug with a new crush washer. Appendix B specifications. vacuum pumps. Refer to the “Engine Installation Drawings” for engine dimensions. Install the exhaust system according to the airframe manufacturer's instructions.3. rear. including the following: a. Do not allow the front.” 8. clearances. safety wire the drain plug according to instructions in Appendix C of M-2. 2-2. WARNING Oil pressure is applied to the face of the accessory drive pads. as the extreme weight may damage the engine or its components. Exhaust system g. Remove the accessory drive covers and install new gaskets. Install accessories in accordance with the airframe manufacturer’s instructions. Ground straps e. Be sure the area is clear when lifting the engine. etc. 1.

Inspect the engine for any debris. If the magnetos were loosened or rotated during engine installation. connect the fuel lines to the carburetor.7 of the Engine Maintenance and Overhaul Manual (M-2). 10. 8. Verify the Ignition Switch is OFF according to the airframe manufacturer's instructions. discrepancies. Purge the aircraft fuel lines.2. Perform an “Installation Inspection” according to instructions in Section 2-2. Service the engine to the specified oil sump capacity according to instruction in “Engine Oil Servicing” instructions in Section 6-3.1. spark plugs. gaskets. WARNING Do not install the ignition harness “B” nuts on the spark plugs until the propeller installation and the ignition system operational checkout is complete.6 of the Engine Maintenance and Overhaul Manual (M-2). 13.TM Engine Installation 5. or damage.1 of the Engine Maintenance and Overhaul Manual (M-2). 12. and leak check the installed fuel lines according to the instructions in Section 2-2. 11. O-200-D Series Installation & Operation Manual 1 May 2009 2-5 . 6. 7. Install the propeller according to the airframe and propeller manufacturer's instructions.4. WARNING Do not operate the engine until all hardware. and seals are in place and torqued and the oil sump is properly filled to the specified capacity with oil. adjust magneto to engine timing according to the “Magneto Timing” instructions in Section 6-3. Perform the “Engine Pre-oiling” procedure according to Section 2-2. Correct any discrepancies. 15. Install any remaining aircraft accessories according to the airframe manufacturer's instructions.8. 14. Connect the remote oil cooler (if equipped) hoses to the engine oil cooler adapter according to the airframe manufacturer's instructions. Failure to comply can result in bodily injury when the propeller is rotated during installation. 9. Perform the“Engine Operational Check” instructions in Section 6-3.3.3.

7 of the Engine Maintenance and Overhaul Manual (M-2). Verify the engine oil is at the proper level according to “Engine Oil Servicing” instructions in Section 6-3. Connect the pre-oiler supply hose to the engine oil pressure output (fitting). Verify lubrication lines. one gallon capacity bladder-type pressure pot with 50 psi output pressure (not to exceed 60 psi). Failure to purge the air from the oil cooler and hoses prior to engine start will damage the engine.Engine Installation TM 2-2. fittings. hoses. Obtain a clean. the oil cooler and hoses will contain trapped air that oil servicing will not evacuate from the engine lubrication system. 3. 6.2 of the Engine Maintenance and Overhaul Manual (M2). Close the pre-oiler valve upon verification of oil flow at the rocker arms. Connect the ignition lead wires according to “Ignition Harness Maintenance” instructions in Section 6-3. 5. 4. Engine Pre-oiling CAUTION: If the engine oil cooler adapter is connected to an airframe mounted oil cooler. 1. 2-6 O-200-D Series Installation & Operation Manual 1 May 2009 .3 of CEM-2.8. and filters are in place prior to preoiling. 10. 9. 7. Install and torque the spark plugs according to the “Spark Plug Maintenance” instructions in Section 6-3.3. Check the oil level in the sump using the oil gauge rod (dip stick). 8. Depending upon oil temperature. It may be necessary to disconnect the airframe oil pressure sensor fitting according to the airframe manufacturer's instructions. Install the rocker covers with new gaskets according to the "Rocker Arm Installation" instructions in Section 17-4.8. Torque the rocker cover fasteners to M-2.3 of the Engine Maintenance and Overhaul Manual (M2). connect the airframe oil pressure sensor to the engine oil pressure output according to the airframe manufacturer's instructions. Appendix B specifications. Open the pre-oiler valve and monitor the engine cylinder rocker areas for oil flow. WARNING Do not operate the engine unless the oil is properly serviced. screens. it may take up to 20 minutes to see an indication of oil flow. Disconnect the pre-oiler supply hose and cap. 2.1. Remove the rocker covers.

Engine mounts are free of cracks. Appendix B specifications specifications. Lubricate the male fitting threads with 50 weight aviation engine oil and connect the aircraft fuel supply to the carburetor (or engine driven fuel pump. Place the mixture control in FULL RICH and the throttle ¼ OPEN. hoses and fitting for evidence of fuel leakage.4.2. 2. if equipped) inlet fitting. b. Place the mixture control to IDLE CUT-OFF and CLOSE the THROTTLE. 2-2. Position the fuel selector valve to the OFF position. or breakage. 9. 7.3. 10. 4. torque the fuel hose “B” nut to M-2.94 liter) of fuel to flow through a paper filter until the fuel is free of contaminants. d. Allow a minimum of one quart (0. Engine Fuel System a. Sufficient clearance exists between the engine (including any customer furnished items attached to the engine) and the aircraft/engine mount and cowling. Installation Inspection Inspect the following areas before attempting engine start: 1. Engine and airframe mounting points are properly aligned and torqued according to the aircraft manufacturer's instructions. 5. Visually inspect all fuel lines. 12. c. Dispose of the fuel/oil mixture in accordance with Federal and State Hazardous Material Regulations. CAUTION: Ensure the ignition switch is in the OFF position and clear the rotational arc of the propeller before proceeding. Fuel lines and hoses are connected to the engine according to the airframe manufacturers' instructions with no leaks under pressure. 3. Connect a length of the appropriate size hose to the aircraft fuel supply using an AN union fitting and secure the end of the hose in a properly grounded Type 1 flammable fluid container. 13. Position the fuel selector valve to the ON position. Remove the hose and union installed in step 1 from the aircraft fuel supply. O-200-D Series Installation & Operation Manual 1 May 2009 2-7 . Turn the aircraft fuel selector valve to the OFF position. Engine Mounts a. Turn the aircraft fuel selector valve to the ON position. 2. 6. Correct any discrepancies noted. All engine to airframe connections are flexible and correctly supported to prevent vibration transmission.TM Engine Installation 2-2. 8. Fuel Purge and Leak Check 1. 11. corrosion or damage. chafing.

Exposed positive connections are protected from accidental shorting with terminal boots or are enclosed in a protective box. operates smoothly and seals properly in the closed position. e. External oil lines to the engine are correctly routed and supported. free of the airframe. c. Engine is securely grounded to the airframe or directly grounded to the negative battery terminal with the adequate size ground wire. Induction system installation will not interfere with access to engine adjustments. 3. b.Engine Installation TM b. Crankcase breather is routed overboard. Oil cooler baffles are installed to maximize oil cooler efficiency. Engine electrical lead length sufficiently permits engine movement in all extremes without breaking wires. c. fittings or elevation changes and supported to prevent exposure to excessive temperature. Air Cooling Baffles And Cowling System a. Alternate air system door is connected. Lubrication System a. Magneto ground leads are routed through separate firewall connectors. b. g. Electrical wires are properly located and protected to prevent chafing. moisture and all moving parts 7. Fuel lines and hoses are per TSO or fabricated from fire resistant material. Oil gauge rod is correctly installed and supported. 2-8 O-200-D Series Installation & Operation Manual 1 May 2009 . Oil screens and oil filters are accessible for service with minimal oil spillage. Oil temperature and pressure monitoring sensors are installed correctly. e. heat radiation. Magneto switches are independently grounded to the engine with shielded wire. Adequate support provided for exhaust tail pipes and mufflers. c. d. f. oil. Fuel lines and hoses are routed with no unnecessary bends. f. Exhaust System a. b. Electrical System a. exposure to fuel. Air Induction System a. 5. d. Induction air filter is correctly installed. will not create suction or pressure and is protected from freezing. Baffles sufficiently accommodate the relative air movement between the individual cylinders. Oil separator used on crankcase breather has oil return line free from low trap points or other areas where sludge deposits can stop drainage. b. c. Flexibility provided for thermal expansion and engine movement. Baffles are not cracked and all fasteners are intact. b. 6. 4.

b. d. Controls operate smoothly through full range of travel at control and controlled device. Side loads on engine or accessory control shafts are not excessive. Accessories are installed with proper gasket and properly torqued. Controls are installed to engine levers to minimize the possibility of engine control separation. Controls are installed properly and accommodate engine movement without binding or change of adjustment. tubes. 9. Accessory Installation a. O-200-D Series Installation & Operation Manual 1 May 2009 2-9 . or other components do not interfere with the free flow of cooling air in or out of the cowling. 8.TM Engine Installation c. c. Engine Controls a. b. Accessories are the correct model to operate in the speed range provided by the engine drive or accessory drive. Ducts.

3. 1Procedure 1. Perform an “Engine Operational Check” instructions in Section 6-3. Preflight and Run-up Perform an Engine Operational Check after completing the engine installation and before performing the flight check according to the Airplane Flight Manual (AFM) or Pilot Operating Handbook (POH). and engine with one or more new cylinders or pistons.Engine Installation TM 2-2. 3.6 of the Engine Maintenance and Overhaul Manual (M-2).3 before releasing the engine for normal operations. require a 25-hour break-in. Perform a flight check before releasing the engine for normal service to ensure the installed engine meets the manufacturer’s performance and operational specifications. After installation. Correct all discrepancies prior to release for flight. including the Flight Check and Break-In period. CAUTION: Adhere to the Operating Limits in the Detailed Model Specification during all modes of engine operation. Perform a “Flight Check” according to instructions in Section 3-2. Appendix B specifications after initial engine run-up. NOTE: Perform a flight check according to instructions in Section 3-2. for continuous negative or zero “G” operation. avoid prolonged ground operation at high power.5. WARNING The fuel system must be adjusted after installation in the airframe according to the “Engine Operational Check” instructions in Section 6-3.6 of the Engine Maintenance and Overhaul Manual (M-2) to ensure proper operation. 2. nor approved. prior to first flight. 2-10 O-200-D Series Installation & Operation Manual 1 May 2009 . O-200 engines are neither designed. Re-torque the exhaust flange nuts to M-2. Engine Mount loads shall not exceed FAR 23 utility category load factors. New and rebuilt engines.

• Flight Prerequisites • Normal Operation • Emergency Operation • Operation in Abnormal Environments This chapter provides O-200-D engine operating instructions with fixed pitch propellers and supplements information in the Airplane Flight Manual (AFM) or Pilot's Operating Handbook (POH) provided by the airframe manufacturer or supplemental type certificate holder as required by the Federal Aviation Regulations (FAR) for aircraft operating procedures.6 of the Engine Maintenance and Overhaul Manual (M-2) prior to releasing the engine for normal operation.6 of M-2 must be completed on an engine that has been installed. inspected. seasonal changes. Engine Operation 3-1. Engines that are flown occasionally (less than one time per week) are more vulnerable to corrosion under these conditions.3. repaired. WARNING The “Engine Operational Check” in Section 6-3. and engine usage influence susceptibility to corrosion. 3-2. O-200-D Series Installation & Operation Manual 1 May 2009 3-1 . Normal operations are presented first. NOTE: Environmental conditions (humidity). Introduction CAUTION: This section pertains to engine operations under various operating conditions. Flight Prerequisites If the engine is newly installed and/or has been repaired/overhauled. DO NOT FLY THE AIRCRAFT UNTIL ALL FLIGHT PREREQUISITES HAVE BEEN MET. timely response is critical. The pilot must read and thoroughly understand Section 3-4 and Section 3-5 prior to the occurrence of such conditions.TM Engine Operation Chapter 3. This chapter contains the O-200-D engine operating instructions to supplement the AFM/ POH. After successful completion of the Engine Operational Check. The owner/ operator is ultimately responsible for recognizing corrosion and taking appropriate corrective action. or overhauled before the aircraft can be released for normal operation. perform the sequential tasks listed in the “Engine Operational Check” instructions in Section 6-3. The best method of reducing the risk of corrosion is to fly the aircraft weekly for at least one hour. followed by emergency and abnormal operating conditions. Whenever abnormal conditions arise. perform a Flight Check according to instructions in Section 3-2.

it may be desirable to increase drag to maintain engine power without gaining excess airspeed.3. 3-2. 3-2 O-200-D Series Installation & Operation Manual 1 May 2009 . A Flight Check is required after engine installation. If outside air temperature is extremely cold. If the aircraft is inadvertently serviced with the incorrect grade of aviation fuel or jet fuel. If the minimum fuel grade is not available. use the next higher grade. Flight Check and Break-In An Operational Inspection and a normal preflight ground run-up in accordance with the Airplane Flight Manual or Pilot's Operating Handbook (AFM/POH) must be completed before the A&P mechanic can approve the airplane for a Flight Check. The Oil Change Interval is specified in Table 6-1.5 of the Engine Maintenance and Overhaul Manual (M-2). New and factory rebuilt TCM engines are calibrated in a test cell prior to shipment. Do not permit cylinder head temperature to drop below 300°F (149°C). 3-2. The recommended break-in period for TCM engines is 25 hours. adjust the propeller to minimum governing RPM to obtain desired performance levels. After the fuel system is decontaminated.Engine Operation TM 3-2. A flight check ensures the engine meets operational specifications after installation in the airframe. The use of lower octane fuel may result in damage to.1.7 of the Engine Maintenance and Overhaul Manual (M-2). If power must be reduced for long periods. an engine the first time high power is applied. repairs. prior to release for normal service. Engine Fuel Requirements WARNING The engine is certified for operation with 100-LL aviation fuel. Never use a lower grade fuel. the fuel system must be completely drained and the fuel tanks serviced in accordance with the aircraft manufacturer's recommendations. Adhere to the following instructions and the “Engine Specifications and Operating Limits” in the Engine Detailed Model Specification applicable to your engine model. or destruction of. Oil Change Interval NOTE: After the first 25 hours of operation. Follow these parameters for the first 25 hours of operation to complete the recommended break-in for TCM engines. inspect the engine according to the “Contaminated Fuel System Inspection” instructions in Section 6-4. inspection. “Engine Inspection and Maintenance Schedule” of the Engine Maintenance and Overhaul Manual (M-2). perform an oil change according to the “Engine Oil Servicing” instructions in Section 6-3. WARNING Avoid long descents at high engine RPM to prevent undesirable engine cooling.2. or adjustments.

d) cylinder head temperature and e) exhaust gas temperature. c) oil pressure and temperature.TM Engine Operation CAUTION: High power ground operation resulting in cylinder and oil temperatures exceeding normal operating limits can be detrimental to cylinders. Engine Break-In Follow flight check parameters for the first 25 hours of operation to complete the recommended break-in for TCM engines. b) fuel flow. If the aircraft indicated values fail to meet the published limits. rated RPM at cruise altitude and operates within the limits specified in the Engine Detailed Model Specification. proceed to step 5. rated RPM is achieved. pistons.6. 3-2. reduce engine RPM to the bottom of the specified operating range to maintain sufficient manifold pressure. valves.” 3. Avoid long descents or descents with cruise power RPM and manifold pressure below 18 inches Hg.1. repeat the Engine Operational Check and Flight Check. Carefully monitor engine instrumentation to maintain levels above the minimum specified cylinder head temperature and oil temperature. Flight Check 1. full rich. Descend at low cruise power settings. 4. O-200-D Series Installation & Operation Manual 1 May 2009 3-3 . Start the engine according to instructions in Section 3-3.2. “Engine Start” 2. 5. If full power. 3-2.3. “Ground Run-up” . Release the engine to normal service. Monitor the following engine instrument panel indications: a) engine RPM.4. If necessary.2. “Take-Off. If the engine fails to reach the rated full throttle RPM during ground operations. and rings.3. ascend to cruise altitude (>2000' above field elevation) and verify the engine achieves full throttle. WARNING All abnormal conditions must be corrected prior to releasing the aircraft for normal operation.3. Conduct a normal ground run-up and take-off according to Section 3-3. “Taxi Preparation” and Section 3-3. Section 3-3.

WARNING Before flying the aircraft. If water or foreign matter is noted in the drained fuel. Check the fuel system according to the Pilot's Operating Handbook (POH) and verify compliance with Section 3-2. continue to drain until only clean fuel flows from the drains 4.2. ensure all “Flight Prerequisites” in Section 3-2 have been completed. 3-4 O-200-D Series Installation & Operation Manual 1 May 2009 . in addition to the aircraft manufacturer's instructions found in the AFM/POH. and verify quantity is with specified limits. Operation of a malfunctioning engine can result in additional damage to the engine. Adhere to the aircraft AFM/POH operating procedures. and serviceable. “Engine Fuel Requirements. 9. Verify oil fill cap and gauge rod are secure.Engine Operation TM 3-3. and security. Verify all baffles and baffle seals are installed. Drain the fuel sumps and strainers in accordance with airframe manufacturer's recommendations into a clean container. Check propeller and propeller hub for cracks. leaks. Inspect the rocker covers at three and nine o'clock positions for evidence of leaks or cracks. correctly positioned. 2. Ensure engine controls operate freely through their full range of travel and are properly adjusted in accordance with airframe manufacturer's instructions. bodily injury or death. Check the oil level.1. Supplemental instructions for normal operation in this section are: • Pre-operational Requirements • Engine Start • Taxi Preparation • Take-off • Climbing/Ascent • Cruising • Descent • Landing/Approach • Engine Shutdown 3-3. oil leaks. 7. 8. Verify the engine cowling is securely fastened. and debris. Normal Operation Information in this section supplements instructions for normal operation found in the AFM/POH. Check engine nacelle for signs of damage. 6. perform one time inspection and corrective action according to instructions in SB08-1. Pre-operational Requirements 1. If leaks or cracks are detected. 3.” 5.

..... “Flight Prerequisites....... Allow 20 seconds for the starter to cool after each engagement. Propeller ......... “Engine Operation in Extreme Cold................... If engine start is unsuccessful after six attempts.....” have been completed in addition to those required by the aircraft POH.. CAUTION: Attempting to start an engine with a partially discharged aircraft battery may result in damage to the starter relay or possible engine kick-back resulting in a broken starter adapter clutch spring........ ensure the battery is completely charged....2..... BOTH CAUTION: Release starter switch as soon as engine fires.....” WARNING Ensure the propeller arc is clear of personnel and obstructions before starting the engine. Never engage the starter while the propeller is still turning... especially in subfreezing temperatures. aircraft manufacturer....... “Ground Operation at High Density Altitude... Do not engage the starter for longer than 10 seconds.....” • If the engine is being started at high altitude.............. Master Switch .. refer to Section 3-5.. Starting an engine with a flooded induction system can result in hydraulic lock and subsequent engine malfunction or failure.2.. Oil pressure indication must be noted within 30 seconds in normal weather. release the starter switch and allow the starter motor to cool for 30 minutes before another starting attempt is made.... preheating may be required.. Be familiar with the quantity and location of the engine fuel system drains.... Note the following: • If the engine is being started in extreme cold. O-200-D Series Installation & Operation Manual 1 May 2009 3-5 . When starting the engine.. Allow excess fuel to drain from the intake manifold and/or cylinder prior to attempting to start the engine..... 1.3... Refer to Section 3-5.... refer to Section 3-5. “Pre-operational Requirements” prior to engine start........ Verify the tasks listed in Table 3-2........1.TM Engine Operation 3-3. If no oil pressure is observed.......... ON 3.. WARNING Do not attempt to start an engine with an over-primed or flooded induction system...... Ignition Switch.... Engine Start Refer to the aircraft POH for detailed engine starting procedures. Clear 2.. “Engine Operation in Hot Weather.... NOTE: Check oil pressure frequently.. or Supplemental Type Certificate (STC) holder..” • If the engine is started in hot weather.. stop the engine and investigate the cause...1........ Complete Section 3-3....

......... Oil Pressure......3........ Oil pressure indication must be noted within 30 seconds in normal weather.....2............. If the engine is hot... verify fuel.....1... 3-3............. Mixture Control ........ If no fuel drainage is observed.. 10....... After priming... 3-6 O-200-D Series Installation & Operation Manual 1 May 2009 .... 3-3..... 3-3. Ignition Switch....2 of M-2............... Fuel Selector Valve ...... Open approximately one (1) inch WARNING Ensure the propeller plane of rotation is clear before engaging the starter........... Check RESULT: Engine starts and runs smoothly at idle.............. do not prime before starting... Hot Start NOTE: For several minutes after stopping a hot engine................ Familiarity and practice will enable to operator to accurately estimate the amount of prime to use........... (especially the fuel pump............................................. FULL OPEN NOTE: The amount of prime required depends on engine temperature...2. WARNING Do not operate the engine if hydraulic lock is suspected..... discontinue starting attempts until the cause is determined...... 9. Perform a “Hydraulic Lock Inspection” according to instructions in Section 6-4...... If the engine fails to start. Hydraulic lock may be a cause of engine starting problems..... turn the primer handle to the "LOCKED" position to prevent the engine from drawing fuel from the primer....... Throttle......... indicated oil pressure is greater than 10 psi. refer to the troubleshooting instructions in Section 8 of the Engine Maintenance and Overhaul Manual (M-2).... Do not attempt further starting until excess fuel has drained from the engine............ 7........ Hydraulic lock is a condition where fluid accumulates in the Induction System or the cylinder assembly.... Prime (if equipped) ........ Engine damage may occur....................... ON or Fullest Tank 6... using the same procedure as for a normal start... stop the engine and investigate the cause...........2. Throttle......... If no pressure is observed. START NOTE: Check oil pressure frequently............2.................. Operate 3-5 strokes 8........ FULL RICH 5. Flooded Engine If prolonged starting occurs.......... heat soaked components. Cold Start Follow the AFM/POH instructions......Engine Operation TM 4.. if equipped) may cause fuel vaporization resulting in restarting difficulties..

900-1000 RPM 5.......... Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage...” Should the propeller be turned by hand...... 1700 RPM O-200-D Series Installation & Operation Manual 1 May 2009 3-7 .................. supplement the AFM/POH normal starting instructions with the following steps: 1....... 3-3.......... IDLE CUT OFF 4............ 6.... Ground Run-up CAUTION: DO NOT operate the engine at run-up speed unless the oil temperature is at least 75°F (24°C) and the oil pressure is within the 30-60 psi range......................... FULL RICH 4.......................................... Maintain engine RPM between 900 and 1000 RPM for at least one minute or until engine oil temperature exceeds 75°F (24°C).. RPM drop exceeding 150 RPM may indicate a faulty magneto or fouled spark plugs............. follow AFM/POH starting instructions.... Throttle...................... 1.................. This condition must be corrected prior to continued aircraft operation.. Avoid prolonged engine operation at low RPM to prevent spark plug fouling...... ON 2..... Fuel Selector Valve .. Mixture Control.................................. NOTE: If the engine runs roughly after single magneto operation.............TM Engine Operation To reduce difficulty.... Maneuver aircraft nose into wind 2....... Throttle......................................... Mixture.... some RPM drop should be noted.. Limit ground operation to time necessary to complete engine warm-up and pre-flight checkout................3..... When operating on single ignition..... WARNING Absence of RPM drop during the magneto check may be an indication of a faulty ignition circuit resulting in a condition known as “Hot Magneto... Normal indications are 25-75 RPM drop and slight engine roughness as each magneto is switched off..... the engine may inadvertently start and cause personal injury or death...... CLOSED 3... Allow fuel to drain from intake prior to engine start...................... IDLE 3......... CAUTION: Do not underestimate the importance of the magneto check........... increase engine speed to 2200 RPM in the BOTH position and lean the mixture control until the RPM peaks for ten seconds before returning to the full rich position to clear the spark plugs and smooth operation before returning to single magneto operation...... Throttle........... Throttle...............

............................................................. BOTH RESULT: Engine speed returns to normal............................. R RESULT: Noticeable RPM (not to exceed 150 RPM) drop and slight engine roughness............ lean until RPM peaks for 10 seconds........................... 2) Ignition Switch............. Throttle......... FULL RICH 7...............................Engine Operation TM a... Maximum allowable RPM drop spread between magneto channels is 50 RPM........... Minor spark plug fowling can be cleared as follows: 1) Ignition Switch................................ 3) Ignition Switch......... Maximum RPM drop for either magneto is 150 RPM........ Proper engine cooling depends upon forward motion of aircraft. BOTH 2) Throttle.. 2200 RPM 3) Mixture Control ........ Allow Ignition switch to remain in BOTH for approximately 30 seconds to clear engine. record Left Magneto channel drop results. Observe engine smoothness during magneto switching....... Magneto Checkout 1) Ignition Switch..................... 1200 RPM 3-8 O-200-D Series Installation & Operation Manual 1 May 2009 . b... 4) Mixture Control ......................... CAUTION: Do not operate the engine at speeds in excess of 2000 RPM longer than necessary to complete ground checks........... Discontinue testing if temperature or pressure limits are approached..... L RESULT: Noticeable RPM (not to exceed 150 RPM) drop and slight engine roughness... The difference between magnetos individual operation should not exceed 75 RPM...................

.. inspect to determine cause. Cowling Flaps ...... Throttle.... extreme ambient temperatures. Monitor Engine Gauges not to exceed operating limits a............... Check the following items: NOTE: For taxi operation during high ambient temperature or from fields at higher altitudes... A FULL RICH mixture must be used for takeoff... or restricted fuel flow.6.... 1....... or if abnormal cowl flap and/or mixture settings are required to maintain temperatures............ Tachometer c...TM Engine Operation 3-3............. Faulty instruments or thermocouples may cause erroneously high (or low) indications......... Possible causes are broken or missing baffles..... etc. Before taxiing........ FULL OPEN (if equipped) 2.. Take-Off Supplement the AFM/POH take-off procedures with these engine settings: 1. then adjust the mixture setting..... If excessive temperatures are noted and cannot be explained............... refer to the AFM/POH for detailed taxi preparation procedures applicable to your aircraft............ sticking oil temperature control unit.. Advance for rated takeoff power CAUTION: Never allow cylinder head and oil temperatures to exceed limits... 4....5.... Refer to troubleshooting procedures in Section 8 of M-2... inoperative cowl flaps............... Oil Temperature and Pressure O-200-D Series Installation & Operation Manual 1 May 2009 3-9 ........ Instrument Checkout ...... 3-3....... per AFM/POH 3...... then advance the throttle to increase RPM..... Refer to AFM/POH 3-3..............4. the mixture control may require leaning for smooth engine operation...... Take remedial steps to reduce such temperatures as soon as possible. Mixture............ Cylinder Head Temperature e.... Power Control When increasing power: enrich the mixture... low airspeed................................ Taxi Preparation CAUTION: DO NOT operate the engine at run-up speed unless the oil temperature is at least 75°F (24°C) and the oil pressure is within the 30-60 psi range...... Fuel Flow d....... Cowl Flaps ... FULL RICH 2.................... Near maximum temperatures should occur only when operating under adverse conditions such as high power settings....... Manifold Pressure b. Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage.. When decreasing power: reduce the RPM.

................ 3.........” 3-10 O-200-D Series Installation & Operation Manual 1 May 2009 .8... NOTE: Maintain mixture and throttle settings until climb is complete. 2. Tachometer c...... Upon completion of climb.... Cruise Climb For climbing or ascent procedures at full power.... Cylinder Head Temperature e.. until engine RPM “peaks” (RPM advances to highest level at throttle setting) for the selected throttle position............ supplement the AFM/POH with these settings: 1... Fuel Flow d... Set to maintain CHT/Oil Temp 4... When reducing power. Adjust the mixture control to lean the fuel mixture.... This setting is referred to as “Best Power Cruise. Advance the mixture control slowly toward the “FULL RICH” position until slight RPM reduction is observed on tachometer...........7. Monitor Engine Instruments .. Throttle... Cowl Flaps .... then advance the throttle to increase RPM............... retard throttle............ Oil Pressure 3-3.. enrich mixture....Allow engine temperatures to stabilize (approximately five minutes after cruise settings). a. Adjust the throttle for the desired cruise power settings.... Excessive mixture leaning will increase engine temperatures and may damage the engine.....Engine Operation TM 3-3..... while monitoring the tachometer........ CAUTION: When increasing power......... Manifold Pressure b.......... Greater than 75% rated power 2. monitor engine gauges not to exceed operating limits... supplement the Airplane Flight Manual or POH instructions with these steps: 1........ then adjust the mixture control. Do not lean the fuel mixture beyond the “Best Power” setting.. Cruise When the desired altitude has been reached........... power settings may be reduced to desired settings... FULL RICH 3... Mixture Control .. Immediately after takeoff.

........... NOTE: Avoid long descents at low manifold pressure..... If outside are is extremely cold..5 in.. This condition must be corrected prior to continued aircraft operation. refer to the Airplane Flight Manual/POH.. Monitor Cylinder Head Temperature and Oil Temperature gauges to maintain operation within the operating limits in the Detailed Model Specification... RPM drop in excess of 150 RPM may indicate a faulty magneto or fouled spark O-200-D Series Installation & Operation Manual 1 May 2009 3-11 . within operating limits 3-3.. it may be necessary to increase drag in order to maintain engine power without gaining airspeed...... the engine may inadvertently start and cause personal injury or death.. Manifold pressure ...........” Avoid engine roughness by leaving the mixture control leaner than Full Rich until the throttle raises manifold pressure above 15 in....... Descend at cruise power settings with mixture control positioned for smooth engine performance....... 3-3..... some RPM drop should be noted.. Engine gauges ..” Should the propeller be turned by hand...... Descent Supplement the AFM/POH with the following: 1.. Normal indications are up to 150 RPM drop and slight engine roughness as each magneto is switched off... If power must be reduced for long periods...... Landing NOTE: Advance mixture slowly toward “Full Rich.11.. Do not permit cylinder temperature to drop below 300°F for periods longer than five minutes.. 2..... Hg............ Throttle....Hg 4.. CAUTION: When operating on single ignition. 1700 RPM WARNING Absence of RPM drop during the magneto check may be an indication of a faulty ignition circuit resulting in a condition known as “Hot Magneto...........10................... Engine Shutdown Supplement the AFM/POH engine shutdown procedures with the following: 1.......9....... For landing and approach procedures............TM Engine Operation 3-3. In anticipation of a go around and subsequent need for higher power.. above 18.. CAUTION: Avoid rapid descents at high RPM and idle manifold pressure. set manifold pressure no lower than necessary to obtain desired performance........... set the Mixture Control to FULL RICH. 3... The engine can cool excessively and fail to accelerate satisfactorily when power is reapplied..

........ Maximum RPM drop for either magneto is 150 RPM......... NOTE: If the engine runs roughly after single magneto operation........ Mixture Control ............. 3. Ignition Switch............. Ignition Switch.................................. Avoid prolonged single magneto operation to preclude spark plug fouling. OFF 3-12 O-200-D Series Installation & Operation Manual 1 May 2009 . 5....... IDLE CUTOFF Wait for the propeller to stop.................................. Observe engine smoothness during magneto switching.................................. Ignition Switch.. Maximum allowable RPM drop spread between magneto channels is 50 RPM................................ WARNING Do not turn the propeller by hand while the Ignition Switch is in the BOTH...... LEFT or RIGHT positions........ Throttle........... Maximum allowable RPM drop spread between magneto channels is 50 RPM.............. 2....... OFF 9........................... Fuel Selector Valve . L RESULT: Noticeable RPM (not to exceed 150 RPM) drop and slight engine roughness... IDLE 7.. Do not turn the propeller on a hot engine even if the Ignition Switch is in the OFF position.... Ignition Switch. BOTH 6... 4....... NOTE: The difference between magnetos individual operation should not exceed 50 RPM. R RESULT: Noticeable RPM (not to exceed 150 RPM) drop and slight engine roughness................................ Ignition Switch............. increase engine speed to 2200 RPM in the BOTH position and lean the mixture control until the RPM peaks for ten seconds before returning to the full rich position to clear the spark plugs and restore smooth operation before returning to single magneto operation................. 8............ Allow Ignition switch to remain in BOTH for approximately 30 seconds to clear engine... BOTH RESULT: Engine speed returns to normal.......................................Engine Operation TM plugs........... The engine could kick back as a result of autoignition caused by a small amount of fuel remaining in the cylinders........... Auto-ignition could restart the engine and cause serious bodily injury or death...

. following instructions in the AFM/POH 3-4. Follow AFM/POH instructions. WARNING Maintain control of the aircraft at all times....... Do not stall the airplane attempting to extend the gliding distance... Some malfunctions which might occur are listed in this chapter.. reduce power....2........ Follow the AFM/POH emergency procedures... Do not stall the airplane attempting to extend the gliding distance.. OPEN 2......TM Engine Operation 3-4...... Mixture.... Engine Fire during Start WARNING Maintain control of the aircraft at all times.. no single procedure will be applicable in every situation.1....... Thorough aircraft and engine familiarity are invaluable assets in assessing a given situation and responding accordingly...... High Cylinder Head Temperature Supplement AFM/POH instructions with these steps: 1.......3............ Cowl Flaps ............ Full Rich 3...... engine failure may be imminent... Recommended corrective action is also included... Perform the following engine-specific steps in addition to the POH requirements when responding to emergency conditions........ If a malfunction should occur in-flight........ Airspeed .. Follow AFM/POH instructions. Emergency Operation Information in this section supplements instructions for emergency operations found in the aircraft POH. Land at the best available landing area within aircraft gliding distance........ 3-4....... Engine Roughness WARNING If roughness is severe or the cause cannot be determined.. certain remedial actions may eliminate or reduce the severity of the condition............................... Increase If temperature cannot be maintained within limits......... land as soon as practical and have the malfunction evaluated prior to further flight....... The following terms are used throughout Section 3-4 Land as Soon as Practical: Land as Soon as Possible: Land at the nearest airport suitable for the aircraft...... However.... 3-4......... O-200-D Series Installation & Operation Manual 1 May 2009 3-13 ..

.................. Have the engine inspected prior to further flight............... do so by reducing power...................... If oil pressure remains normal. 3-4............. OPEN (if equipped) 2............Engine Operation TM 3-4........ Increase 3.............. CLOSED 4........................ If oil temperature drops as temperature increases: 1..........6................ Engine Fire In Flight 1...... Ignition Switch..7...... A few minutes exposure to temperatures and airspeed at flight altitudes can have the same effect on an inoperative engine as hours of cold-soak in sub-arctic conditions. 3-4.............. Mixture. If the engine must be restarted............. High Oil Temperature CAUTION: If these steps do not restore oil pressure to normal................................... OFF 5......... Follow AFM/POH emergency procedures.. Reduce Power if steps 1 and 2 do not lower temperature 4.. Cowl Flaps . Follow AFM/POH instructions....... Throttle........ Execute AFM/POH EMERGENCY/FORCED LANDING PROCEDURES and LAND AS SOON AS POSSIBLE 3-14 O-200-D Series Installation & Operation Manual 1 May 2009 .. IDLE/CUTOFF 3........... OFF 2.. Airspeed ........5... If the oil pressure drops suddenly from a normal indication of 30-60 psi............................. an engine failure is imminent.. NOTE: Prolonged high oil temperature indications are accompanied by reduced oil pressure......... Closely monitor for excessive oil pressure as engine RPM increases. In-Flight Restart CAUTION: Do not shutdown an engine in-flight for practice or training purposes.... Follow the AFM/POH emergency instructions and LAND AS SOON AS POSSIBLE.......... an engine failure or severe damage is imminent.... Fuel Selector .. LAND AS SOON AS PRACTICAL 3-4.. consider descending to warmer air..... Whenever engine failure is simulated. Low Oil Pressure WARNING If oil pressure drops below 30 psi. monitor temperature closely and LAND AS SOON AS POSSIBLE... Allow the engine to warm at minimum RPM before continued flight operations...4............ a high temperature indication may be caused by a faulty gauge or thermocouple........

further complicating the starting procedure. and subsequent engine failure.3.1. Cold soaking causes the oil to become thicker (more viscous).TM Engine Operation 3-5. lines. An inadequate application of preheat may warm the engine enough to permit starting but will not decongeal oil in the sump.1. WARNING Over-priming can cause a flooded intake resulting in a “hydraulic lock” event and subsequent engine malfunction or failure. At low temperatures. CAUTION: Use an external power source when attempting to start aircraft engine in cold weather. WARNING Failure to properly preheat a cold-soaked engine may result in oil congealing within the engine. but can be damaged from lack of lubrication due to the congealed oil O-200-D Series Installation & Operation Manual 1 May 2009 3-15 . Engine Operation in Abnormal Environments The anticipated types of abnormal environments are: • Extreme cold weather • Extreme hot weather • High density altitude ground operation 3-5. At ambient temperatures between 20º and 40ºF (-7º and 4ºC). making it difficult for the starter to crank the engine which results in slow cranking speeds and an abnormal drain on the battery capacity. Superficial application of preheat to a cold soaked engine can cause damage to the engine.1. oil hoses. make certain that excess fuel has drained from the intake manifold and/or cylinder prior to attempting engine start. Congealed oil in these areas require considerable preheat. If you over-prime (flood) the engine. Engine Operation in Extreme Cold Engine starting during extreme cold weather is generally more difficult. cooler. etc. possible internal damage to the engine. aviation gasoline does not vaporize readily. The engine may start and appear to run satisfactorily. refer to Section 3-5. filter.1 and the AFM/POH for specific instructions. and oil cooler with subsequent loss of oil flow. Engine preheating and an auxiliary power unit (APU) are required to facilitate engine starting when the engine has been exposed to temperatures below 20ºF (-7°C) for more than two hours. Refer to Section 3-5. Attempting to start an engine with a partially discharged aircraft battery may result in damage to the starter relay or possible engine kick-back resulting in a broken starter adapter clutch spring False starting (failure to continue running after starting) often results in condensation on spark plug electrodes.1. This moisture can freeze and must be eliminated either by preheating the engine or removing and cleaning the spark plugs.

Engine Operation TM blocking proper oil flow through the engine. However. Engine Preheating CAUTION: Proper engine preheating procedures require thorough application of preheat to all parts of the engine. The amount of damage will vary and may not become evident for many hours. Oil sump b.2. Oil cooler e. Because excessively hot air can damage non-metallic components such as seals.1. refer to Section 3-5. Apply preheated air directly to the listed parts for at least 30 minutes: a. 3-5. cylin- ders. Select a high-volume air heater. OR • An engine mounted preheating system. External oil lines d. The preferred method of preheating is to place the aircraft in a heated hangar for a minimum of four hours prior to flight. Prior to operation and/or storage in cold weather. Oil filter c. 2.1. and oil cooler. refer to Section 3-5. Apply hot air directly to the oil sump and external oil lines as well as the cylinders.7 of the Engine Maintenance and Overhaul Manual (M-2). do not attempt to hasten the preheat process. In the event of temporary cold weather operation. use the following method: 1.1.1. and drive belts. store the aircraft in a heated hangar between flights. hoses.1. air intake. Service the oil sump as required with the specified oil grade according to the “Engine Oil Servicing” instructions in Section 6-3. and oil cooler. Optional preheating methods are: • A high volume combustion heater with ducts directed to the engine oil sump. ensure the engine is serviced with the correct viscosity oil for the ambient air temperature.1. the engine may be severely damaged and may fail shortly after application of high power.1. without an engine mounted preheating system.1. 3-5. Engine Preheat with a Combustion Heater If a heated hangar is not available and the aircraft and engine have been exposed to temperatures below 20ºF (-7ºC) for two hours or more. NOTE: Small electric heaters inserted in the cowling opening do not appreciably warm the oil and may result in superficial preheating. Cylinder assemblies 3-16 O-200-D Series Installation & Operation Manual 1 May 2009 . Preheat all engine parts.1.1.

the engine has been warmed sufficiently to accept full rated power. CAUTION: Continually monitor oil pressure during run up.2. WARNING Operating the engine above 1700 RPM before reaching the minimum oil temperature may result in engine malfunction. Apply heat directly to the induction tubes and cylinders will promote vaporization and ease starting. Since the engine will be warm. Do not close the cowl flaps to facilitate engine warm-up. Start the engine immediately after completion of the preheating process. retard the throttle to maintain oil pressure below 100 psi. 6. If oil pressure is less than 30 psi. engine failure. CAUTION: DO NOT operate the engine at run-up speed unless the oil temperature is at least 75°F (24°C) and the oil pressure is within the 30-60 psi range. Air intake 3. in 100 RPM increments to prevent oil pressure from exceeding 100 psi. 3-5. When oil temperature has reached 75°F (24°C) and oil pressure does not exceed 60 psi at 2500 RPM. 7. 4.TM Engine Operation f. shut down the engine and determine the cause. a. injury or death. Run the engine up to 1700 RPM. b. Continuous operation of enginemounted preheater systems may result in aggressive internal engine corrosion.1. Do not close the cowl flaps in an attempt to hasten engine warm-up. Operate the engine at 1000 RPM until some oil temperature is indicated. Alternately heat the sump and engine cylinders until engine start.2.1. If a heated hangar is not available and the aircraft and engine have been exposed to temperatures below 20ºF (-7ºC) for two hours or more and has an engine-mounted preheating system the following procedure may be used. Engine Preheat with an Engine-Mounted Preheater WARNING Do not leave an engine-mounted pre-heater system on for more than 24 hours prior to flight. Periodically feel the top of the engine for warmth. Monitor the oil pressure closely. If necessary. Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage. 5. Operating the engine without oil pressure may result in engine damage. CAUTION: If oil pressure is not indicated within 30 seconds. shut the engine down and repeat the preheat process. O-200-D Series Installation & Operation Manual 1 May 2009 3-17 . or cannot be maintained below 100 psi. Monitor the oil temperature until it reaches at least 75°F (24°C). follow the normal start instructions in Section 3-3.

shut down the engine and determine the cause.1.2. Begin preheating of the engine at least five hours prior to expected departure. When oil temperature has reached 100°F (38°C) and oil pressure does not exceed 60 psi at 2500 RPM. the engine has been warmed sufficiently to accept full rated power. 2. Cold Weather Starting Without Preheating At ambient temperature between 20° to 40ºF (-7°to 4°C). Operate the engine at 1000 RPM until some oil temperature is indicated. 6. If necessary. injury or death. 4. 1. b. perform the following: CAUTION: Attempting to start your engine with a partially discharged aircraft battery may result in damage to the starter relay 3-18 O-200-D Series Installation & Operation Manual 1 May 2009 . 5. Operating the engine without oil pressure may result in engine damage. Do not operate an engine preheating system continuously for more than 24 hours. Monitor the oil pressure closely. Start the engine immediately after completion of the preheating process using the normal start procedure in Section 3-3. Follow the preheating system's manufacturer's installation and operation instructions. CAUTION: Do not operate the engine at speeds above 1700 RPM unless the oil temperature is at least 75°F (24°C) and the oil pressure is between 30 to 60 psi. engine failure. Run the engine up to 1700 RPM. approach this RPM in increments to prevent oil pressure from exceeding 100 psi. oil sump heater pad and crankcase heater pad. Do not close the cowl flaps to facilitate engine warm-up. If oil pressure is less than 30 psi.3. CAUTION: If oil pressure is not indicated within 30 seconds. CAUTION: Continually monitor oil pressure during run up. or cannot be maintained below 100 psi. retard the throttle to maintain oil pressure below 100 psi.1. The preheating system manufacturer should have thermal blankets available. Monitor the oil temperature until it reaches at least 75°F (24°C). Do not close the cowl flaps in an attempt to hasten engine warm-up. 3-5.Engine Operation TM Engine mounted preheating systems should include individual cylinder head heater thermocouples. shut the engine down and repeat the preheat process. 3. NOTE: The use of an approved thermal blanket or cover will help reduce the effects of wind and cold air circulation when the aircraft is not stored in a hangar. The use of a nacelle blanket will increase the effectiveness of engine preheating. WARNING Operating the engine above 1700 RPM before reaching the minimum oil temperature may result in engine malfunction. a.

Operating the engine without oil pressure may result in engine damage. engine failure. Do not close the cowl flaps in an attempt to hasten engine warm-up. If necessary. When oil temperature has reached 100°F (38°C) and oil pressure does not exceed 60 psi at 2500 RPM. WARNING Operating the engine above 1700 RPM before reaching the minimum oil temperature may result in engine malfunction. Do not close the cowl flaps to facilitate engine warm-up. Run the engine up to 1700 RPM. the engine has been warmed sufficiently to accept full rated power. 6. ensure excess fuel has drained from the intake manifold and/or cylinder prior to attempting engine starting. or cannot be maintained below 100 psi. Do not overprime the engine. shut down the engine and determine the cause. Operate the engine at 1000 RPM until some oil temperature is indicated. If oil pressure is less than 30 psi. 7. O-200-D Series Installation & Operation Manual 1 May 2009 3-19 . approach this RPM in increments to prevent oil pressure from exceeding 100 psi. Operating the engine above idle before reaching minimum oil temperature may cause a loss of oil pressure and engine damage. Use an external power source or ensure the aircraft battery is fully charged. or flood your engine. CAUTION: Continually monitor oil pressure during run up. Check the oil temperature.TM Engine Operation or possible engine kickback. shut the engine down and follow the preheat instructions to prevent engine damage. 4. it should be at least 75°F (24°C). If you over prime. CAUTION: DO NOT operate the engine at run-up speed unless the oil temperature is at least 75°F (24°C) and the oil pressure is within the 30-60 psi range. Use the normal start procedure in Section 3-3. CAUTION: If oil pressure is not indicated within 30 seconds. 5.2 and the aircraft AFM/POH. resulting in a broken starter adapter clutch spring. injury or death. WARNING Overpriming can cause a flooded intake resulting in a “hydraulic lock” event and subsequent engine malfunction or failure. 2. retard the throttle to maintain oil pressure below 100 psi. 3. 1. Monitor the oil pressure closely.

to maintain the oil capacity specified in the according to the “Engine Oil Servicing” instructions in Section 6-3.2.2.2. • If the aircraft is flown in dusty conditions. the entire unit will stabilize near the ambient temperature. At the same time. store the aircraft in a hangar between flights. Operating Tips • Inspect the induction air filter frequently for contamination.7 of the Engine Maintenance and Overhaul Manual (M-2). After an engine is shutdown. Service the oil sump. the fuel system will warm causing the fuel in the pump and fuel lines to “boil” or vaporize. • Open cowl flaps fully while taxiing.4) Ensure the engine is serviced with the correct viscosity oil specified in the Engine Detailed Model Specification prior to starting the engine. while other parts will begin to heat up due to lack of air flow or heat convection from those engine parts that are cooling.2) • “Take-off and Initial Climb Out in Hot Weather” (Section 3-5.2. the fuel lines will be filled with varying amounts of fuel and vapor. Three hot weather operation situations requiring special instructions are: • “Cooling an Engine in Hot Weather” (Section 3-5. • Use dust covers over openings in the cowling for additional protection. 3-20 O-200-D Series Installation & Operation Manual 1 May 2009 .2. if necessary. be prepared to clean or replace it. difficult starting and unstable engine operation can be expected. Until the entire fuel system becomes filled with liquid fuel.1) • “Engine Restart in Hot Weather” (Section 3-5. During subsequent starting attempts. as required. Heat soaking occurs between 30 minutes to one hour following shutdown. During this time. the fuel pump will initially be pumping a combination of fuel and fuel vapor. This time period will be determined by temperature and wind conditions and may take several hours. TCM recommends more frequent oil changes. In the event of temporary cold weather exposure.1. The hotter parts such as cylinders and oil will cool. Engine Operation in Hot Weather “Hot weather” is defined as ambient temperature exceeding 90°F (32°C). Cooling an Engine in Hot Weather • Reduce ground operation to a minimum to keep engine temperatures down.Engine Operation TM 3-5. • Face the nose of aircraft into the wind to take advantage of the cooling effect. the temperature of various components will begin to stabilize. 3-5. At some point following engine shutdown.

.. ON 2.... Do not operate the engine at maximum power longer than necessary to establish the climb configuration recommended by the aircraft manufacturer.........2.. Monitor temperatures closely. Maintain sufficient airspeed and attitude to provide engine cooling...... Do not operate the engine at high RPM except for necessary operational checks... Fuel selector ... Cowl flaps ..4..... 3-5...... 3....... Follow the “Engine Start” instructions in the AFM/POH and Section 3-3............... Mixture Control .....2...... fuel vapor will decrease and present less of a restart problem...... 2......... face the aircraft into the wind with the engine idling at 900-1000 RPM.............2.. 3-5..3.....2...... 2..................... CLOSED 3....... Engine Restart in Hot Weather Restarting attempts will be the most difficult between thirty minutes and one hour after engine shutdown... Ground Operation in Hot Weather 1........................ it may be necessary to manually lean the mixture to sustain engine operation at low RPM..... 1... Mixture control ...... FULLY OPEN (if equipped) O-200-D Series Installation & Operation Manual 1 May 2009 3-21 ..........2............... Operate with cowl flaps full open 3. Following that interval.......................... 4............ Monitor oil and cylinder temperatures closely during taxiing and engine run up... IDLE/CUTOFF 4.. 5......... WARNING Allow excess fuel to drain from the induction system prior to starting the engine..... Throttle............. 4............. Take-off and Initial Climb Out in Hot Weather 1. FULL RICH NOTE: Under extreme conditions. If take-off is not to be made immediately following engine run-up.....TM Engine Operation 3-5...

3. face the aircraft into the wind with the engine idling between 900-1000 RPM. 3-22 O-200-D Series Installation & Operation Manual 1 May 2009 . establish a lower angle of attack or higher climb speed. If higher than desired temperatures are experienced during the climb phase. • If take-off is not to be made immediately following engine run-up. When practical. Idle fuel mixture may be rich during high density altitude conditions. NOTE: A FULL RICH mixture is required during takeoff. • Do not operate the engine at high RPM except for necessary operational checks. Lean the fuel mixture to sustain operation at low RPM. Ground Operation at High Density Altitude CAUTION: Reduced engine power will result from higher density altitude associated with high temperature. consistent with safe operating practices to provide increased engine cooling. • Monitor oil and cylinder temperatures closely during taxiing and engine run up. • Operate with cowl flaps full open. operate the engine at higher idle speed.Engine Operation TM 3-5.