TELEDYNE CONTINENTAL AIRCRAFT ENGINE M84-15

SUPERSEDES M76-18 Rev.1

service bulletin Technical Portions are

FAA Approved

21 December 1984

TO: Aircraft Manufacturers, Distributors, Dealers, Engine Overhaul Facilities,

Owners and Operators of Teledyne Continental Motors Aircraft Engines.

SUBJECT: CYLINDER LEAKAGE CHECK (Compression)

MODELS
AFFECTED: ALL

The differential pressure test is an accepted method of determining cylinder condition by measuring
air pressure loss past the pistons, rings and valves. The operation of the equipment is based on the
principle that, for any given airflow through a fixed orifice, a constant pressure drop across that
orifice will result. On many engines it is now a regular part of the 100 hour or annual inspection.
We have received reports of incorrect cylinder leakage check results caused by improper use of test
equipment and/or by the use of faulty test equipment.
To help you accurately accomplish a leakage check, we submit the following information on leakage
and use of the Master Orifice Tool (Ref. Figure 1) to calibrate the leakage checking equipment used
on Teledyne Continental engines.

LEAKAGE CHECKS

Cylinder leakage is broken down into two areas of concern, the "Static Seal" and the "Dynamic
Seal.”

Static Seal
The static seal consists of the valve to valve seat seals, spark plug to spark plug port seals and
cylinder head to barrel seal (Ref. Figure 2). No leakage of the static seal is permissible.

Dynamic Seal
The dynamic seal consists of the piston rings to the cylinder wall seal (Ref. Figure 2). This seal
leakage can vary from engine to engine by the cylinder displacement, cylinder choke, ring end gap
and piston design.

TELEDYNE INDUSTRIES INC. 1984 TELEDYNE CONTINENTAL MOTORS

Member of GAMA Aircraft Products Division
P.O. Box 90 • Mobile, Alabama 36601
21 December 1984 Page 2 M84-15

FACTORY CALIBRATED ORIFICE

DUST CAP DUST CAP
(Clean with soft brush. Do not alter
size)

SPARK PLUG
THREADS (18mm)

NOTE: THREAD HAND TIGHT TO

SPARK PLUG ADAPTER

FIGURE 1. MASTER ORIFICE ASSEMBLY TOOL BORROUGHS P/N 646953

Borroughs Tool & Equipment Corp.
2429 N. Burdick St.
Kalamazoo, MI 49007
Tel. 616/345-2700

STATIC DYNAMIC

EXHAUST
INTAKE
VALVE
VALVE
SEAL
SEAL

CYLINDER
WALL
SPARK CYLINDER DIMENSION
PLUG HEAD & & CHOKE
SEAL BARREL
SEAL
1ST & 2ND
COMPRESSION
RING GAP

PISTON
DIMENSION

FIGURE 2.
21 December 1984 Page 3 M84-15

B. EQUIPMENT

Testing equipment must be kept clean and checked periodically for accuracy as follows: Using a
line pressure of 100 to 120 P.S.I., close the cylinder pressure valve, then set the regulator pressure
valve to 80 P.S.I. The pressure in both gages should stabilize with no leakage.
The restrictor orifice dimension in the differential pressure tester for Teledyne Continental aircraft
engines must be 0.040 inch orifice diameter, 0.250 inch long with 60 degrees approach angle, and
must flow 120 + or - 5 cubic feet per hour at 30 P.S.I. differential pressure.
Master Orifice Tool
For conformity in tester equipment, a Master Orifice Tool has been developed to calibrate equipment
and determine the low indicated leakage limit prior to the engine leakage check. Connect
compressed air at 100-120 P.S.I. to the tester with cylinder pressure valve closed. Turn the
regulator pressure valve on, adjusting pressure to indicate 80 P.S.I. Remove the dust caps from
both ends of the Master Orifice Tool and install onto your cylinder spark plug adapter. Turn the
cylinder pressure valve on and readjust regulator pressure gage to read 80 P.S.I.. At this time the
cylinder pressure gage indication will be the low allowable limit for cylinder leak checks. The low
allowable limit is referred to as the master orifice calibrated pressure reading. After the master
orifice calibrated pressure reading has been recorded, close regulator pressure valve and remove
Master Orifice Tool from your cylinder adapter.
A schematic diagram of a typical differential pressure tester is shown in Figure 3.
C. PERFORMING THE CHECK
The following procedures are listed to outline the principles involved, and are intended to
supplement the manufacturer's instructions for the particular tester being utilized.
CAUTION...Magnetos and fuel must be shut off prior to test to make certain that the engine cannot
accidentally fire.
(a) Perform the test as soon as possible after the engine is shut down to ensure that the piston
rings, cylinder walls, and other engine parts are well lubricated and at running tolerance.
(b) Remove the most accessible spark plug from each cylinder.
(c) Turn the crankshaft by hand in the direction of rotation until the piston (in the cylinder being
checked) is coming up on its compression stroke.
(d) Install an adapter in the spark plug hole and connect the differential pressure tester to the
adapter. (NOTE: Cylinder pressure valve is in the Closed position). Slowly open the
cylinder pressure valve and pressurize the cylinder not to exceed 20 P.S.I..
Continue rotating the engine against this pressure until the piston reaches top dead center (TDC).
Reaching TDC is indicated by a flat spot or sudden decrease in force required to turn the crankshaft.
If the crankshaft is rotated too far, back up at least one-half revolution and start over again to
eliminate the effect of backlash in the valve operating mechanism and to keep the piston rings
seated on the lower ring lands. This is critical because the slightest movement breaks this piston
ring sealing and allows the pressure to drop.
CAUTION...Care must be exercised in opening the cylinder pressure valve, since sufficient air
pressure will be built up in the cylinder to cause it to rotate the crankshaft if the piston is not at TDC.
It is recommended that someone hold the propeller during check to prevent possible rotation.
21 December 1984 Page 4 M84-15

(e) Open the cylinder pressure valve completely. Check the regulator pressure gauge and
adjust, if necessary, to 80 P.S.I..
(f) Observe the pressure indication on the cylinder pressure gage. The difference between this
pressure and the pressure shown by the regulator pressure gage is the amount of leakage
through the cylinder. If the cylinder pressure gage reading is higher than the previously
determined master orifice calibrated pressure reading, proceed to the next cylinder leak
check. If the cylinder pressure gage reading is lower, proceed with the following.

CYLINDER
ADAPTER

CYLINDER CYLINDER
PRESSURE CYLINDER PRESSURE
VALVE ADAPTER VALVE

CYLINDER CYLINDER
PRESSURE PRESSURE
GAUGE GAUGE

RESTRICTOR RESTRICTOR
ORIFICE ORIFICE

REGULATOR REGULATOR
PRESSURE MASTER ORIFICE PRESSURE
GAUGE (HAND TIGHT) GAUGE CYLINDER

REGULATOR REGULATOR
PRESSURE PRESSURE
VALVE VALVE

COMPRESSED COMPRESSED
AIR SOURCE AIR SOURCE

FIGURE 3 – DIFFERENTIAL PRESSURE TESTER

Static Seal Check (Table 1)
(g) The source of air leakage should first be checked for the static seal. Positive identification of
static seal leakage is possible by listening for air flow sound at the exhaust or induction
system cylinder port. When checking for cylinder head to barrel leakage, use a soapy
solution between the fins and watch for bubbles. Use a soapy solution also around both
spark plug seals for leakage. NO LEAKAGE IS ALLOWED IN STATIC SEALS.
(h) If leakage is occurring in the intake or exhaust valve areas, it may be possible to correct a
low reading by staking the valves. This is accomplished by placing a fiber drift on the rocker
arm directly over the valve stem and tapping the drift several times with a hammer to
dislodge any foreign material that may be between the valve face and seat.
CAUTION...When correcting a low reading in this manner, rotate the propeller so the piston will not
be at TDC. This is necessary to prevent the valve from striking the top of the piston in some
engines. Rotate the propeller again before rechecking leakage to reset the valves in the normal
manner.
NOTE...When the rocker cover is removed, inspect valve springs, valve retainers, and valve stem for
wear. This may have contributed to the valve leakage.
(i) If leakage is noted between the cylinder head and barrel, REPLACE THE CYLINDER. If
leakage cannot be corrected at the valves by "staking", the cylinder must be removed and
repaired before a Dynamic Seal Check.
21 December 1984 Page 5 M84-15

NOTE...When the cylinder is removed, with the spark plugs installed, inspection can be
accomplished by filling the inverted cylinder bore with nonflammable solvent and then inspected for
leaks at the static seal areas.
(j) If the cylinder was removed for static leakage, replacement or repair, inspect piston ring gap
and cylinder wall for tolerance (Ref. Dynamic Seal, Figure 2). Once the piston and the
cylinder have been cleaned, inspected, and ring gap tolerances have been met, reassemble
to the engine.
Dynamic Seal Check
(k) To check the dynamic seal of a cylinder, proceed with the leakage test and observe the
pressure indication of the cylinder pressure gage. The difference between this pressure and
the pressure shown by the regulator gage is the amount of leakage at the dynamic seal.
(l) If the leakage is below the previously determined low cylinder gage reading, loss past the
dynamic seal may be due to piston ring end gap alignment or by the piston and piston rings
angular direction in the cylinder bore see Figure 4. First assure that the piston and piston
rings are centered. This may be accomplished by reducing regulator pressure to 20 P.S.I.
and working piston through TDC several times, bringing the piston to TDC in the normal
direction of engine rotation. Adjust regulated pressure to 80 P.S.I. and determine amount of
loss. If the gage reading is higher than the previously determined master orifice calibrated
reading, proceed to next cylinder to be tested.

TOP COMPRESSION
RING GAP
T.D.C.

DIRECTION
OF
MOVEMENT

TOP COMPRESSION
RING GAP

T.D.C.

DIRECTION
OF
MOVEMENT

FIGURE 4.
NOTE...Piston ring rotation within the ring land is a normal design characteristic. As illustrated in
Figure 4, the compression ring location may have a direct bearing on the dynamic seal pressure
check. Therefore, we suggest you complete the test in the opposite direction if readings are below
prescribed limits.
21 December 1984 Page 6 M84-15

(m) If recheck of cylinder pressure gage reading indication remains below allowable loss, engine
may be run-up to operating temperature and rechecked prior to cylinder being removed and
repaired. Rework of cylinders should be accomplished as outlined in the engine overhaul
manual and service bulletins.

FIRST CHECK CHECK FOR METHOD 1. DISCREPANCY 2. CORRECTIVE 2. CORRECTIVE

ACTION ACTION

Carbon Stake Valve

Intake Valve to Listen for Air Flow Cracked Cylinder Replace Cylinder
Seat Seal in Intake Port
Seat worn or burned Grind or Replace Reinspect
STATIC SEAL Valve worn or burned Grind or Replace
(NO LEAKAGE
Carbon Stake Valve
PERMISSIBLE)
Exhaust Valve to Listen for Air Flow Cracked Cylinder Replace Cylinder
Seat Seal in Exhaust Port
Seat worn or burned Grind or Replace
Reinspect
Valve worn or burned Replace
Spark Plug (2) to Apply Soapy Loose Heli-Coil Replace Heli-Coil Reinspect
Port Seal Solution Around
Cracked Cylinder Replace Cylinder
Spark Plug
Cylinder Head to Apply Soapy Bubbles Replace Cylinder
Barrel Seal Solution Between
Head and Barrel
Cylinder Head Apply Soapy Bubbles Replace Cylinder
Cracks Solution Around
Fins

SECOND CHECK CHECK FOR METHOD 1. DISCREPANCY 2. CORRECTIVE 2. CORRECTIVE

ACTION ACTION

Piston cracked or out Replace Piston

of limits
Test Gauge
Below Worn Rings Replace Rings
Leakage Tolerance
Cylinder Wall Replace Cylinder
DYNAMIC SEAL By dimensions out of
Piston Rings limits
Test Gauge None None
Above
Tolerance

TABLE 1