FUEL SET UP PROCEDURE

CONTINENTAL TSIO-360 WITH TURBOPLUS INTERCOOLER

IT IS NECESSARY TO USE THE FOLLOWING PROCEDURE FOR THE ENGINE TO

OPERATE PROPERLY IN ALL POWER RANGES.

MATERIALS AND TOOLS

1. CALIBRATED GAUGES:
a. 0-15 psi (monitoring low end UNMETERED fuel pressure)
b. 0-60 psi (monitoring 100% power UNMETERED pressure)
c. 0-30 psi (monitoring 100% power METERED pressure)

NOTE: The hoses on the gauges should be long enough to reach the
cockpit for run-up. It is recommended that the engine cowling be installed
during all run-ups. It is mandatory that the cowling is installed on 100%
power run-ups to aid in engine cooling to avoid the possibility of developing
"hot spots" and for the Intercooler cooling air to flow as designed.

2. PROPELLER STROBE TACHOMETER

3. MISC. HAND TOOLS AS REQUIRED
4. SAFETY WIRE

CONNECT GAUGES (Refer to figure 1-1)

Some engines have capped fittings for this purpose and on others a "tee"
fitting must be installed at an existing "B" nut.
UNMETERED FUEL: Connect gauge between the fuel pump and the
metering cam on the throttle body 2 . (0-15 gauge for low end reading &
0-60 gauge for high end reading.)
METERED FUEL: Connect the 0-30 gauge test· fuel line at the fuel flow
Divider 5 and the fuel flow vent line at the fuel .flow vent ( upper deck
pressure) 6

TSIO-360
Revised: June 30, 1988
ACD CORPORATION
Page 1
 Figure 1-1 Fuel Set Up and Adjustment Locations

PURGE TEST LINES

Purge all air from the test hoses at the gauges by loosening the "B" nuts and
turning on the boost pump with controls at full throttle and full rich. After
tightening "B" nuts check for leaks with boost pumps on for 8-10 seconds.

ADJUSTMENTS
1. Pre-adjustment of Turbo by-pass valve to 8-10 threads exposed
past the locknut.
NOTE: Any adjustment other than 8-10 threads indicates: 1). Induction leaks
and/or 2). Exhaust leaks. and/or 3). Defective turbo and/or 4). Improperly
adjusted fuel system.

2. Back off the idle speed adjustment screw 7 (ccw) two turns.

3. Start engine and warm up at 1500-1800 RPM until oil temperature is

150°-180°F and cylinder head temperature is in the lower 1/4 of
the green arc.

TSIO-360
Revised: June 30, 1988
ACD CORPORATION
Page 2
UNMETERED FUEL PRESSURE
(0-15 gauge) should read 6.5 psi +.25 at 700 RPM. This adjustment is made at
the bolt 4 located on the fuel pump body center line. To increase pressure
turn the bolt clockwise and to decrease pressure counter-clockwise.

IDLE MIXTURE
(Note: run engine 1200-1400 RPM before each test to clear the engine).

Stabilize at 700 RPM and then slowly and positively move the mixture control
from full rich to idle cut-off. A properly adjusted engine will produce an RPM rise
of 50 + 25 just prior to RPM dropping to zero. This adjustment is made at the
metering cam 1 located on the right side of the throttle body. The adjustment
housing points forward and up approximately 30 degrees using a common
screw driver, turn the adjustment screw clockwise to lean and counter clockwise
to enrich the mixture.

NOTE: The unmetered fuel pressure adjustment and the idle-mixture

adjustment affect each other.

FOR EXAMPLE: If unmetered pump pressure reads 5.2 psi and idle cut of RPM
rise is only negligible, increasing the unmetered pressure to 6.5 psi will increase
fuel through the throttle metering unit thus, a mixture adjustment may not have
to be made. Sometimes it is necessary to work these adjustments several times
to fine tune the system as proper low end unmetered pump pressure and
proper mixture adjustments are essential prior to proceeding to the 100% power
fuel pressure adjustment.

IDLE SPEED
After #4 & #5 adjustments have been completed, move the throttle to the idle
stop. If the engine idles above 700 rpm, turn the idle speed adjustment screw 7
counterclockwise. If the engine RPM is below 700 turn clockwise.

100% POWER METERED FUEL PRESSURE

CAUTION: At high power settings it is mandatory that all engine cowlings be
installed on each run-up for proper engine cooling to prevent hot spots and to
get the Intercooler cooling air to flow as designed. Operate the engine below
temperature limits.

TSIO-360
Revised: June 30, 1988
ACD CORPORATION
Page 3
 1. Taxi to a suitable run-up location with the aircraft facing into the wind. Set parking
brakes and if desired, chock and or tie down the aircraft.

NOTE: For fuel set up, 100% horsepower is defined as (1) maximum rated
static rpm, (2) maximum rated fuel flow, and (3) maximum rated
manifold pressure for a standard day (15 degrees C). Since
horsepower is affected by temperature and the Intercooler lowers
the charge air temperature, USE THE MANIFOLD PRESSURE ON
CHART #1 for 100% POWER SETTING.

OAT-C -35 -25 -15 -5 +5 +15 +25 +35 +45

M.P. 34.9" 35.6" 36.3" 37.0" 37.7" 38.4" 39.1" 39.8" 40.0"

CHART #1 MANIFOLD PRESSURE FOR SETTTING UP 100% MAX CONTINOUS

POWER

2. Run the engine up to 100% H.P. (the rpm should be 25-.75 below red line).
Check the tachometer with the prop strobe tachometer. Adjust engine rpm
as necessary prior to proceeding with the fuel adjustment. This is
accomplished by adjusting the forward stop screw 8 on the governor head.
NOTE: 100% H.P. unmetered fuel pressure is for reference only. It may end
up somewhat higher than the limits specified in Continental S/B M84-6
(chart #2) due to the throttle metering cam position at reduced manifold
pressure selling to compensate for the Intercooler effect.
3. When the actual rpm is correct, run the engine to 100% H.P. as described
above, and monitor the calibrated METERED fuel pressure gauge and fuel
flow as indicated on the aircraft gauge. If these readings are not within the
limits specified on chart #2, make the necessary adjustments as per step 4.

TSIO-360
Revised: June 30, 1988
ACD CORPORATION
Page 4
 RPH Unmetered or Metered or Fuel Flow Fuel Flow
Nozzle
Engine Propeller Pump Pres. Lbs. / Hr. Gal./Hr
Pres.
TSIO-360E,EB 700 6.5 + .25 3.5-4.0 130-140 22-24
LTSIO-360E,EB 2575 43-46 16-18
TSIO-360F,FB 700 6.5 + .25 3.5-4.0 132-142 22.5-24
2575 43-46 16.0-18.5
TSIO-360,FBC 700 6.5 + .25 3.5-40 , 140-155 23.8-26.4
200HP Conver. 2800 36-39 18-21 .
TSIO-360G,GB 700 6.5 + .25 3.5-4.0 135-145 23.0-24.7
2700 46-50 17-19
L/TSIO-360KB 700 6.5 + .25 3.5-4.0 140-155 23.8-26.4
2800 36-39 18-21
TSIO-360LB 700 6.5 + .25 3.5-4.0 135-145 23.0-24.7
2700 15.0-16.4
CHART #2 (Data from Continental S/B M84-6)

4. The METERED fuel pressure is adjusted by turning the screw 3

on the Fuel Pump aneroid housing. Clockwise decreases pressure,
counterclockwise increases pressure. One turn equals approximately
2 psi. Care must be taken when loosening and tightening the jam nut
because the adjustment screw will turn with it. If more than just a
minor adjustment must be made, the low end unmetered fuel pressure
and mixture settings will be affected and no longer will be within
tolerance and must be reset. After the low end has been reset, then
the 100% power metered pressure must also be reset.

REMOVE TEST EQUIPMENT AND PRE-FLIGHT INSPECTION

1. Remove all of the test gauges and hoses. Cap or connect all fuel and vent
lines. Place the throttle full forward and mixture full rich. Turn on the boost
pump and check all of the fuel line connectors for leaks.
2. If not previously done safety wire the turbo by-pass valve. It is also
recommended to safety the turbo and exhaust coupling clamps.
3. After a final inspection, install the cowlings.

TEST FLIGHT
Determine aircraft performance and critical altitude. If this is the first test
flight after the Intercooler installation, it is important to duplicate the same
aircraft configuration, i.e. amount of fuel, oil, pilot & passenger weights, etc.
so that an accurate comparison can be made to the pre-modification test
flight. Take off and climb power settings should be duplicated except the
manifold pressure should be reduced for Intercooler effect in accordance
with the POH Supplement power setting procedure. Complete the post-
modification flight form attached.

TSIO-360
Revised: June 30, 1988
ACD CORPORATION
Page 5
CRITICAL ALTITUDE
Is determined by climbing at best rate of climb IAS and max continuous M.P. and
RPM. Since the Intercooler reduces the charge air temperature and power varies
with temperature it is necessary to use the attached max. continuous power table
for setting M.P. When max. continuous M.P. can no longer be maintained, this Is
termed critical altitude.

NOTE: Critical altitude will vary approximately 500' for every 9 degrees C temperature
variation. The colder the air the higher the critical altitude. IF THE CRITICAL
ALTITUDE IS BELOW 14,000' THE BY-PASS CAN BE SCREWED IN TO 8
THREADS (1 thread will increase critical altitude approximately 1,000'). WHEN
THIS IS DONE THE 100% METERED PRESSURE MUST BE RESET. IF
CRITICAL ALTITUDE OF AT LEAST 14,000' CAN NOT BE OBTAINED WITH
8 THREADS, DO NOT SCREW THE BY-PASS IN ANY FURTHER. INSTEAD
LOOK FOR ONE OR MORE OF THE FOLLOWING PROBLEMS:

1. Exhaust leaks. 2. Induction Leaks. 3. Defective Turbo. 4. Improperly adjusted

fuel
system.

TSIO-360
Revised: June 30, 1988
ACD CORPORATION
Page 6