TELEDYNE CONTINENTAL AIRCRAFT ENGINE CATEGORY 3 SERVICE .

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TELEDYNE CONTINENTAL AIRCRAFT ENGINECATEGORY 3SB 04-11SERVICE BULLETINCompliance Will Enhance Safety, Maintenance orEconomy of OperationTECHNICAL PORTIONSFAA APPROVEDSUBJECT:VALVE GUIDE APPLICATION, INSTALLATION ANDREAMING PROCEDURESPURPOSE:PROVIDE VALVE GUIDE APPLICATION BY CYLINDER PARTNUMBER AND DIMENSIONAL FITS AND LIMITS FOR VALVES,PRE-FINISHED AND REAM IN PLACE VALVE GUIDESCOMPLIANCE:MODELSAFFECTED:AT ENGINE MAJOR OVERHAUL, CYLINDER OVERHAUL ORCYLINDER REPAIRC-75, C-85, C-90, O-200, O-240 Rolls-Royce, O-300, G0-300, IO-240 IO-360,TSIO-360, LTSIO-360 E-SERIES, O-470, IO-470, TSIO-470, IO-520, TSIO-520,LTSIO-520, GTSIO-520, IO-550, TSIO-550 AND TSIOL-550 SERIES ENGINES.GENERAL INFORMATIONTeledyne Continental Motors has utilized pre-finished intake and exhaust valve guides in productioncylinders and as service replacement parts for many years. This service bulletin announces the release ofreplacement ream in place valve guides. Dimensional specifications for ream in place and pre-finishedvalve guides are provided in tabular form in Table 1 and Table 3.Ream in place valve guides may be installed as a replacement for pre-finished valve guides. However,pre-finished valve guides must not be installed as replacements for ream in place valve guides.NOTE:Refer to the applicable engine overhaul manual for valve guide removal and installationinstructions and specifications.All measurements must be made using properly calibrated and certified precision measuring devices.IN SERVICE VALVE AND VALVE GUIDE MEASUREMENTS1. Refer to the applicable engine Maintenance or Overhaul Manual for specific inspection criteria forintake and exhaust valves. Valve stems must conform to specified new parts dimensions.2. When measuring valve guide inside diameter during cylinder repair, take valve guide measurementsat locations in the upper 1/3 and center 1/3 of the valve guide length, reference Figure 1 and Table 1.Measurements taken at the bottom of the intake and exhaust valve guide are not indicative of theoverall serviceability of the valve guide.ISSUEDREVISEDPAGE NO REVISIONTMMODAYYEAR11022004MODAYYEARTeledyne Continental Motors, Inc.1 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11 2004 Teledyne Continental Motors, Inc.

3. Valve guide inside diameter must not exceed the “Service Limit” dimension for the specific engineand cylinder combination. Valve guides exceeding the “Service Limit” dimensions specified inTables 1 and 3 as applicable will require replacement.PRE-FINISHED VALVE GUIDE MEASUREMENTS:1. Pre-finished valve guides must be measured before installation to insure they conform with the newparts dimensions specified in Tables 1 and 3.2. Measure valve guide inside diameter at three equally spaced locations along the length of the valveguide. Reference Figure 2 and Table 1.3. Measure the outside diameter of the valve guide below the flange, reference Figure 2. Record thesereadings on the repair work order.4. Measure valve stem diameter between the valve keeper annulus and the face of the valve. Record thisreading on the repair work order.VALVE GUIDE INSTALLATION:CAUTION:When installing valve guides in cylinders verify that the valve guide is correct for the cylinder andengine application. Reference Table 1.1. Refer to the applicable engine overhaul manual for specific installation instructions and specializedequipment and tooling required.2. Before installing a replacement valve guide, the valve guide bore in the cylinder head must be reamedto the proper oversize dimension. The difference between the valve guide outside diameter and thevalve guide bore inside diameter must be within the dimensional specification provided in Tables 1and 3 for the applicable engine and cylinder combination.3. A. (Pre-finished Guides) After installing new valve guides allow the cylinder to cool and stabilize atroom temperature before taking any dimensional measurements. Measure valve guide insidediameter at three equally spaced locations along the length of the valve guide. Reference Figure 2. Ifinside diameter is not within the specific new minimum and maximum dimensional limits, the guidewill require finish reaming to size or replacement.B. (Ream-in-place Guides) Post installation measurements are only required on ream-in-place guidesafter reaming procedures have been completed. Allow the cylinder to cool and stabilize at roomtemperature before taking any dimensional measurements. Measure valve guide inside diameter at threeequally spaced locations along the length of the valve guide, reference Figure 2. If inside diameter is notwithin specifications, the guide will require refinishing or replacement.ISSUEDREVISEDPAGE NO REVISIONTMMO11DAYYEAR22004MODAYYEARTeledyne Continental Motors, Inc.2 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11

VALVE GUIDE REAMING PROCEDURESWARNINGDo not attempt this procedure with hand held power tools. Valve guides that are reamed with handheld power tools must be replaced.(1) Install a suitable cylinder holding fixture (Borroughs 5221B or equivalent) into a drill press or verticalmill to hold the cylinder. Index the fixture to the proper angle and install the cylinder into the fixture.(2) Zero in the guide with a dial indicator(3) Select a proper size high-speed steel or carbide-tip spiral reamer. Ream the valve guide at 400 RPMfor high-speed steel reamers and 700 RPM for carbide-tip reamers. Use a high quality cutting oil forall valve guide reaming operations.CAUTIONReamers are made to cut right hand only. Do Not turn backwards even a partial turn. (4) Check the valve guide final dimensions using precision measuring equipment.(5) Inspect the surface finish of valve guide inner bore after final reaming. The surface finish of theintake valve guide must not exceed 63 RA, the surface finish of the exhaust valve guide must notexceed 125 RA.Guide Aluminum-BronzeAluminum-BronzeAluminum-BronzeGuide SUEDTABLE 1INTAKE VALVE GUIDESLengthReamerReamer 3750.36301.81.3750.36302.22.3440.3310EXHAUST VALVE GUIDESLengthReamerReamer 0Finished I.D.Replaces GuidePre-finished P/N.4350 - .4362.3745 - .3755.3745 - .3755.3432 - .3442643766646681653802643422Finished I.D.Replaces GuidePre-finished P/N.4370 - .4380.3745 - .3755.3745 - .3755.4370 - .4380.4350 - .4362643767653214653726649177643766REVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.3 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

MEASURE IN SERVICEVALVE GUIDE I.D. ATTHESE LOCATIONS. SEETABLE 1 FOR VALVEGUIDE LENGHTS TOCALCULATEMEASUREMENTLOCATIONSFIGURE 1IN SERVICE VALVE GUIDE DIMENSIONAL MEASURMENTSVALVE GUIDEMEASURE NEWVALVE GUIDES ATALL THREELOCATIONS (1)BEFORE AND AFTERINSTALLATION(PREFINISHEDGUIDES) OR (2)AFTER REAMING(REAM-IN-PLACEGUIDES) SEE TABLE 1FOR VALVE GUIDELENGHTS.MEASURE VALVE GUIDEO.D. AT THIS LOCATIONVALVE GUIDE BOREIN CYLINDER HEADMEASURE BORE AFTER REAMINGPRIOR TO INSTALLING GUIDE INCYLINDER HEADFIGURE 2INSTALLATION CRITICAL MEASUREMENT LOCATIONSISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.4 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 2VALVE GUIDE APPLICATIONSENGINEC-75, C-85C-75, C-85C-90, O-200O-300O-200, O-300GO-300E-165, E-185E-225IO-346360 SeriesExcept as B,SBLTSIO-360-RBO-470-A,E,JO-470-G,K,L,R,S [Except G(7),G(10) and GCI]O-470-UO-470-G(7) ,F, H,L,M,N,S,U,VIO-520 SeriesExcept as ginalStyle655482A6New StyleINTAKEVALVE GUIDE655527INTAKEVALVE655968EXHAUSTVALVE 5771Note: Consult the latest version of the applicable parts manual for part number information.TCM provides parts history and application data on line via FBO Services and InformationServices. Visit TCM’s website at www.tcmlink.com for full details.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.5 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 2 (Con’t)ENGINEIO-550-GPlatinum 550-B,CIO-550-B,CPlatinum SeriesIO-550-B, CSpecial atinum SeriesIO-550-N,P,RExcept PlatinumSeriesIO-550-NPlatinum SeriesIOF-550-N,P,RTSIO-520-UB(17)Special EditionTSIO-520-AF,CE,UB [ExceptUB(17) NB,P,R,T,VB,WBTSIO-550-A,B,C,ETSIOL-550-A,B, CGTSIO-520-C,D, SEMBLYINTAKEVALVE GUIDEINTAKEVALVEEXHAUSTVALVE 8655166655783636242655771Note: Consult the latest version of the applicable parts manual for part number information.TCM provides parts history and application data on line via FBO Services and InformationServices. Visit TCM’s website at www.tcmlink.com for full details.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.6 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 3AVALVE GUIDE FITS and LIMITSO-240 Rolls-Royce, IO/IOF240A&B, IO-360-Series, L/TSIO360-SeriesPRE-FINISHED GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In GuidePre-Finished GuidesIntake Guide Bore(New)Pre-finished GuidesIntake Guide Bore(installed in cylinder)Pre-Finished GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve inGuidePre-Finished GuidesExhaust Guide Bore(New)Pre-Finished GuidesExhaust Guide Bore(installed in cylinder)Pre-Finished GuidesExhaust Valve StemDiameterMinimum.0010 TMaximum.0025 TService Limits.0010 L.0040 L.006 L.3760.3770.3745.3770.3725.3733.0010 T.0025 T.0025 L.0057 L.3760.3770.3745.3770.3712.3720.008 LREAM-IN-PLACE GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In GuideReam-In-Place GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuideReam-In-Place GuidesExhaust Valve StemDiameterMinimum.0010 TMaximum.0025 TService Limits.0012 L.0030 L.006 L.3725.3733.0010 T.0025 T.0025 L.0043 L.3712.3720.008LNOTESee Table 1 for intake and exhaust valve guide finished dimensions and recommended reamer sizes.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.7 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 3BO/IO470-Series, O-470 4,11 and 13, L550-Series, GTSIO520-SeriesVALVE GUIDE FITS AND LIMITSPRE-FINISHED GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In GuidePre-Finished GuidesIntake Guide Bore(New)Pre-Finished GuidesIntake Guide Bore(installed in cylinder)Pre-Finished GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuidePre-Finished GuidesExhaust Guide Bore(New)Pre-Finished GuidesExhaust Guide Bore(installed in cylinder)Pre-Finished GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0010 L.0042 L.0065 L.4367.4377.4350.4377.4335.4340.0010 T.0025 T.0035 L.0062 L.4385.4395.4375.4395.4334.4341.0085 LREAM-IN-PLACE GUIDESIntake Valve GuideIn Cyl. HeadIntake Valve In GuideReam-In-Place GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuideReam-In-Place GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0010 L.0032 L.0065 L.4335.4340.0010 T.0025 T.0029 L.0046 L.4334.4341.0085 LNOTESee Table 1 for intake and exhaust valve guide finished dimensions and recommendedreamer sizes.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.8 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 3CC-75, C-85, C-90, O-200-Series, O/GO300-SeriesWith P/N 655482 New Style CylindersVALVE GUIDE FITS and LIMITSPRE-FINISHED GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In GuidePre-Finished GuidesIntake Guide Bore(New)Pre-Finished GuidesIntake Guide Bore(installed in cylinder)Pre-Finished GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuidePre-Finished GuidesExhaust Guide Bore(New)Pre-Finished GuidesExhaust Guide Bore(installed in cylinder)Pre-Finished GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0010 L.0040 L.006 L.3760.3770.3745.3770.3730.3735.0010 T.0025 T.0025 L.0057 L.3760.3770.3745.3770.3713.3720.008 LREAM-IN-PLACE GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In GuideReam-In-Place GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuideReam-In-Place GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0012 L.0030 L.006 L.3730.3735.0010 T.0025 T.0025 L.0043 L.3713.3720.008 LNOTESee Table 1 for intake and exhaust valve guide finished dimensions and recommendedreamer sizes.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.9 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 3DC-75, C-85, C-90, O-200-Series, O/GO300-SeriesWith P/N 655483 Old Style CylindersVALVE GUIDE FITS AND LIMITSPRE-FINISHED GUIDESIntake Valve GuideIn Cyl. HeadIntake Valve In GuidePre-Finished GuidesIntake Guide Bore(New)Pre-Finished GuidesIntake Guide Bore(installed in cylinder)Pre-Finished GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuidePre-Finished GuidesExhaust Guide Bore(New)Pre-Finished GuidesExhaust Guide Bore(installed in cylinder)Pre-Finished GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0010 L.0045 L.006 L.3447.3457.3432.3457.3413.3421.0010 T.0025 T.0035 L.0057 L.4367.4377.4360.4377.4320.4325.008 LREAM-IN-PLACE GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In GuideReam-In-Place GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuideReam-In-Place GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0011 L.0029 L.006 L.3413.3421.0010 T.0025 T.0025 L.0042 L.4320.4325.008 LNOTESee Table 1 for intake and exhaust valve guide finished dimensions and recommendedreamer sizes.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.10 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

TABLE 3EO470-4, 11 and 13, E-SeriesWith P/N 654761 or P/N 654947 CylindersVALVE GUIDE FITS and LIMITSPRE-FINISHED GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve In Guide Pre-FinishedGuidesIntake Guide Bore(New)Pre-Finished GuidesIntake Guide Bore(installed in cylinder)Pre-Finished GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuidePre-Finished GuidesExhaust Guide Bore(New)Pre-Finished GuidesExhaust Guide Bore(installed in cylinder)Pre-Finished GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limits.0010 L.0042 L.0065 L.4367.4377.4350.4377.4335.4340.0010 T.0025 T.0026 L.0053 L.4376.4386.4366.4386.4333.4340.0076 LREAM-IN-PLACE GUIDESDescriptionIntake Valve GuideIn Cyl. HeadIntake Valve in GuideReam-In-Place GuidesIntake Valve StemDiameterExhaust Valve GuideIn Cylinder HeadExhaust Valve in GuideReam-In-Place GuidesExhaust Valve StemDiameterNew Minimum.0010 TNew Maximum.0025 TService Limit.0010 L.0027 L.0065 L.4335.4340.0010 T.0025 T.0030 L.0047 L.4333.4340.0076 LNOTESee Table 1 for intake and exhaust valve guide finished dimensions and recommendedreamer sizes.ISSUEDREVISEDPAGE NOTMMODAY112YEAR2004MODAYYEARTeledyne Continental Motors, Inc.11 of 11P.O. Box 90 Mobile Alabama 251-438-3411SB04-11REVISION

IO-470-J,K 655475A5 655166 655783 636242 655771 IO-470-D,E, F, H,L,M,N,S, U,V 655468A7 655166 655783 636242 655771 IO-520 Series Except as noted 655469A6 655166 655783 636242 655771 IO-520-P LIO-520-P 655476A3 655166 655783 636242 655771. Note: Consult the latest version of the applicable parts manual for part number information.

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