Publication X300082011 CONTINENTAL MOTORS, INC. AUG 2011

A-65A-75

CONTINENTAL AIRCRAFT ENGINE

MAINTENANCE AND

OVERHAULMANUAL

FAA APPROVED

A A-65 & A-75 Series Engines Maintenance and Overhaul Manual31 August 2011

Supersedure Notice

This manual revision replaces the front cover and list of effective pages for Publication Part No. X30008, datedAugust 1977. Previous editions are obsolete upon release of this manual.

Effective Changes for this Manual0 ..............1 August 19771 ............ 31 August 2011

List of Effective Pages

Document Title: A-65 & A-75 Series Engines Maintenance and Overhaul ManualPublication Number: X30008 Initial Publication Date: 1 August 1977Page Change Page Change Page Change Page ChangeCover............................ 1A................................... 1iii-vi ............................... 0vii thru viii ..................... 11 thru 68 ....................... 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 otherwisealtered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher willnot be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content issubject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners.

TABLE OF CONTENTS Section

1 TABLE OF SPECIFICATIONS.

2 GENERAL DESCRIPTION. 1. DIFFERENCES BETWEEN

ENGINE MODELS. 2. CYLINDER CONSTRUCTION. 3. VALVE OPERATING MECHANISM 4. CRANKSHAFT CONSTRUCTION 5. CRANKCASE & OIL SUMP

CONSTRUCTION. 6. CONNECTING RODS 7. PISTON & PISTON PIN

CONSTRUCTION . 8. CRANKCASE COVER . 9. LUBRICATING SYSTEM.

Page

1

4

4 4 4 5

5 5

5 5 5

OPERA TING & MAINTENANCE INSTRUCTIONS 7

3 PACKING, UNPACKING & PREPARA-TION FOR STORAGE 7

1. SHIPPING BOXES. . 7 2. PACKING .... 7 3. UNPACKING THE ENGINE. 7 4. TREATMENT OF ENGINES FOR

PERIODS OF IDLENESS. 7 5. PREPARATION OF ENGINES FOR

SERVICE AFTER TREATMENT 8

4 INSTALLATION AND REMOVAL. 9 1. MOUNTING THE ENGINE . 9 2. REMOVING THE ENGINE . . 9

5 GENERAL OPERATING INSTRUCTIONS 10 1. BEFORE STARTING.. 10 2. STARTING. .. 10 3. WARM-UP AND GROUND TEST 10 4. TAKE-OFF 10 5. FLIGHT. . . . 10 6. LANDING . . . 10 7. STOPPING. . . ., 10 8, CARBURETOR HEAT CONTROL . 11 9. MIXTURE CONTROL, 11

10. GASOLINE & OIL RECOMMENDATIONS. , 11

6 ENGINE TROUBLES & SERVICE REPAIRS. . . ,

1. FAILURE TO START. 2. LOW OIL PRESSURE 3. HIGH OIL TEMPERATURE 4. LOW POWER OR SPEED. 5. ROUGH RUNNING. . . 6. ENGINE FAILS TO ACCELERATE

PROPERLY 7. ENGINE FAILS TO IDLE

PROPERLY, . .

11 11 11 12 12 12

12

12

Section

7 SERVICE INSPECTION & ASSOCIA TED MAINTENANCE .

1. GENERAL. 2. INSPECTION & MAINTENANCE

8 ADJUSTMENT, REPLACEMENT & MINOR REPAIR

1. GENERAL. 2. CARBURETOR. 3. MAGNETOS 4. MAGNETO INSTALLATION &

TIMING TO ENGINE. 5. IGNITION WIRING. 6. REMOVING PARTS 7. GENERAL INSPECTION . 8. REASSEMBLY

OVERHAUL INSTRUCTIONS

9 DISASSEMBLY, CLEANING & INSPECTION.

1. GENERAL 2. PRELIMINARY OPERATIONS 3. DISASSEMBLY 4. CLEANING. 5. INSPECTION.

10 REPAIR & REPLACEMENT , 1. GENERAL 2. REPAIR & REPLACEMENT OF

ENGINE PARTS. ,

11 ASSEMBL Y, TIMING & TESTING. 1. GENERAL. 2. REASSEMBLY OF MAJOR

SUB-ASSEMBLIES 3. FINAL ASSEMBLY PROCEDURE 4. TESTING ENGINE AFTER

OVERHAUL.

12 TABLE OF LIMITS.

ILL USTRA TED PARTS LIST

13 ILLUSTRA TED PARTS LIST.

14 NUMERICAL PARTS LIST.

Page

12 12 12

14 14 14 14

14 14 14 15 15

16

16 16 16 16 18 19

21 21

21

23 23

23 24

29

30

36

36

56

15 OVERSIZE & UNDERSIZE PARTS 61

ACCESSORIES. . . 63

16 STROMBERG NA-S3Al CARBURETOR 63

17 SCINTILLA MAGNETO TYPES, SF4RN-8 & SF4LN-8 65

18 HYDRAULIC LIFTERS . 67

iii

Figure No.

iv

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

INDEX FOR ILLUSTRATIONS

Title

Three-Quarter Left Front View of A65-8F Three-Quarter Right Rear View of A65-8F Performance and Fuel Consumption Curves Deleted ........... . Section Through Hydraulic Tappet . . . . Cutaway View Showing Gear Train . . . . Engine in Shipping Cradle . . . . . . . . Hoisting Engine with Crankshaft Lifting Eye. Hoisting Engine with Crankcase Lifting Eye Typical Installation Diagram. . . . . . . . Ignition Wiring Diagram . . . . . . . . . Cylinder Flange Torque Sequence . . . . Compressing Valve Springs for Installation and Removal of Locks Removal of Hydraulic Unit from Cam Follower Body Deleted ........... . Stud Identification. . . . . . . . . . . Assembling Rocker Shaft Bushings . . . . Installing Cam Follower Body into Crankcase Installing Crankshaft Bearings into Crankcase. Installing and Removing Crankshaft and Connecting Rods Installing Crankcase 1-3 over Crankcase 2-4 Installing Gears in Crankcase . . . . . Installing Crankcase Cover to Crankcase Installing Cylinder on Crankcase. . . Determining Firing Position. . . . . . Timing Marks on Flanged Crankshaft. . Lubrication Chart - Cross-Section View. Lubrication Chart - Side View Lubrication Chart - Rear View. . . . . Crankcase ............. . Crankshafts, Connecting Rods and Pistons. Cylinder and Valves . . . . . . . . Rear Crankcase Cover and Gear Train Oil Sump and Oil Suction Tube Ignition System. . . . . . . . . . . Ignition System. . . . . Carburetor, Air Intake and Filter System. Camshaft, Push Rods & Valve Tappets Propeller Hub Oil Cooler Equipment. . . . Fuel Pump ...... Showing Magneto Timing Marks Timing Magneto . Breaker Mechanism. . . . . .

TABLES

Page

v vi 3

4 6 7 8 8 9

14 15 17 17

21 22 24 24 24 25 26 26 27 28 28 33 34 35 39 41 43 45 46 47 49 51 53 55 56 65 65 66

Table 1. Magnaflux Inspection Data. . . . . .. 20

'vi

Airworthiness Limitations

The Airworthiness Limitations Section is FAA approved and specifies maintenance required under 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.

Federal Aviation Regulations 43.16 and 91.403 require owner/operator compliance with all maintenance limitations in this section concerning mandatory replacement times, inspection intervals, and other related procedures that are specific to this engine. Any such limitations listed below are part of the design limits of the engine, which was type certified based upon required owner/operator compliance with the limitations.

1. Mandatory Replacement Times

Subject to additional information contained in FAA Airworthiness Directives issued after the date of certification, the engines covered in this manual do not contain any components having mandatory replacement times required by type certification.

2. Mandatory Inspection Intervals

Subject to additional information contained in FAA Airworthiness Directives issued after the date of certification, the engines covered in this manual do not require specific intervals of inspection pursuant to type certification.

3. Other Related Procedures

Subject to additional information contained in Airworthiness Directives issued after the date of certification, there are no other related procedures required pursuant to the type certification for the engines covered in this manual.

4. Distribution of Changes to Airworthiness Limitations

Changes to this Airworthiness Limitations Section constitute changes to the type design of the engines covered in this manual and require FAA approval pursuant to Federal Aviation Regulations. Changes which result in new or more restrictive limits, will be published in FAA Airworthiness Directives. vii

INTENTIONALLY

LEFT

BLANKviii

SECTION 1

TABLE OF SPECIFICATIONS GENERAL

Type ....... . Operating Cycle. . . Cooling System Type. No. of Cylinders. Cylinder Bore. Stroke .....

Horizontally Opposed . Otto (4 stroke) ...... Air ....... 4 All Models 3-7/8" All Models 3-5/8"

Piston Displacement (cubic in. ) . Number of Mounting Bolts . . Diameter of Mounting Bolts. . Overall Width. . . . . . . . Average Dry Weight (Series 8) Average Dry Weight (Series 9) Crankshaft Rotation . . . . .

FEATURES PECULIAR TO EACH MODEL:

Model ...... . Type Certificate No .. Compression Ratio. . Rated RPM ..... Rated Horsepower at Sea Level. ........... . Maximum Allowed Manifold Pressure in In. Hg. (at rated RPM) Recommended Cruising RPM . . . . . . . . . . . . . . . . . . . . Maximum Recommended Manifold Pressure in In. Hg. (at cruising RPM) Minimum Fuel Octane Rating (Aviation Grade) . . . . ..... . Maximum Allowable Cylinder Head Temperature (OF. ). . . . . . . Maximum Oil Temperature (OF.) . . . . . . . . . . . . . . . . Oil J'emperature in OF. (Minimum at Take-Off). . . . . . . . . . \pproximate Fuel Consumption in Gallons per Hr. (at cruising RPM) .l.pproximate Maximum desirable Oil Consumption in pints per Hr. Oil Sump Capacity in Quarts . . . . . . . . . Oil Pressure (Cruising) in Lbs. /Sq. In. . . . . . . . . . . . . Oil Pressure (Idling) in Lbs. /Sq. In. (Minimum) . . . . . . . .

IGNITION:

Type .......... . Magneto Type. . . . . . . Magneto Rotation (as viewed

. Dual Magneto . Various

from Drive End). . . . . Crankshaft: Magneto Speed Ratio: .

Right Magneto Fires Upper Plugs BTC. Left Magneto Fires Lower Plugs BTC Firing Order . . . . . . . . . . . .

Clockwise 1: 1

Radio Shielding (Optional). Spark Plugs (Shielded) . . Spark Plugs (Shielded) . . Spark Plugs (Unshielded) .

NOTES: * Direction of rotation as viewed from rear of engine.

A65 205 6.3: 1 2300 65 29. 4 2150 26.8 80/87 550 220 90 4.4 3/4 4 30-40 10

A65 30 30

1-3-2-4

. . . . 171 ..... 4 3/8" or 7/16"

.31-1/2" .170 Ibs. .177 Ibs. *CIockwise

A75 213 6.3: 1 2600 75 29.3 2350 26.0 80/87 525 220 90 4.8 3/4 4 30-40 10

.. C.M.C. Champion 62S .. EM42E Champion C27

A75 29 32

1-3-2-4

TABLE OF SPECIFICATIONS - Continued

FUEL SYSTEM

Feed ..... Carburetor Type. . . tttPrimer Connection Carburetor Inlet. . .

... ttGravity Float (See Catalog) .. 1/8" N. P. T. .. 1/4" N. P. T.

ACCESSORY DRIVES AND INSTRUMENT CONNECTIONS

Oil Pressure Gauge Line . . . Tachometer Drive Shaft: Std. .

ACCESSORIES AND WEIGHTS

**Magnetos (2), Eisemann Magnetos (2), Eisemann Magnetos (2), Scintilla. . Radio Shielding . . . . . Oil Cooler (Harrison). . . Air Intake and Filter Assembly Propeller Attaching Parts

(Flanged Crankshaft). . . . Carburetor (Stromberg NA-S3Al)

(Optional) ......... .

.1/8" N. P. T.

. .. S.A. E.

. . AM-4: 10. 69#

.. LA-4:12.02# S4RN-20: 10.35#

2.26# 4.00# 2. 56#

0.90#

2.70#

LUBRICATION SYSTEM

Pump ........ . ... Gear Type Crankshaft: Pump Speed Ratio. Pump Drive Gear Rotation

. . .... 1:.50 *Counterclockwise

Sump Type ......... . ...... Wet

Crankshaft: Tachometer Drive Ratio. . . . .1:.50 Tachometer Drive Rotation . . . *Counterclockwise

**Carburetor (Stromberg NA-S3B) Carburetor (Marvel MA-3PA)

(Optional). . . . . . . . . . Fuel Pump (AC Diaphragm Type) Exhaust Flanges and Gaskets (4) . Rubber Mount Bushings (8) and

Steel Washers (4). . . . . . .

2.60#

3.00# 1. 75# 0.55# 0.55#

NOTES: * Direction of rotation as viewed from rear of engine.

2

** Accessories included in Engine Dry Weight. Add 1. 04 lbs. for Flanged Crankshaft (Series 8F). Magneto Weights include Drive Gears.

tt A Stromberg carburetor suitable for use with a pump feed system is available. Gravity feed requires the fuel tank to be elevated and located so that the static fuel head will be at least two inches in the steepest climb and less than 90 inches in the steepest glide.

ttt The primer nozzles supplied for installation in the intake manifold is effective :l'.lt temperatures above _7C. (20F.). For starting at lower temperatures a primer manifold system with jets in cylinder intake ports is recommended.

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