Teledyne Continental C75, C85, C90 & O-200 Engine Overhaul Manual 1976-Present

Complete overhaul manual for Teledyne Continental C75, C85, C90 & O-200 engines. Details engine systems, components, and procedures for maintenance and repair. PN C4077-90960

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Document Details

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Document Number / Seller:
25608 / Peter King
File Size:
9.02 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Aircraft
Last updated / verified
Apr 1, 2025

Models Covered & Key Technical Specifications

Teledyne Continental C75, C85, C90 & O-200 (C4077-90960) - 1976-Present

Official Teledyne Continental Engine Overhaul Manual | Aircraft Engine Binder.

  • Authorized: For C75/C85/C90, 4 cylinders establish the standard cooling system operation.
  • Critical: O-200 models feature a 4-1/16 inch cylinder bore for enhanced performance.
  • Operational: C90 and 0-200 engines have a 3-7/8 inch piston stroke, leading to higher compression ratios.
  • Established: The manual covers variations in equipment denoted by suffix dash numbers, which adapt basic engines to aircraft.
  • Measured: Carburetor calibration in C90 models differs from C75 and C85 models.
  • Maximum: Cylinder heads are identified as aluminum alloy castings with externally finned steel barrels.

Professional Workshop Service Manual & Technical Specifications

Structured Training Diagnostic Manual: Aircraft Continental C75, C85, C90 & O-200 1976–Present - Comprehensive Aircraft Engine Overhaul Manual Manual-Nexus

Reference-Category: C75, C85, C90, O-200 // Design-Core: Engine / Aircraft Logic // Reference-Category: Overhaul Procedures. TABLE OF CONTENTS (Con't) Section & Para. Title Page
1-1 Model Designation 9
1-2 Definitions and Abbreviations 9
3-1 Difference Between Model Groups 16
3-2 Significance of C Series Dash Numbers and Letters 16
3-3 Model Conversions 16
3-4 Optional Equipment 17
3-5 Superseding Parts 17
3-6 Crankcase Construction 17
3-7 Crankshafts 18
3-8 Nitrided Crankshafts 18
3-9 Crankshaft Gears 19
3-10 Connecting Rods 19
3-11 Camshafts 19
3-12 Camshaft Gears 20
3-13 Hydraulic Valve Lifters 20
3-14 Construction 20
3-15 Types 21
3-16 Operation 21
3-17 Pushrods and Housings 21
3-18 Piston Assemblies 21
3-19 Cylinder Assemblies 21
3-20 Cylinder and Head 21
3-21 Valves 21
3-22 Valve Springs 21
3-23 Rocker Arms and Shaft 22
3-24 Types 22
3-25 Crankcase Cover Assembly for -12, -14, -16 and 0-200 Models 22
3-26 Crankcase Cover Assembly for -8 Models 23
3-27 Gear Train 23
3-28 Carburetor Induction System 24
3-29 Oil Sumps 24
3-30 Ignition System 24
3-31 Unshielded 24
3-32 Radio Shielded Ignition Systems 25
3-33 Switch Wire Terminals 25
3-34 Magneto Drive Gears 25
3-35 Impulse Coupling Operation 26
3-36 Delco-Remy Starter 26
3-37 Prestolite Starter 26
3-38 Generator/Alternator and Drive 26
3-39 Side Mounted Fuel Pump 26
3-40 Dual Fuel Pump Equipment 26
3-41 Lubrication System 27
3-42 Oil Circulation in -8 Models 27
3-43 Oil Circulation in -12, -14, -16 and 0-200 Models 27
3-44 Oil Cooler Equipment 27
SECTION IV UNPACKING THE ENGINE 29
4-1 Shipping Crates 29
4-2 Method of Packing and Preservation 29
4-3 Removal of Engine from Crate 30
4-4 Preparation for Installation 30
SECTION V STORAGE OF ENGINES 31
5-1 General 31
5-2 Flyable Storage (7 to 30 days) 31
5-3 Temporary Storage (Up to 90 days) 31
5-4 Indefinite Storage 32
5-5 Procedures Necessary for Returning an Aircraft to Service are as Follows 33
5-6 Aircraft Stored in Accordance with the Indefinite Storage Procedures Should be Inspected per the Following Instructions 33
SECTION VI INSTALLATION IN AIRPLANE AND REMOVAL 34
6-1 Mounting the Engine 34
6-2 Fuel Systems 38
6-3 Oil System 38
6-4 Propeller Installation 38
6-5 Engine Removal 39
SECTION VII OPERATING INSTRUCTIONS 40
7-1 Procedure Preliminary to Starting 40
7-2 Starting Procedure 40
7-3 Warm-Up 40
7-4 Ground Test 41
7-5 Take-Off 41
7-6 Climbing 41
7-7 Level Flight 41
7-8 Let-Down and Landing 42
7-9 Stopping the Engine 42
7-10 Lubricating Oil 42
7-11 Viscosity 42
7-12 Oil Change Periods 43
7-13 Oil Change Procedure 43
7-14 Engine Fuel 43
SECTION VIII ENGINE TROUBLES AND SERVICE REPAIR 44
SECTION IX PERIODIC INSPECTION AND MAINTENANCE 48
9-1 Daily Inspection 48
9-2 First Fifty Hour Inspection 48
9-3 100-Hour Periodic Inspection 49
SECTION X ADJUSTMENT AND MINOR REPAIR 51
10-1 Carburetors 51
10-2 Removal 51
10-3 Installation 51
10-4 Stromberg Carburetor Adjustment 51
10-5 Marvel-Schebler Carburetor Adjustment 52
10-6 Maintenance 52
10-7 Magnetos 53
10-8 Removal 53
10-9 Installation and Timing 53
10-10 54
10-11 54
10-12 54
10-13 Connections 55
10-14 Maintenance of Eisemann AM-4 Magnetos 56
10-15 Maintenance of Eisemann LA-4 Magnetos 56
10-16 Maintenance of Bendix S4RN-21 and S4-LN-21 Magnetos 56
10-17 Slick Magnetos 57
10-18 Replacement of Ignition Cables 57
10-19 Unshielded Cables 57
10-20 Shielded Ignition Cables 58
10-21 58
10-22 58
10-23 58
10-24 Delco-Remy Starter 59
10-25 Removal 59
10-26 Installation 59
10-27 Adjustment 60
10-28 Maintenance 60
10-29 Performance Data 60
10-30 Prestolite Starter 60
10-31 Removal 60
10-32 Installation 60
10-33 Adjustment 60
10-34 Maintenance 60
10-35 Performance Data 60
10-36 Prestolite Starter Clutch Overhaul 60
SECTION XI DISASSEMBLY 67
11-1 Preliminary Operations 67
11-2 Fixtures 67
11-3 Starter and Generator 67
11-4 Preliminary Cleaning 67
11-5 Ignition System 67
11-6 Locking Parts 68
11-7 Fuel Pumps 68
11-8 Carburetor and Air Intake Housing 68
11-9 Air Scoop 68
11-10 Disassembly 68
11-11 Non-Reusable Parts 68
11-12 Oil Sump and Suction Tube 68
11-13 Air Induction System 68
11-14 Rocker Covers 68
11-15 Cylinders 69
11-16 Piston Assemblies 69
11-17 Protectors 69
11-18 Crankcase and Cover 69
11-19 Connecting Rods 70
11-20 Crankcase 70
11-21 Crankcase Cover 70
11-22 Cylinders 71
SECTION XII CLEANING PARTS 72
12-1 Materials and Processes 72
12-2 72
12-3 72
12-4 72
12-5 72
12-6 Specific Parts 72
12-7 Cylinders 72
12-8 Pistons 72
12-9 Valves 73
12-10 Rocker Shafts 73
11-11 Pushrods, Valve Rockers and Other Small Steel Parts 73
12-12 Camshaft and Crankshaft 73
12-13 Connecting Rods 73
12-14 Crankcase 73
12-15 Gears 73
12-16 Sheet Metal Parts 73
SECTION XIII INSPECTION 74
13-1 Definitions 74
13-2 Inspection Tools 74
13-3 Gauges 74
13-4 Fixtures 75
13-5 Inspection Methods 75
13-6 Visual Inspection 75
13-7 Etching 75
13-8 Dimensional Inspection 75
13-9 Magnaflux Inspection 76
13-10 76
11-11 76
13-12 76
13-13 Fluorescent Particle Inspection 77
13-14 Inspection of Critical Parts 77
13-15 Crankcase 77
13-16 Crankshaft 78
13-17 Connecting Rods 78
13-18 Piston Pins 78
13-19 Pistons 78
13-20 Pushrods 78
13-21 Rocker Arms 78
13-22 Valves 79
13-23 Valve Springs 79
13-24 Camshafts 79
13-25 Cylinders 79
13-26 Hydraulic Valve Lifters 79
13-27 Gears 79
SECTION XIV REPAIR AND REPLACEMENT 81
14-1 General Repair 81
14-2 Castings 81
14-3 Stud Replacement 81
14-4 Helical Coil Insert Installation 81
14-5 82
14-7 Repair and Replacement of Specific Parts 82
14-8 Cylinder and Head Assembly 82
14-9 Crankshaft 85
14-10 Connecting Rods 86
14-11 Pistons, Rings and Pins 86
14-12 86
14-13 Crankcase and Cover Assembly 87
14-13A Starter Clutch and Crank Shaft Modification 87
14-14 Camshaft 90
14-15 Hydraulic Valve Lifters 90
14-16 Oil Sump 90
14-17 Intake Tubes 90
14-18 Gears 90
14-19 Air Scoops and Intake Housings 90
14-20 Vacuum Pump Adapter 90
14-21 Protective Coatings 90
14-22 91
14-23 Refinishing Enameled Parts 91
14-24 "Alodizing" and Repair of "Alodized" Surfaces 91
14-25 Application of "Alodine 1200" 91
14-26 Repair of Alodized Surfaces 91
14-27 Ignition Cables 92
14-28 Delco-Remy Starter 92
14-29 Prestolite Starter 92
14-30 Delco-Remy Generator 92
14-31 Stromberg NA-S3A1 Carburetor 92
14-32 Marvel-Schebler MA-3SPA Carburetor 92
14-33 Magnetos 92
SECTION XV ASSEMBLY OF SUBASSEMBLIES 93
15-1 General Procedure 93
15-2 Cleaning and Lubrication 93
15-3 New Parts Required 93
15-4 Detailed Procedure 93
15-5 Crankcase Cover Assembly 93
15-6 Crankcase 94
15-7 Crankshaft and Connecting Rods 94
15-8 95
15-9 Intake Pipe and Hose Connectors 95
15-10 Intake Air Filter 95
15-11 Oil Sump and Suction Tube 95
15-12 Magnetos 95
15-13 Cylinders 95
15-14 Pistons 96
15-15 Pushrods 96
15-16 Vacuum Pump Adapter 96
SECTION XVI FINAL ASSEMBLY 97
16-1 General Procedure 97
16-2 Assembly Stand 97
16-3 New Parts Required 97
16-4 Detailed Procedure 97
16-5 Crankcase and Enclosed Parts 97
SECTION XVII TESTING AFTER OVERHAUL 106
17-1 Testing Equipment 106
17-2 Test Stand 106
17-3 Instruments 106
17-4 Test Club 106
17-5 Engine Test After Overhaul 107
17-6 Preservation 107
17-7 Fuel and Lubricating Oil 107
17-8 Testing Engines Installed in Aircraft 111
17-9 Inspection 111

Safely requiring 1200 RPM establishes the operational parameters for engine diagnostics. Technical notes are provided for 4-stroke Otto cycle engines to ensure proper operation. Quality checks are addressed for cylinder head temperatures and oil pressure readings. The [component] section documents fuel systems and oil circulation. The troubleshooting chapter addresses common engine problems and their remedies. Torque Statement: Documents torque specifications for engine mounting bolts to ensure proper vibration dampening. The service manual covers engine components, maintenance procedures, troubleshooting, and testing.

FAQ

Confirm the **recommended** diagnostic procedures for engine health checks? keyboard_arrow_down

2750 RPM is the maximum specified for the 0-200 engine during testing and operation.

What tools **calibrated** for engine oil viscosity levels? keyboard_arrow_down

SAE 40 oil is recommended for ambient temperatures above 40° F, and SAE 20 or 10W-30 for temperatures below 40° F.

Identify the **applicable** component identification for airframe installations? keyboard_arrow_down

The manual specifies that the carburetor must be the correct parts list number for the make and model of aircraft.

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I had a question regarding the specifications, and the support team responded quickly and helped me out. Highly recommend!
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Rated 4 out of 5 stars
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The manual is incredibly detailed and easy to follow. The diagrams are a lifesaver!