The Continental O-200 Parts Manual provides a comprehensive reference guide for engine components, including group assembly parts, numerical lists, and customer specifications, ensuring easy navigation and troubleshooting.
1.1 Overview of the Continental O-200 Engine
The Continental O-200 engine is a four-cylinder, air-cooled, horizontally opposed piston engine, producing approximately 100 horsepower. Designed for light aircraft, it is known for its reliability and fuel efficiency. The engine features a forged crankshaft and is widely used in popular aircraft like the Cessna 150 and Piper PA-28. Its compact design and lightweight construction make it ideal for smaller general aviation planes. The O-200 engine is available in various models, including the O-200-A, O-200-B, and O-200-C, each tailored to specific aircraft applications. Its durability and performance have made it a trusted choice for pilots and aircraft manufacturers.
1.2 Purpose of the Parts Manual
The Continental O-200 Parts Manual serves as an essential resource for identifying and procuring engine components. It provides detailed part numbers, descriptions, and assembly diagrams, aiding mechanics and operators in maintenance, repair, and overhaul tasks. The manual ensures compliance with manufacturer specifications, promoting safety and optimal engine performance. By referencing this guide, users can efficiently locate replacement parts, troubleshoot issues, and understand compatibility across various engine models, such as the O-200-A and O-200-B. It is indispensable for maintaining the longevity and reliability of the Continental O-200 engine.
Continental O-200 Parts Catalog Overview
The Continental O-200 Parts Catalog provides a structured overview of engine components, including group assemblies, numerical listings, and repair materials, ensuring easy navigation and quick access to essential information.
2.1 Table of Contents
The Table of Contents in the Continental O-200 Parts Manual is organized to provide quick access to all sections. It includes:
- Group Assembly Parts List for major engine components
- Numerical Parts List for easy identification
- Overhaul and repair parts specifications
- Customer-specific engine configurations
- Illustrated diagrams and technical support resources
This structure ensures users can navigate seamlessly through the manual, finding necessary information efficiently.
2.2 Group Assembly Parts List
The Group Assembly Parts List categorizes components by major engine assemblies, such as crankcase, crankshaft, and cylinder assemblies. Each group is detailed with part numbers, descriptions, and quantities. This section simplifies identification and ordering of related parts. Exploded diagrams accompany each assembly, visually mapping components and their relationships. Critical overhaul parts are highlighted, ensuring essential items are easily located. The list also notes parts not available separately, guiding users to order complete assemblies when necessary. This structured approach streamlines maintenance and repair workflows for the Continental O-200 engine.
2.3 Numerical Parts List
The Numerical Parts List organizes components alphabetically by part number, providing descriptions, applications, and quantities. This section aids in quickly locating specific parts, ensuring accurate ordering. Each entry includes essential details to help users identify and source components efficiently. The list is cross-referenced with the Group Assembly Parts List for a comprehensive overview. It is a vital resource for maintenance, repairs, and overhauls, making it easier to manage part identification and procurement for the Continental O-200 engine.
Major Overhaul Parts Replacement
Mandatory parts for overhaul include gasket sets, fuel pump drive couplings, and specific engine components. Always refer to the manual for updated part numbers and specifications.
3.1 Mandatory Overhaul Replacement Parts
The Continental O-200 engine requires specific parts to be replaced during a major overhaul to ensure safety and performance. Key mandatory parts include the major overhaul gasket set (SA248890-A5), which contains intake hoses, and the oil screen (per SB 96-4). Additionally, the fuel pump drive coupling must be replaced as per TCM MSB 95-6. These parts are critical for maintaining engine integrity and preventing potential failures. Always refer to the latest parts manual for updated part numbers and specifications before ordering. Proper replacement ensures compliance with manufacturer standards and guarantees optimal engine operation. Consult the manual for additional details.
3.2 Gasket Sets and Oversize Parts
The Continental O-200 parts manual includes detailed specifications for gasket sets and oversize parts, essential for maintaining engine performance. Standard size parts are marked with a symbol (t) in the catalog, indicating non-standard size availability. Oversize parts, such as pistons or cylinders, are often required for repairs where tolerances have been exceeded. The manual provides a dedicated section (Section III) for oversize and undersize parts, ensuring easy identification and ordering. Proper installation of these parts is critical for sealing and engine longevity. Always refer to the manual for correct part numbers and compatibility before ordering or installing.
Troubleshooting and Repair Parts
The manual provides troubleshooting guides and repair parts sets, helping identify and resolve common issues. It includes materials for diagnosing problems and replacing damaged components effectively.
4.1 Common Issues and Solutions
Common issues with the Continental O-200 engine include oil leaks, fuel pump failures, and ignition system malfunctions. Solutions involve replacing worn gaskets and seals, updating fuel pump components, and inspecting ignition systems. Oil screen clogging is another frequent problem, requiring periodic cleaning or replacement. Additionally, cylinder compression loss can occur, often resolved by examining cylinder assemblies and valve trains. The manual provides detailed troubleshooting steps and part replacement guidelines to address these issues effectively, ensuring optimal engine performance and longevity.
4.2 Repair Parts Sets and Materials
The Continental O-200 Parts Manual provides detailed repair parts sets and materials for maintenance and overhaul. Gasket sets, such as SA248890-A5, are essential for sealing engine components. Oversize parts, including pistons and cylinders, are available for repairing worn surfaces. The manual also lists materials like gasket makers and sealants for proper installation. Additionally, it specifies torque specifications and crush washer requirements for critical fasteners. These resources ensure technicians can perform accurate repairs, maintaining engine integrity and performance. Proper use of these parts and materials is crucial for compliance with Continental’s standards and warranty requirements.
Customer Specifications and Variants
This section covers Continental O-200 engine variants, detailing customer specifications, differences from base models, and compatible accessories. It ensures parts match specific aircraft requirements, including manufacturer compatibility.
5.1 O-200-B Basic and Customer Specifications
This section outlines the standard specifications for the O-200-B engine, including basic configurations and customer-defined modifications. It details differences between the base model and custom variants, ensuring compatibility with specific aircraft installations. The manual lists part numbers and descriptions for each modification, guiding users to identify correct components for their engine; This helps maintain compliance with original manufacturer standards while accommodating unique operational requirements.
5.2 Accessory Manufacturers and Compatibility
This section provides detailed information on approved accessory manufacturers and compatibility with the Continental O-200 engine. It lists components such as ignition systems, fuel pumps, and oil coolers, ensuring they meet engine specifications. Compatibility charts help users verify interchangeability and avoid installation errors. The manual emphasizes adhering to manufacturer guidelines to maintain performance and warranty compliance. Additionally, it offers troubleshooting tips for resolving compatibility issues, ensuring seamless integration of accessories with the engine.
Illustrated Parts Catalog Navigation
This section guides users in navigating the Illustrated Parts Catalog, highlighting features like bookmarks and search tools for efficient parts lookup and organization.
6.1 How to Use the Catalog Effectively
The Continental O-200 Illustrated Parts Catalog is designed for ease of use, featuring bookmarks for quick navigation and a robust search function to locate specific parts. Users can zoom in and out for detailed viewing and utilize the navigation pane for easy access to sections. The catalog includes hyperlinks to quickly jump to related pages, and the table of contents provides a clear structure. Printing specific pages is also supported for convenience. By using these tools, users can efficiently find and identify parts, ensuring accurate ordering and maintenance of the engine. Regular updates keep the catalog current with the latest parts information.
6.2 Bookmarking and Searching Features
The Continental O-200 Illustrated Parts Catalog offers advanced bookmarking and searching capabilities. Users can easily navigate by clicking on bookmarks to jump to specific sections or pages. The search function allows quick location of parts or terms by keyword, enhancing efficiency. The catalog is fully searchable, indexed, and bookmarked for rapid access to information. These features ensure users can quickly identify and locate parts, streamlining maintenance and repair processes. The intuitive design helps users save time and ensures accurate part identification, making the catalog a valuable resource for engine maintenance.
Technical Support and Resources
Contact Continental Technical Support for assistance with parts identification, troubleshooting, and maintenance. Additional resources include supplementary service manuals and repair guides for comprehensive engine maintenance support.
7.1 Contacting Continental Technical Support
For assistance with the Continental O-200 engine, contact technical support via email or phone. Visit the official website for detailed contact information and support resources. Ensure you have your engine serial number and specification ready for efficient troubleshooting. Technical support specialists can address parts identification, repair guidance, and maintenance queries. Additionally, refer to the Illustrated Parts Catalog and service manuals for self-help resources. Continental’s support team is available to provide expert advice, ensuring optimal engine performance and compliance with maintenance standards.
7.2 Additional Maintenance and Service Manuals
Continental provides a range of supplementary manuals to support engine maintenance and service. These include Maintenance Manuals, Overhaul Manuals, and Operator Manuals, all available free of charge during the engine’s warranty period. The Illustrated Parts Catalog is also accessible, offering detailed diagrams and part numbers. These resources ensure comprehensive guidance for repairs, overhauls, and routine maintenance. Additionally, the Installation and Operation Manuals provide specific instructions for engine setup and usage. Together, these manuals offer a complete suite of information for optimal engine performance and longevity.
The Continental O-200 Parts Manual serves as an essential resource for engine maintenance, repair, and overhaul. It provides detailed part listings, troubleshooting guides, and service specifications, ensuring compliance with manufacturer standards. By following the manual, users can efficiently identify and replace parts, reducing downtime and enhancing engine performance. The comprehensive catalog and supplementary manuals offer a complete solution for maintaining the O-200 engine. For further assistance, technical support and additional resources are available, making this manual an indispensable tool for aircraft engine maintenance professionals and enthusiasts alike.