Continental engine overhaul service manual IO-520 IO520

A IO-520 Series Engine Overhaul Manual 31 August 2011 Supersedure Notice This manual revision replaces the front cover and list of effective pages for Publication Part No. X30039, dated September 1977. Previous editions are obsolete upon release of this manual. Effective Changes for this Manual 0 .......... September 1977 1 ............ 31 August 2011 List of Effective Pages Document Title: IO-520 Series Engine Overhaul Manual Publication Number: X30039 Initial Publication Date: September 1977 Page Change Page Change Page Change Page Change Cover ............................ 1 A ................................... 1 i thru v .......................... 0 1-1 thru 1-10................. 0 2-1 thru 2-10................. 0 3-1 thru 3-2................... 0 4-1 thru 4-30................. 0 5-1 thru 5-12................. 0 6-1 thru 6-30................. 0 7-1 thru 7-8................... 0 8-1 thru 8-20................. 0 9-1 thru 9-8................... 0 10-1 thru 10-2............... 0 Published and printed in the U.S.A. by Continental Motors, Inc. Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601 Copyright © 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise altered without the publisher's written permission. This manual is provided without express, statutory, or implied 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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MAY 1980 1-1 SECTION I INTRODUCTION 1-1. SCOPE. This publication comprises Overhaul Instructions for the IO-520 Series Aircraft Engines. 1-2. RELATED PUBLICATIONS. Detail part numbers and service assemblies for these engine models are contained in Parts Catalog X-30040A. Operating instructions are contained in Operator's Handbook X-30041. a. Service instructions for Slick Magneto Model No. 662 may be obtained from Slick Electro Inc., Rockford, Illinois 61100. b. Service instructions for Bendix Magneto Model S6RN-201, S6RN-205, S6RN-1201 and S6RN-1205 may be obtained from Bendix Corporation, Electrical Components Division, Sidney, New York 13830. c. Service instructions for Delco-Remy Starters, Generators or Alternators may be obtained from Delco-Remy Division, General Motors Corporation, Anderson, Indiana 96011. 1-3. SERVICE BULLETINS. Important changes and product improvements are covered by factory service bulletins available for study at all Approved Distributors. These Bulletins are also available to owners, operators or maintenance personnel on an annual subscription basis. 1-4. SERVICE REPORTS AND INQUIRIES. It is the policy of Teledyne Continental Motors to handle all reports of service difficulty and requests for information through Approved Distributors. Request for further copies of this or any other Teledyne Continental Aircraft Engine Service Publication should be made through these facilities. There is an Approved Distributor at every major airport. 1-5. CYLINDER ARRANGEMENT. Cylinders are numbered starting from the rear, with odd numbers on the right and even numbers on the left. 1-6. DEFINITIONS AND ABBREVIATIONS Term . Explanation A.B.C. After Bottom Center Approx. Approximately A.T.C. After Top Center Bar. Barometric B.B.C. Before Bottom Center B.H.P. Brake horsepower B. T.C. Before Top Center F.A.A. Federal Aviation Administration C.A.R. Civil Air Regulations c.f.m. Cubic feet per minute C.G. Center of Gravity Dia. Diameter ° Degrees of Angle °F. Degrees Farenheit Fig. Figure (Illustration) Front Propeller End ft. foot or feet G.P .M. Gallons per minute H2O Water Hg. Mercury I.D. Inside Diameter in. (") Inches Hex. Hexagon hr. Hour Left Side Side on which Nos. 2, 4 and 6 cylinders are located Lbs. Pounds Lockwire Soft steel wire used to safety connections, etc. Man. Manifold or manometer Max. Maximum Min. Minimum 30' thirty minutes of angle (60' equal one degree) N.P.T. National pipe thread (tapered)

1-2 Term . Explanation N.C. National Coarse (thread) N.F. National Fine (thread) O.D. Outside Diameter Press. Pressure p.s.i. Pounds per square inch Rear Accessory end of engine Right Side Side on which Nos. 1, 3 and 5 cylinders are located R.P.M. Revolution per minute Std. Standard T.D.C. Top dead center Temp. Temperature Torque Force x lever arm (125 ft.-lbs. force applied one ft. from bolt center or 62-1/2 lbs. applied 2 ft. from center) TABLE I. PURCHASED ACCESSORIES ACCESSORY QTY Magneto ....................................................................... 2 Starter .......................................................................... 1 Alternator ..................................................................... 1 Generator ..................................................................... 1 Oil Cooler ..................................................................... 1 Fuel Pump.................................................................... 1 Spark Plugs................................................................ 12 TABLE II. IGNITION SYSTEM DETAILS FEATURE VALUE Left Magneto Fires ............................... Lower No. 1-3-5 And Upper No. 2-4-6 plugs Right Magneto Fires ............................. Upper No. 1-3-5 And Lower No. 2-4-6 plugs Firing order (cylinder numbers) .................... 1-6-3-2-5-4 Permissible RPM spread when Switched from “Both” to either “Left” or “Right” magneto ............................................ 50 1-7. DEFINITION OF TERMS. Front, rear, left and right, as used in this manual, refer to the engine as viewed by the mechanic in a normal position, facing the accessory end. TABLE III. CHARACTERISTICS AND DIMENSIONS DIMENSION VALUE Piston stokes per cylinder ............................................ 4 Number of cylinders ..................................................... 6 Cylinder bore (inches) ............................................. 5.25 Piston stroke (inches) ............................................. 4.00 TABLE IV. TEMPERATURE LIMITS INDICATED CONDITION MIN. MAX. Oil temperature at takeoff 75°F -- Oil temperature in flight -- 240°F. Cylinder head temperature (bayonet thermocouple)* -- 460°F. Magneto temperature (at coil hold-down screw) -- 170°F. * Installed in tapped hole in bottom of cylinder head. TABLE V. PRESSURE LIMITS INDICATION MIN. MAX. Oil pressure (idling) 10 psi -- Oil pressure (in flight) 30 psi 60 psi Oil pressure (with cold oil) -- 100 psi TABLE VI. VISCOSITY OIL GRADES OIL OPERATING OIL TEMPERATURE GRADE Below 40°F. 30 OR 10W-30 Above 40°F. 50 Ambient air temperature is the controlling factor on all engines having oil temperature control valves installed.

Continental engine overhaul service manual IO-520 IO520

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