Superior O-360 SERIES, IO-360 SERIES, Vantage Engine O-360 SERIES, Vantage Engine IO-360 SERIES Overhaul Manual

O-360 & IO-360 SERIES ENGINES

OVERHAUL MANUAL

621 South Royal Lane, Suite 100 / Coppell, TX 75019 / 800-277-5168

Manual P/N SVOHM01 Revision A, March 2005

www.superiorairparts.com

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Overhaul Manual

O-360 and IO-360 Series Engines

Manual Number SVOHM01

Revision History

Revision

Letter

A 08/31/04 Initial Release All

Effective

Date

Description

Pages

Revised

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O-360 and IO-360 Series Engines

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O-360 and IO-360 Series Engines

SAFETY ADVISORY

WARNING: BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE

HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE MANUFACTURERS' OR SUPPLIERS’ RECOMMENDATION CAN RESULT IN PERSONAL INJURY.

The user must know the manufacturer or supplier information and keep to the procedures, recommendations, warnings and cautions set forth for the use, handling, storage, and disposal of materials. The WARNINGS used in this manual inform the user about dangerous materials or equipment that can cause injury; they do not replace the manufacturer's instructions.

This Safety Advisory has all the warnings included in this manual.

WARNING: OPERATION OF A DEFECTIVE ENGINE WITHOUT A PRELIMINARY EXAMINATION CAN

CAUSE FURTHER DAMAGE TO A DISABLED COMPONENT AND POSSIBLE INJURY TO PERSONNEL. MAKE SURE THOROUGH INSPECTION AND TROUBLESHOOTING PROCEDURES ARE ACCOMPLISHED. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.

WARNING: FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE INA A WELL

VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES.AVOID EYE AND SKIN CONTACT. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH GOGGLES AND

INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON

PERSONNEL PROTECTIVE GEAR.

WARNING: USE THE CORRECT PERSONAL PROTECTION. HEATED PARTS WILL CAUSE BURNS. WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT

THE PRESSURE IS NOT MORE THAN 30 PSI. DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. IF YOU GET AN EYE INJURY, GET MEDICAL ATTENTION.

WARNING: LUBRICANTS ARE TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE

YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING: USE THE CORRECT PERSONAL PROTECTION. POLISHING WILL CAUSE LOOSE

PARTICLES THAT CAN GET IN YOUR EYES.

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O-360 and IO-360 Series Engines

WARNING: PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE. WARNING: USE THE CORRECT PERSONAL PROTECTION EQUIPMENT TO AVOID INJURY.

ENSURE AREA IS FREE OF MOVABLE OBJECTS THAT COULD IMPACT BY PROPELLER AIR BLAST.

WARNING: ADHESIVE SEALANT IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.

AVOID EYE AND SKIN CONTACT. USE PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING: SOLVENT IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN

CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING: DO NOT INSTALL THE IGNITION HARNESS “B” NUTS ON THE SPARK PLUGS UNTIL

THE PROPELLER INSTALLATION IS COMPLETED. FAILURE TO COMPLY COULD RESULT IN BODILY INJURY WHEN THE PROPELLER IS ROTATED DURING INSTALLATION.

WARNING: IF ONE SURFACE IS POLISHED TO UNDERSIZE, ALL CORRESPONDING SURFACES

MUST BE POLISHED TO THE SAME SIZE.

WARNING: PLACE A SUITABLE STAND UNDER THE AIRCRAFT TAILCONE IF NEEDED BEFORE

REMOVING THE ENGINE. THE LOSS OF WEIGHT MAY CAUSE THE AIRCRAFT TAIL TO DROP.

WARNING: DO NOT DAMAGE THE NITRIDED SURFACES OF THE CRANKSHAFT. WARNING: USE CORRECT PERSONAL PROTECTION. SOME CHEMICAL SOLUTIONS CAN CAUSE

EYE, SKIN, AND LUNG DAMAGE. FOLLOW THE MANUFACTURER’S INSTRUCTIONS FOR EACH STRIPPING SOLUTION.

WARNING: USE THE CORRECT PERSONAL PROTECTION. USE OF A HAMMER CAN CAUSE

LOOSE PARTICLES THAT CAN GET IN YOUR EYES.

WARNING: DO NOT ROTATE ENGINE OR CRANKSHAFT BEFORE REMOVAL OF TIMING

LOCATOR PINS.

WARNING: TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH, BEFORE

MOVING THE PROPELLER DO THE FOLLOWING:

VERIFY ALL SPARK PLUG LEADS ARE DISCONNECTED. •

•

VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT THEY ARE IN THE “OFF” POSITION AND “P” LEADS ARE GROUNDED.

•

THROTTLE POSITION “CLOSED.”

•

MIXTURE CONTROL “IDLE-CUT OFF.”

•

SET BRAKES AND BLOCK AIRCRAFT WHEELS. ENSURE THAT AIRCRAFT TIE DOWNS ARE INSTALLED AND VERIFY THAT THE CABIN DOOR LATCH IS OPEN.

•

DO NOT STAND WITHIN THE ARC OF THE PROPELLER BLADES WHILE TURNING THE PROPELLER.

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Section

Chapter

General Information

Sub-Section

Revision History i Safety Advisory iii Table of Contents v List of Figures ix List of Tables xi

Overhaul Manual

O-360 and IO-360 Series Engines

TABLE OF CONTENTS

Page Number

01 00 00 Introduction

02 00 00 Description and Operation

04 00 00 Airworthiness Limitations

72 00 03 Testing and Fault Isolation

About This Manual 1 Related Publications 1 Obtaining Service Information 1 Abbreviations 1 Consumable Materials List 3

General Description 1 Continued Airworthiness 1 Model Designations 1 Engine Components General Description 3 Specifications 3 Features and Operating Mechanisms 16

Mandatory Replacement Time 1 Mandatory Inspection Intervals 1 Other Mandatory Intervals or Procedures 1 Distribution of Changes to Airworthiness 1

General 1 Troubleshooting 1

04 Special Procedures

Prior to Break-In Start-Up Break-In Ground Run Break-In Flight Operation

General Break-In Procedures 1 Special Tools and Equipment 1 Break-In Procedures 1

Post Break-In Procedures 2

1 1 1

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O-360 and IO-360 Series Engines

Chapter

TABLE OF CONTENTS (cont’d)

Page Number

Section

Sub-Section

05 Engine Removal

06 Engine Disassembly

07 Cleaning

Degreasing Decarbonizing Scratch and Corrosion Removal Accessory Mounts Fuel Injector and Primer Nozzles Screens and Filters Accessories

General 1 Removal 1 Preservation 1

General 1 Disassembly Materials 1 Parts for Discard 1 Special Tools and Equipment 1 General Disassembly Procedures 2 Disassembly 2

General 1 Tools and Materials 1 Cleaning Instructions 1

Preservation and Corrosion Prevention 4

1 2 2 2 3 3 3

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Section

Chapter

72 00 08 Inspection and Check

Sub-Section

General 1 Materials and Tools 1 General Inspection Procedures 2 General Non-Destructive Testing 2 Accessory Housing 3 Crankcase Assembly 3 Cylinder Head 6 Cylinder Head Dimensional Inspections 6 Cylinder Barrel Inspections 6 Cylinder Barrel Dimensional Inspections 7 Cylinder Assembly Inspection 7 Piston Inspections 7 Piston Dimensional Inspections 7 Valve Rockers 11 Pushrod Inspection 11 Valve Springs Inspection 11 Crankshaft 13 Crankshaft Counterbore Face Inspection 13 Camshaft Inspection 14 Connecting Rods Inspection 14

Overhaul Manual

O-360 and IO-360 Series Engines

TABLE OF CONTENTS (cont’d)

Page Number

09 Engine Assembly

10 Engine Installation

General 1 Fits, Clearances and Torque Values 1 Materials Required for Assembly 1 Special Tools and Equipment 1 Engine Assembly 2 Engine Accessory Assembly Installation 46 Storage After Assembly 58

General 1 Preparing Engine for Service 1 Installation of Engine 1

ix

General Information

Section

Chapter

72 00 11 Fits and Clearances

Sub-Section

General 1 Service Limits 1

Overhaul Manual

O-360 and IO-360 Series Engines

TABLE OF CONTENTS (cont’d)

Page Number

12 Preservation and Storage

13 Repair

Repair 1 – Threaded Area Repair and Stud Replacement Repair 2 – Nick and Scratch Repair Repair 3 – Crankshaft or Crankpin Repair Repair 4 – Painted Parts Repair 5 – Crankshaft Oil Seal Surface Repair 6 – Cylinder Interior Surface Repair 7 – Cylinder Head Cooling Fins Repair 8 – Valve, Valve Seat, and Valve Guide Repair 9 – Spark Plug Threaded Insert Repair 10 – Rocker Bushing Replacement Repair 11 – Connecting Rod Bushing Replacement

14 Testing

Appendix A Assembly In Process Quality Inspections

General 1 Temporary Storage 2 Indefinite Storage 3 Returning an Engine to Service After Storage 3

General 1 Repair Procedures 1

General 1 Special Tools and Equipment 1 Engine Installation and Testing Procedures 1 Engine Storage After Testing 1

5 7

9 11 13 15 17 19 27 29 31

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O-360 and IO-360 Series Engines

LIST OF FIGURES

Figure

02-00-00.1 Engine Model Number Designation 02 00 00 1 02-00-00.2 O-360 Engine Front View 6 02-00-00.3 O-360 Engine Left Side View 7 02-00-00.4 O-360 Engine Top View 8 02-00-00.5 O-360 Engine Rear View 9 02-00-00.6 IO-360 Engine Front View 10 02-00-00.7 IO-360 Engine Left Side View 11 02-00-00.8 IO-360 Engine Top View 12

02-00-00.9 IO-360 Engine Rear View 13 02-00-00.10 Ignition Wiring Diagram 14 02-00-00.11 Oil System Schematic 15

72-00-08.1 Reserved 08 -

72-00-08.2 Accessory Housing 4

72-00-08.3 Crankcase Bearing and Flange Surfaces 5

72-00-08.4 Cylinder Assembly 8

72-00-08.5 Piston Assembly 9

72-00-08.6 Piston Rings and Lands 10

72-00-08.7 Valve Train 12

72-00-08.8 Camshaft Assembly 15

Chapter

Section

Page

Sub-Section

72-00-09.1 Crankcase Bearing Retention Dowel 09 4

72-00-09.2 Crankshaft Bearing and Oil Pressure Relief Valve 5

72-00-09.3 Crankshaft Assembly 6

72-00-09.4 Crankshaft Thrust and Slinger Clearance 7

72-00-09.5 Crankcase Assembly 8

72-00-09.6 Connecting Rod and Piston Assembly 12

72-00-09.7 Connecting Rod Installation 13

72-00-09.8 Camshaft Assembly 14

72-00-09.9 Main Bearing Reference Marks 15 72-00-09.10 Main Bearing Installation 16 72-00-09.11 Crankcase Attaching Hardware 17 72-00-09.12 Crankcase Attaching Hardware (cont’d.) 18 72-00-09.13 Sealant Compound and Silk Thread Application 19 72-00-09.14 Crankcase Halves Assembly 20

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O-360 and IO-360 Series Engines

LIST OF FIGURES (cont’d.)

Figure

72-00-09.15 Cylinder Valve Train and Spring Assembly 72 00 09 22 72-00-09.16 Piston Assembly to Connecting Rod 23 72-00-09.17 Cylinder Assembly and Head Oil Drain Line 25 72-00-09.18 Piston Assembly with Ring Compressor Tool 26 72-00-09.19 Cylinder Base Nuts Sequence of Tightening 27 72-00-09.20 Idler Gear and Tachometer Shaft Assemblies 30 72-00-09.21 Idler Gear and Tachometer Shaft Assemblies (cont’d.) 31 72-00-09.22 Accessory Drive Gear Arrangement 32 72-00-09.23 Accessory Housing 35 72-00-09.24 Oil Pump Assembly 36 72-00-09.25 Accessory Housing Gasket Trimming 37 72-00-09.26 Inner Cylinder Cooling Baffle 39 72-00-09.27 Oil Sump and Induction System 40 72-00-09.28 Oil Level Gage 41 72-00-09.29 Induction System 42 72-00-09.30 Intake Tube Assembly 43 72-00-09.31 Vacuum Pump Drive 45 72-00-09.32 Fuel Pump 47 72-00-09.33 Propeller Governor Adapter 49 72-00-09.34 Propeller Governor Oil Line 50 72-00-09.35 Oil Filter Assembly 51 72-00-09.36 Fuel Priming System 53 72-00-09.37 Carburetor Installation 54 72-00-09.38 Fuel Injection Servo Installation 55 72-00-09.39 Fuel Injection Manifold Installation 56 72-00-09.40 Magneto and Adapter Installation 59 72-00-09.41 Starter Ring Gear Alignment 60 72-00-09.43 Alternator Installation 61

Chapter

Section

Page

Sub-Section

72-00-13.1 Cylinder Interior Resurface Crosshatch 15 16

72-00-13.2 Cooling Fin Removal Maximum 18

72-00-13.3 Valve Seat Dimensions 23

72-00-13.4 Valve Guide Dimensions 24

72-00-13.5 Valve to Seat Fit Acceptable Criteria 25

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O-360 and IO-360 Series Engines

LIST OF TABLES

Table

Section

Chapter

01-00-00.1 Abbreviations 01 00 00 2

01-00-00.2 Consumable Materials 3

02-00-00.1 Manufacturer’s General Specifications 02 00 00 3

02-00-00.2 Accessory Drive Specifications 4

02-00-00.3 Manufacturer’s Physical Specifications 4

02-00-00.4 Engine Accessories 4

02-00-00.5 Illustrated Views of the Engine 5

72-00-03.1 Special Tools and Equipment 72 00 03 1

72-00-03.2 Abnormal Operating Procedures 1

72-00-03.3 Engine Will Not Start 2

72-00-03.4 Rough Idling 2

72-00-03.5 Engine Not Able To Develop Full Power 2

72-00-03.6 Rough Engine Operation 3

72-00-03.7 Low Power & Engine Runs Rough 3

72-00-03.8 Low Oil Pressure On Engine Gage 3

72-00-03.9 High Oil Temperature 4 72-00-03.10 Excessive Oil Consumption 4

Page

Sub-Section

72-00-05.1 Equipment and Materials List 05 1

72-00-06.1 Disassembly Materials 06 1

72-00-06.2 Discard Parts 1

72-00-06.3 Special Tools and Equipment 3

72-00-07.1 Equipment Required for Cleaning 07 1

72-00-07.2 Materials Required for Cleaning 1

72-00-08.1 Inspection Materials 08 1

72-00-08.2 Special Tools and Equipment 1

72-00-09.1 Assembly Materials 09 1

72-00-09.2 Special Tools and Equipment 2

72-00-10.1 Equipment and Materials List 10 1

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O-360 and IO-360 Series Engines

LIST OF TABLES (cont’d)

Table

Section

Chapter

72-00-11.1 Dimensional Limits 72 00 11 1

72-00-11.2 Torque Limits 3

72-00-11.3 Backlash and End Clearance Limits 4

72-00-11.4 Valve Spring Dimensional Limits 4

72-00-11.5 Crush Type Gasket Tightening Angles 4

72-00-12.1 Storage Materials 14 1

72-00-13.1 List of Repairs 13 2

72-00-13.2 List of Materials 2

72-00-13.3 List of Equipment 3

72-00-13.4 List of Repair Codes 3

72-00-13.5 Reserved -

72-00-13.6 Consumable Materials for Paint Procedures 11

72-00-13.7 Exhaust Valve Seat Standard and Oversize Dimensions 20

72-00-13.8 Intake Valve Seat Standard and Oversize Dimensions 20

72-00-13.9 Exhaust Valve Guide Standard and Oversize Dimensions 21 72-00-13.10 Intake Valve Guide Standard and Oversize Dimensions 21

Page

Sub-Section

xiv

General Information

Overhaul Manual

O-360 and IO-360 Series Engines

INTRODUCTION

About This Manual

The purpose of this Overhaul Manual is to provide the necessary instructions for major repair and replacement of Superior Vantage O-360 and IO-360 series engines. Maintenance information may be found in the Maintenance Manual, SVMM01.

The information in this publication is based on data available at the time of publication and is updated, supplemented, and automatically amended by Service Bulletins and Publication Revisions that are issued by Superior Air Parts Inc.

This manual is divided into separate sections relating to the general and specific overhaul instructions required for the engine. These general and specific instructions are generally organized and numbered per the recommendations of the General Aviation Manufacturers Association (GAMA). In this way, information may be located in a conventional manner to aid in both accuracy and timeliness.

Page numbering is organized within each section. The section number (e.g., 72-00-01) is displayed in the right hand section of the footer on each page. The page number is displayed in the center of the footer on each page.

Superior Air Parts has made clear and accurate information available for those who maintain, own and repair the Vantage O-360 and IO-360 Series Engines. Superior Air Parts values your input regarding revisions and additional information for our manuals. Please forward your comments and input to:

Superior Air Parts Attn: Engineering Department 621 South Royal Lane Suite 100 Coppell, Texas 75019

Related Publications

The following are related engine and accessory publications.

O & IO-360 Installation and Operation Manual, SVIOM01 O & IO-360 Maintenance Manual, SVMM01 O & O-360 Illustrated Parts Catalog, SVIPC01 Unison Master Service Manual, F-1100 Unison Autolite Manual, L-1710A Precision RSA-5 Service Manual, 15-338 Precision MA-4-5 Manual, MSAHBK-1 Champion Aerospace Service Manual, AV-6R Kelly Aerospace Service Manual, OE-A2

Obtaining Service Information

All Vantage Series Engine manuals and service information may be downloaded at: www.superiorairparts.com

All Vantage Series Engine manuals and service information may be purchased by contacting:

Superior Air Parts 621 South Royal Lane, Suite 100 Coppell, Texas 75019

or call: 972-829-4600 Accessory Information may be obtained at:

www.championaerospace.com www.unisonindustries.com www.skytecair.com www.precisionairmotive.com www.aeroaccessories.com www.kellyaerospace.com

Abbreviations

A list of abbreviations used in this manual is shown in Table 01-00-00.1 below.

1

01-00-00

Introduction

Overhaul Manual

O-360 and IO-360 Series Engines

Table 01-00-00.1 • Abbreviations

Abbreviation Definition

AMS Aerospace Material Standard Assy Assembly BTC / BTDC Before Top Center / Before Top Dead Center CHT Cylinder Head Temperature DIA Diameter F Fahrenheit Fig. Figure Ft-Lb Foot-Pounds IAW In Accordance With I.D. Inside Diameter In-Lb Inch-Pounds Lb Pounds No. Number NPT National Pipe Thread O.D. Outside Diameter Oz. Ounce P/N Part Number Prop Propeller PSI Pounds per Square Inch RPM Revolutio ns Per Minute SAE Society of Automotive Engineers TIR Total Indicator Reading UNF Unified National Fine ° Degree

2

01-00-00

Introduction

Overhaul Manual

O-360 and IO-360 Series Engines

Consumable Materials List

Refer to Table 01-00-00.2 below for consumable materials used during repair of the Vantage O360 and IO-360 series engines.

Table 01-00-00.2 • Consumable Materials

Material Source

Acetone or Methyl Ethyl Ketone (MEK) Commercially Available Assembly Grease – Lubriplate No. 105 Commercially Available Cleaning Solvent Comm ercially Available Copper Based Anti-seize, Fel-ProTM C5-A Commercially Available Fuelube Isopropyl alcohol Commercially Available LoctiteTM 271, P/N 27183 Commercially Available LoctiteTM No. 2 Gasket Sealant P/N 30514 Commercially Available Lubricating Oil, SAE 10 Commercially Available Lubricating Oil, SAE 50 Commercially Available Mineral Oil (MIL-L-6082), SAE 50 weight Commercially Available PermatexTM, P/N 27100 Commercially Available PliobondTM #20 Commercially Available Pre-Lube Mixture – approx. 15% pre-lubricant

(STPTM brand or equivalent) plus 85% SAE 50 straight weight mineral oil

Preservative oil mix (MIL-C-6529, type 1 plus MIL-L-6082)

RTVTM 102 Silicon Sealant General Electric Safety Wire (0.032) Type 304 Stainless Steel,

P/N MS20995 C32 Safety Wire (0.041) Type 304 Stainless Steel,

P/N MS20995 C41 SilasticTM 140 Sealant Commercially Available Silk thread, size 00 (100% Silk) Commercially Available STPTM High Viscosity Oil Treatment Commercially Available TitesealTM No. 2 Gasket and Joint Compound

P/N T2-01 Phthalate resin-type enamel AMS3125C or

equivalent MIL-E-7729 Randolph Black (#303) Toluene or equivalent AMS3180 (or equivalent

Federal Spec TT-T-548) Zinc Chromate Primer Commercially Available

TM

NOTE:

Equivalent substitutes may be used.

Ohio Industrial Lubricants

Locally Prepared Mixture

Commercially Available

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Introduction

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O-360 and IO-360 Series Engines

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Introduction

Overhaul Manual

O-360 and IO-360 Series Engines

DESCRIPTION AND OPERATION

General Description

Superior Vantage Engines are four-cylinder, horizontally opposed, air-cooled, direct drive powerplants incorporating a wet sump, bottom mounted induction, bottom exhaust with either carbureted or port injected fuel systems. Provisions exist for both front and rear mounted accessories. All engine components will be referenced as they are installed in the airframe. Therefore, the “front” of the engine is the propeller end and the “rear” of the engine is the accessory mounting drive area. The oil sump is on the “bottom” of the engine and the cylinder shroud tubes are on the “top”. The terms “left” and “right” are defined as being viewed from the rear of the engine looking toward the front. Cylinder numbering is from the front to the rear with odd numbered cylinders on the right side of the engine. The direction of crankshaft rotation is clockwise as viewed from the rear of the engine looking forward unless otherwise specified. Accessory drive rotation direction is

defined as viewed from the rear of the engine looking forward.

Continued Airworthiness

Vantage Engines discussed in this document must be installed and operated in accordance with the limitations, conditions and operating procedures described in the Installation and Operation Manual (SVIOM01). They must also be maintained in accordance with this manual and the applicable Overhaul Manual (SVOHM01) and other Instructions for Continued Airworthiness. The engine’s time between overhaul (TBO) period is initially defined as 1000 hours. A TBO extension program is in process.

Model Designations

The model number designation is defined in a way that the digits of the model number can easily identify the basic configuration of the engine as described in Figure 02-00-00.1.

Figure 02-00-00.1 • Engine Model Number Designation

1

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Fuel System Type

IO Denotes Port Fuel Injection System and “opposed cylinder” arrangement. O Denotes a carbureted system and “opposed cylinder” arrangement.

Cylinder Type

360 Parallel valve cylinder, 361 cubic inches.

Model Suffix

1st Digit Crankshaft & Propeller Type A Fixed-Pitch, Thin-wall front main

B Constant-Speed, Thin-wall front main D Constant-Speed, Heavy-wall front main

E Fixed-Pitch, Solid front main

2nd Digit Crankcase & Engine Mount Type

3rd Digit Accessory Package

4th Digit Power Rating: Piston Compression Ratio

Denotes detail engine configuration

C Fixed-Pitch, Heavy-wall front main

1 #1 Dynafocal Mount 2 #2 Dynafocal Mount 3 Conical Mount

Fuel System Ignition System

Carbureted (O-360) Fuel Injected (IO-360)

A Unison Magnetos Precision Carburetor Precision Fuel Injection

1* - 2 8.5:1 180

* For Future Use

Cylinder Type 360 CR HP

2

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Engine Components General Description

The O-360 and IO-360 series engines are aircooled, four cylinder, horizontally opposed, direct drive engines. See Table 02-00-00.1 for Manufacturer’s General Specifications.

The complete engine includes the following components and assemblies:

Crankcase Assembly Crankshaft Assembly Camshaft Assembly Valve Train Assembly Cylinder Assemblies Connecting Rod Assemblies Oil Sump Assembly Intercylinder Baffles Starter Lubrication System (Includes Oil Filter) Accessory Drive Ignition System (Includes Spark Plugs) Fuel System Starter Support Assembly Oil Gage Induction System Accessories

NOTE: Complete engine does not include outer cylinder baffles, propeller governor, and airframe to engine control cables, attaching hardware, hose clamps, vacuum pump, exhaust system, or fittings. Fuel pump is included, unless otherwise specified, on carbureted engines. Alternator may be included, if specified.

Specifications

The manufacturer’s physical specifications are listed in Table 02-00-00.2 and are applicable to the O-360 and IO-360 series engines. Accessory Drive Specifications are provided in Table 02-00-00.2 and is also applicable for both O-360 and IO-360 models. Table 02-00-00.3 lists Physical Specifications for the engines and Accessories are provided in Table 02-00-00.4. The Model Specification Data (MSD) provides more specific information by engine type and is available from Superior Air Parts, Inc.

Illustrated views of the O-360 and IO-360 engines identifying key components and subassemblies are provided in Figures 02-00-00.1 thru 02-00-00.9 of this section and are listed Table 02-00-00.5 for convenience. Figure 0200-00.10 illustrates the engine wiring diagram and Figure 02-00-00.11 illustrates the oil system schematic.

Table 02-00-00.1 • Manufacturer’s General Specifications

Model O-360 and IO-360 Rated Power Hp 180 Rated Speed, RPM RPM 2700 Bore, inches In 5.125 Stroke, inches In 4.375 Displacement cubic inches In Compression Ratio 8.5:1 Firing Order 1-3-2-4 Spark timing °BTDC 25 Propeller drive ratio 1:1 Propeller drive rotation

(viewed from rear)

3

361.0

Clockwise

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Table 02-00-00.2 • Accessory Drive Specifications

Accessory

Starter 16.556:1 Counter-Clockwise Alternator (not included) 3.250:1 Clockwise Tachometer 0.500:1 Clockwise Magneto 1.000:1 Clockwise Vacuum Pump (not included) 1.300:1 Counter-Clockwise Propeller Governor (not included) 0.866:1 Clockwise Fuel Pump (if furnished) 0.500:1 Plunger Operated

Table 02-00-00.3 • Manufacturer’s Physical Specifications

Model

O-360-Axxx 24.6 33.4 32.8 288 O-360-Bxxx 24.6 33.4 32.8 291 O-360-Cxxx 24.6 33.4 32.8 291 O-360-Dxxx 24.6 33.4 32.8 294 O-360-Exxx 24.6 33.4 32.8 295 IO-360-Axxx 24.0 33.4 32.8 290 IO-360-Bxxx 24.0 33.4 32.8 293 IO-360-Cxxx 24.0 33.4 32.8 IO-360-Dxxx 24.0 33.4 32.8 296 IO-360-Exxx 24.0 33.4 32.8 297

Height

(In)

Table 02-00-00.4 • Approved Engine Accessories

Drive Ratio

Width

(In)

Direction of

Rotation

Length

(In)

Weight

(Lb)

293

Model

O-360

IO-360

Left

Magneto

Unison

4371

Unison

4371

Right

Magneto

Unison

4371

Unison

4371

Fuel

System

Precision

MA-4-5

Precision

RSA-5

Fuel Pump

(if furnished)

Aero Acc.

AF15472

Aero Acc.

AF15473

4

Starter

SkyTec

149-12LS

SkyTec

149-12LS

Spark Plug

Harness

Unison M4001

Alternator

(if furnished)

Kelly Aerospace

ALY8520LS

Kelly Aerospace

ALY8520LS

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Table 02-00-00.5 • Illustrated Views of the Engine

Engine View Figure Number Location

O-360 Engine Front View Figure 02-00-00.2 p. 7 O-360 Engine Left Side View Figure 02-00-00.3 p. 8 O-360 Engine Top View Figure 02-00-00.4 p. 9 O-360 Engine Rear View Figure 02-00-00.5 p. 10 IO-360 Engine Front View Figure 02-00-00.6 p. 11 IO-360 Engine Left Side View Figure 02-00-00.7 p. 12 IO-360 Engine Top View Figure 02-00-00.8 p. 13 IO-360 Engine Rear View Figure 02-00-00.9 p. 14 Ignition Wiring Diagram Figure 02-00-00.10 p. 15 Oil System Schematic Figure 02-00-00.11 p. 16

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Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

SPARK P LUG

SPARK PLUG

CHT PROBE LOCATION (TYPICAL EACH HEAD)

ALTERNATOR & BELT NOT

PROVIDED WITH ENGINE

THROTTLE LEVER

FUEL LINE

CARBURETOR

Figure 02-00-00.2 • O-360 Engine Front View

STARTER

PRIMING

SYSTEM

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

CYLINDER

CRANKCASE

ASSEMBLY

ACCESSORY

HOUSING

STARTER SUPPORT

ASSEMBLY

PRIMING

SYSTEM

STARTER

INDUCTION

SYSTEM

SPARK P L U G

OIL SUMP

ASSEMBLY

CARBURETOR

MIXTURE

LEVER

OIL FILTER

FUEL

PUMP

FUEL LINE

HARNESS

MAGNETO

Figure 02-00-00.3 • O-360 Engine Side View

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

INTER-CYLINDER BAFFLE

SPARK P L U G

MAGNETO

OIL FILTER

Figure 02-00-00.4 • O-360 Engine Top View

8

MAGNETO

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 02-00-00.5 • O-360 Engine Rear View

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

FUEL INJECTION

MANIFOLD

CHT PROBE LOCATION (TYP ICAL EAC H H EAD)

NOT PROVIDED WITH ENGINE

SPARK PLUG

ALTERNATOR & BELT

STARTER

SPARK PLUG

FUEL

INJECTOR

Figure 02-00-00.6 • IO-360 Engine Front View

FUEL INJECTION

SERVO

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

STARTER SUPPORT

ASSEMBLY

CRANKCASE

ASSEMBLY

STARTER

SPARK PLUG

OIL SUMP

CYLINDER

ASSEMBLY

FUEL INJECTION

MANIFOLD

ACCESSORY

FUEL INJECTION

SERVO

HOUSING

FUEL LINE

OIL FILTER

WIRING

HARNESS

MAGNETO

FUEL PUMP

Figure 02-00-00.7 • IO-360 Engine Left Side View

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Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

FUEL INJECTION

MANIFOLD

FUEL INJ ECTIOR

Figure 02-00-00.8 • IO-360 Engine Top View

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 02-00-00.9 • IO-

360 Engine Rear View

13

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 02-00-00.10 • Ignition Wiring Diagram

14

02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 02-00-00.11 • Oil System Schematic

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Features and Operating Mechanisms Crankshaft - The crankshaft is made from high

quality, aerospace grade steel. All bearing journal surfaces are nitrided. There are 3 kinds of crankshafts: thin-wall, thick-wall, and solid front mains which can be identified by looking at the center of the front of the crankshaft or prop oil cavity. The thin-wall and thick-wall crankshafts are each available as fixed-pitch or constant-speed. Fixed-pitch versions have a plug installed in the inner diameter of the front main, or prop oil, cavity which prevents escape of oil out the front, since there isn’t a prop governor or constant-speed prop for the oil pressure to act upon.

Cylinders - Millennium exclusively. These air-cooled cylinders are manufactured by screwing and shrinking the two major parts, head and barrel, together. The cast heads are made from a special aluminum alloy. All barrels are made from forgings produced to aerospace specifications. They are internally choked and honed to allow optimal operating conditions for the rings and pistons at operating temperatures.

Pistons - The pistons are made from an aluminum alloy. The piston pin is a full floating type with a plug located in each end of the pin. The piston is a 3-ring type with 2 compression rings and 1 oil control ring.

®

Cylinders are used

Connecting Rods - The connecting rods are made from aerospace grade, high quality steel. They have replaceable bearing inserts in the crankshaft ends and bronze bushings in the piston ends. The bearing caps on the crankshaft ends are retained by two bolts with self locking nuts per cap. Caps are tongue and groove type for improved alignment and rigidity.

Camshaft - Valve Operating Mechanism - The camshaft is located above and parallel to the crankshaft. The camshaft actuates hydraulic lifters that operate the valves through pushrods and valve rockers.

Crankcase - The crankcase is made from aerospace grade, stabilized structural aluminum alloy. The assembly consists of two reinforced aluminum alloy castings fastened together by means of studs, bolts, and nuts. The main bearing bores are machined for use with precision type main bearing inserts.

Accessory Housing - The accessory housing is made from an aluminum casting and is fastened to the rear of the crankcase and the top rear of the sump.

Oil Sump - The sump incorporates an oil drain plug, oil suction screen, mounting pad for carburetor or fuel injector, the intake riser, and intake pipe connections.

Cooling System – Superior Vantage Engines are designed to be air-cooled. Baffles are provided to build up air pressure and force the air between the cylinder fins. The air is exhausted to the atmosphere through the rear of the cowling.

Induction System - The distribution of the air to each cylinder is through the center zone of the induction system. This is integral with the oil sump.

Fuel Systems Carbureted

are equipped with a float type carburetor The MA-4-5 carburetors are of the single barrel float type equipped with a manual mixture control and an idle cut-off.

Fuel Injected

equipped with a direct cylinder injected RSA-5 fuel injector. The fuel injection system schedules fuel flow in proportion to airflow. Fuel vaporization takes place at the intake ports. The RSA fuel injection system is based on the principle of measuring airflow and using the air pressure in a stem type regulator, converting the air pressure into a fuel pressure. The fuel pressure (fuel pressure differential), when applied across the fuel metering section (jetting system), makes fuel flow proportional to airflow.

- Superior Air Parts O-360 engines

- IO-360 series engines are

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02-00-00

Description and Operation

Overhaul Manual

O-360 and IO-360 Series Engines

Lubrication System - The full pressure wet sump lubrication system is supplied by a gear type pump. It is contained within the accessory housing.

Priming System - A manual primer system is provided on all engines using a carburetor. Fuel injected engines do not require a manual priming system, relying instead on the fuel injectors for priming.

Ignition System - Dual ignition is furnished by two Unison magnetos with two spark plugs per cylinder.

Electrical System – Engines may be furnished with an alternator, if provided for in the model specification. If an alternator is furnished, installation brackets, hardware and belt are provided. Alternators are available in either 12 or 24 volt systems and a range of amperages.

17

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Airworthiness Limitations

Overhaul Manual

O-360 and IO-360 Series Engines

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Airworthiness Limitations

Overhaul Manual

O-360 and IO-360 Series Engines

AIRWORTHINESS LIMITATIONS

The Airworthiness Limitations Section is FAA approved and specifies maintenance required under sections 43.16 and 91.403 of the Federal Aviation Regulations unless an alternate program has been FAA approved. This section is part of the type design of the O-360 and IO360 engine series pursuant to certification requirements of the Federal Aviation Regulations.

Mandatory Replacement Time

Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification, the O-360 and IO-360 engine series do not contain any components having mandatory replacement times required for type certification.

Mandatory Inspection Intervals

Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification, the O-360 and IO-360 engine series do not contain any components having mandatory inspection intervals other than 100 and 500 hour inspections of magnetos as required by Unison Slick Service Bulletin SB2-80C.

Other Mandatory Intervals or Procedures

Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification, the O-360 and IO-360 engine series do not have any inspection-related or replacement time-related procedures required for type certification.

Distribution of Changes to Airworthiness Limitations

Changes to this Airworthiness Limitations Chapter constitute changes to the type design of the O-360 and IO-360 engine series and require FAA approval pursuant to Federal Aviation Regulations. Such changes will be published in FAA Approved Mandatory Service Bulletins. Superior Vantage Engine Service Bulletins may be obtained by writing to:

Superior Air Parts 621 South Royal Lane, Suite 100 Coppell, Texas 75019

or call: 972-829-4600 or on the web at www.superiorairparts.com

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Airworthiness Limitations

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O-360 and IO-360 Series Engines

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Airworthiness Limitations

Overhaul Manual

O-360 and IO-360 Series Engines

TESTING AND FAULT ISOLATION

General

This section provides the Fault Isolation procedures. Review all probable causes given. The engine electrical diagram and engine oil system schematic are provided as an additional aid in determining probable cause. Testing is limited to continuity checks of the ignition wiring harness.

Table 72-00-03.1 • Special Tools and Equipment

Item Vendor

Electrical Tester Commercially Available

Table 72-00-03.2 • Abnormal Operating Procedures

Special tools and equipment are listed in

•

Table 72-00-03.1.

•

The Fault Isolation procedures are listed in Table 72-00-03.2.

•

The engine ignition diagram is provided in Figure 02-00-00.10.

•

The engine oil system is provided in Figure 02-00-00-11.

Symptom Table

Engine will not start 72-00-03.3 Rough Idling 72-00-03.4 Engine Not Able to Develop Full Power 72-00-03.5 Rough Engine Operation 72-00-03.6 Low Power and Engine Runs Rough 72-00-03.7 Low Oil Pressure On Engine Gage 72-00-03.8 High Oil Temperature 72-00-03.9 Excessive Oil Consumption 72-00-03.10

Troubleshooting WARNING

ENGINE WITHOUT A PRELIMINARY EXAMINATION CAN CAUSE FURTHER DAMAGE TO A DISABLED COMPONENT AND POSSIBLE INJURY TO PERSONNEL. MAKE SURE THOROUGH INSPECTION AND TROUBLESHOOTING PROCEDURES ARE ACCOMPLISHED. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.

WARNING EYES AND SKIN. PUT ON SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

: OPERATION OF A DEFECTIVE

: HOT OIL MAY CAUSE BURNS TO

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE

: FUEL IS TOXIC AND

: The Fault Isolation sequence is in order of

approximate ease of checking, not necessarily in order of probability.

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72-00-03

Testing and Fault Isolation

Overhaul Manual

O-360 and IO-360 Series Engines

Table 72-00-03.3 • Engine Will Not Start

Probable Cause Correction

No Fuel Fill with fuel Excessive Priming Leave ignition "Off" and mixture control in "Idle

Cut-Off", open throttle and clear cylinders by cranking a few seconds. Turn ignition switch "On" and proceed to start.

Defective ignition wire Check with electric tester, and replace any

defective wires.

Dead battery Replace battery. Malfunction of magneto breaker Clean points. Check internal timing of

magnetos

Lack of sufficient fuel flow Disconnect fuel line and check fuel flow Water in fuel injector or carburetor Drain fuel injector or carburetor and fuel lines. Internal failure Check oil screens for metal particles. If found,

complete overhaul of the engine may be required.

Table 72-00-03.4 • Rough Idling

Probable Cause Correction

Incorrect idle mixture Adjust mixture Leak in the induction system Tighten all connections in the induction system.

Replace any damaged parts.

Incorrect idle adjustment Adjust throttle stop to obtain correct idle. Uneven cylinder compression Check condition of piston rings and valve seats

Faulty ignition system Check entire i gnition system

Table 72-00-03.5 • Engine Not Able To Develop Full Power

Probable Cause Correction

Leak in the injection system Tighten all connections and replace damaged

parts. Throttle lever out of adjustment Adjust throttle lever. Improper fuel flow Check strainer, gage and flow at the fuel inlet.

Restriction in air scoop Examine air scoop and remove restrictions. Improper fuel Drain and refill tank with proper fuel

Faulty ignition Tighten all connections. Check system with

tester. Check ignition timing. Internal Timing Check rocker arm motion as engine is rotated

on nose stand.

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72-00-03

Testing and Fault Isolation

Overhaul Manual

O-360 and IO-360 Series Engines

Table 72-00-03.6 • Rough Engine Operation

Probable Cause Correction

Broken engine mount Replace or repair mount. Mounting bushings worn Install new mounting bushings. Unstable compression Check compression.

Table 72-00-03.7 • Low Power & Engine Runs Rough

Probable Cause Correction

Mixture too rich; indicated by sluggish engine operation, red exhaust flame at night. Extreme cases indicated by black smoke from exhaust

Mixture too lean; indicated by overheating or back firing

Leaks in induction system Tighten all connections. Replace damaged

Defective spark plugs Clean and gap or replace spark plugs. Improper fuel Drain and refill tank with proper grade.

Magneto breaker points not working properly Clean points. Check internal timing of

Defective ignition wire Check wire with electric tester. Replace

Defective spark plug terminal connectors Replace connectors on spark plug wire.

Readjustment of fuel injector or carburetor may

be required by authorized personnel.

Check fuel lines for dirt or other restrictions.

Readjustment of fuel injector or carburetor may

be required by authorized personnel.

parts.

magnetos.

defective wire.

Table 72-00-03.8 • Low Oil Pressure On Engine Gage

Probable Cause Correction

Lack of oil Add to proper level. Air lock or dirty relief valve Clean relief valve. Leak in line Inspect gasket between accessory housing and

crankcase. High oil temperature See Table 72-00-03.9, “High Oil Temperature”.

Defective pressure gage. Replace defective gage. Stoppage in oil pump intake passage Check line for obstruction. Clean suction

strainer.

3

Testing and Fault Isolation

72-00-03

Overhaul Manual

O-360 and IO-360 Series Engines

Table 72-00-03.9 • High Oil Temperature

Probable Cause Correction

Insufficient air cooling Che c k air inlet and outlet for deformation or

obstruction. Insufficient oil supply Fill to proper level with specified oil. Low grade of oil Replace with oil conforming to specifications.

Clogged oil lines or strainers Remove and clean oil strainers. Excessive blow-by Check condition of engine rings. Replace if worn

or damaged. Failing or failed bearing Examine sump for metal particles. If found,

engine overhaul may be required. Defective temperature gage Replace gage.

Table 72-00-03.10 • Excessive Oil Consumption

Probable Cause Correction

Low grade of oil Fill tank with oil of proper weight and grade. Failing or failed bearings Check sump oil for metal particles. Worn piston rings Install new rings.

Incorrect installation of piston rings I nstall new rings. Failure of rings to seat on new cylinders Use mineral base oil. Climb to cruise altitude at

full power and operate at 75% cruise power

setting until oil consumption stabilizes. See

Break-In Procedures, Special Procedures

Section of this manual. Oil siphoned from engine in flight Insure that oil filler cap is tight and that o-ring is

in good condition. Insure that breather hose exit

is cut and located to avoid creating a vacuum in

the breather hose.

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72-00-03

Testing and Fault Isolation

Overhaul Manual

O-360 and IO-360 Series Engines

SPECIAL PROCEDURES

General Break-In Procedures

This section provides the Break-In Procedures to achieve satisfactory ring seating and long cylinder life. On all new Vantage engines, after top overhaul or major engine overhaul, break-in is critical.

NOTE

: Refer to the engine warranty. Violation

of these procedures will void the engine's warranty.

Special Tools and Equipment

•

Standard aviation shop tools are required.

•

Engine test stand.

•

The aircraft can be a suitable test stand for running-in cylinders.

Break-In Procedures WARNING

ENGINE WITHOUT A PRELIMINARY EXAMINATION CAN CAUSE FURTHER DAMAGE TO A DISABLED COMPONENT AND POSSIBLE INJURY TO PERSONNEL. MAKE SURE THOROUGH INSPECTION AND TROUBLESHOOTING PROCEDURES ARE ACCOMPLISHED. THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.

Prior to Break-In Start-Up

•

Engine oil sump should be filled with 100% straight weight mineral oil. Use MIL-L-6082, specific grade depending on ambient temperature. Refer to chapter 72-00-13 for fluid requirements.

•

Engine must be pre-oiled and oil pressure obtained prior to start-up.

•

To pre-oil an engine, do the following:

1. Attach pressure-oiling equipment to one

2. Engine baffles and seals must be in

3. Verify accuracy of instruments required

: OPERATION OF A DEFECTIVE

end of the main gallery and force oil through the galley at 35 psi until oil flows from the opposite galley with the plug removed from the front end of the opposite galley.

good condition and properly installed. for engine operation.

CAUTION

: BREAK-IN OF AN ENGINE IN FRIGID CONDITIONS CAN LEAD TO CYLINDER GLAZING AND FAILED BREAK-IN DUE TO LOW OIL TEMPERATURE. IT IS RECOMMENDED THAT OIL TEMPERATURE BE MAINTAINED BETWEEN 180° AND 190°F.

Break-In Ground Run

Flight propeller may be used if test club is

•

not available.

•

Head aircraft into the wind.

•

Start engine and observe oil pressure. Oil pressure should be indicated within 30 seconds. If this does not occur, shut down engine and determine cause.

•

Run engine just long enough to confirm all components are properly adjusted and secured. There must be no fuel and/or oil leaks.

•

Install cowling.

•

Operate engine at 1000 -1200 RPM until oil has reached minimum operating temperature 120 °F.

•

Check magneto drop at normal RPM.

•

If engine is equipped with a controllable pitch propeller, cycle only to a 100 RPM drop.

•

Shut down engine and check for fuel and/or oil leaks and repair any discrepancies.

•

At no time should cylinder head temperature be allowed to exceed recommended maximum cruise limit of 430°F.

Break-In Flight Operation

•

Perform normal pre-flight and run-up in accordance with the Installation and Operation Manual, SVIOM01 (remember: cycle controllable pitch prop to only a 100 RPM drop). Keep ground runs to a minimum.

•

Conduct normal take-off at full power, full rich mixture, to a safe altitude.

NOTE:

In certain geographic locations and

weather conditions (eg; high density altitudes) “Full Rich” operation may not be practical. In this event, substitute the requirement of “Full Rich” as discussed in this chapter with the “richest practical setting”.

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72-00-04

Special Procedures

Overhaul Manual

O-360 and IO-360 Series Engines

NOTE

: Verify the crankcase breather and vent

lines are correctly installed and positioned. Excessive oil discharge through the breather can often be directly related to an improperly installed or restricted breather line.

•

Maintain shallow climb. Use caution to not overheat the cylinders. Should overheating occur, reduce power and adjust mixture appropriately.

•

Monitor RPM, oil pressure, oil temperature and cylinder temperature.

•

During the first hour of operation, maintain level flight at 75% power. Vary the power setting every 15 minutes during the second hour between 65-75%.

•

Avoid long descents at cruise RPM and low manifold pressure (could cause ring flutter).

•

Continue flying at 65-75% power and full rich mixture on subsequent flights, while

monitoring RPM, Oil Pressure, Oil Temperature, Cylinder Head Temperature and oil consumption. Continue until oil consumption stabilizes and cylinder head temperatures drop (and stabilize). These are indications that the piston rings have seated and the cylinders are broken in.

•

At no time should cylinder head temperature be allowed to exceed recommended maximum cruise limit 430°F.

•

After landing, check again for any fuel and/or oil leaks, or other discrepancies, and repair as required.

Post Break-In Procedures

•

After break-in, drain all mineral oil. Examine this oil for foreign matter or metal particle content.

•

Fill with ashless dispersant of the appropriate grade for the expected normal operating conditions and ambient temperature.

2

72-00-04

Special Procedures

Overhaul Manual

O-360 and IO-360 Series Engines

ENGINE REMOVAL

General

This section contains engine removal procedures.

Equipment and Materials to accomplish removal procedures are listed in Table 72-00-05.1.

NOTE:

Removal

• Remove the engine from the airframe as

NOTE:

•

NOTE: Standard aviation shop tools

are required.

Table 72-00-05.1

Equipment and Materials List

Item Vendor

Engine Stand

Engine Hoist Protective Covers for

Open Lines or Ports

Commercially Available

follows:

Identify each item as the item is

disconnected from the engine to aid in reinstallation.

Turn all cockpit switches and fuel selector valves to OFF. Remove aircraft cowling as required. Disconnect the battery ground cable. Disconnect the start cable. Remove engine baffles as required. Remove air intake ducting and heat ducting as required. Remove engine exhaust system as required. Disconnect and remove the “B” nuts from the spark plugs. Tag and disconnect the engine wiring bundles from all applicable components. Remove all clamps attaching engine wire bundles to engine components and route bundles clear of the engine. Drain the engine oil from the sump. Replace drain plug and tighten. Remove propeller in accordance with the airframe manufacturer’s instructions.

•

Consult the airframe manufacturer for engine to airframe connections.

WARNING

: PLACE A SUITABLE STAND UNDER THE AIRCRAFT TAILCONE IF NEEDED BEFORE REMOVING THE ENGINE. THE LOSS OF WEIGHT MAY CAUSE THE AIRCRAFT TAIL TO DROP.

•

Attach a hoist to the engine lifting eye bracket and relieve the weight from the engine mounts. Only the lifting eye bracket installed on the backbone of the crankcase should be used to hoist the engine.

•

Remove the engine mounts and engine as follows:

1. Loosen and remove the engine mounts bolts in accordance with manufacturer’s instructions.

2. Hoist the engine vertically out of the nacelle and clear of the aircraft.

NOTE:

Hoist the engine slowly and make sure

that all wires, lines, and hoses have been disconnected.

3. Install the engine onto a transportation stand, dolly, or an engine shipping container base.

•

Install protective covers/plugs on any remaining open fuel, oil/hydraulic lines, and electrical leads and exhaust ports.

Preservation

•

If the engine is to be stored for longer than 30 days, refer to the Preservation and Storage section of this manual for procedures and materials.

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Engine Removal

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O-360 and IO-360 Series Engines

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72-00-05

Engine Removal

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O-360 and IO-360 Series Engines

DISASSEMBLY

General

This section contains disassembly procedures. When necessary, disassembly illustrations are also provided. All item number references in the text are specific to this manual and the figures cited.

Table 72-00-06.1 • Disassembly Materials

Description Source

Penetrating Oil Commercially Available

Parts for Discard

Parts to be discarded are listed in Table 72-00-06.2.

Table 72-00-06.2 • Discard Parts

Disassembly Materials

The materials required for disassembly are listed in Table 72-00-06.1.

NOTE:

Equivalent substitutes may be used.

Nomenclature

All Engine Oil, Air and Fuel Hoses

Gaskets, Oil Seals, and O-Rings

Bearing Inserts (Connecting Rod and Crankshaft)

Piston Rings and Piston Pins

Stressed Bolts and Fasteners

Intake and Exhaust Valves, Valve Guides and Valve Keepers

Crankshaft Gear Attaching Bolt

Connecting Rod Nuts and Bolts

All Lockwashers, Circlips, Retaining Rings, Locktabs and Locknuts

Counterweight Bushings in Crankshaft and Counterweights (if applicable)

Counterweight Washers (if applicable)

Vermatherm (Oil Temperature Bypass Valve)

Special Tools and Equipment

Special tools and equipment required for disassembly are listed in Table 72-00-06.3.

NOTE:

Standard reciprocating engine aviation

shop tools and equipment are used unless otherwise specified.

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72-00-06

Engine Disassembly

Overhaul Manual

O-360 and IO-360 Series Engines

Table 72-00-06.3 • Special Tools and Equipment

Nomenclature Source

Compressor, Piston Ring Commercially Available Expander, Piston Ring Commercially Available Puller, Slide Hammer-Medium Commercially Available Compressor, Valve Spring Bar Commercially Available Intercylinder Baffle Tool Commercially Available Puller, Valve Guide Commercially Available Puller Set, Oil Seal Commercially Available Stand, Vertical Nose Support Commercially Available Tool, Hydraulic Tappet Removal Commercially Available

General Disassembly Procedures

• Place engine in horizontal position on a

transfer cart.

WARNING

: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT ON PERSONNEL PROTECTIVE GEAR.

Remove the oil drain plug and drain the oil

•

from the engine, if not previously drained.

•

Remove the starter ring gear support.

•

Perform visual inspection during disassembly and immediately after disassembly. All individual parts should be laid out in an orderly manner as they are removed.

•

All loose studs, cracked baffles, and loose or damaged fittings should be tagged to prevent being overlooked during regular inspection.

•

Tag all components and parts as they are removed. Bag loose assemblies or attaching hardware.

•

Prior to starting the component or parts disassembly phase, engine may be placed on a vertical nose support stand.

Disassembly WARNING

: FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. AVOID EYE AND SKIN CONTACT. USE PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING

: PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE.

Removal of Carburetor and Priming System

(1) Remove engine fuel lines (30, Figure

72-00-09.37) and all attaching hardware. (a) Remove engine fuel priming system

attaching hardware clamps, (25, 30, 45 Figure 72-00-09.36) screws (35) and nuts, (40). Disconnect tube (1, 5, 10, 15) coupling nuts at cylinder head and attaching tee tubes (20).

(2) Remove the carburetor on O-360 series

engines as follows. (a) Remove nuts (1, Figure 72-00-

09.37), lockwashers (2) and flat washers (3) from studs four places.

(b) Remove carburetor (7) from studs

and discard gasket (4).

(c) Remove elbow (5) and discard o-

ring (6).

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72-00-06

Engine Disassembly

Overhaul Manual

O-360 and IO-360 Series Engines

Fuel injection system removal

(1) Remove engine fuel injection manifold

tubing clamps (70, 75 Figure 72-00-

09.39), nuts (85), and screws (80).

(2) Disconnect injector tubing (55, 60), eight

places at fittings (40), elbow (25), and injector nozzle assembly (90). Re move nozzle assemblies (90) four places.

(3) Remove fuel manifold bracket (1)

retaining nuts, washers, (5) and bolts (10). Remove manifold (15) retaining bolts (25) and washer (20).

(4) Disconnect and remove fuel hoses (30,

35, Figure 72-00-09.38). Remove nuts, (25) lockwashers (20), and flat wa shers (15) from studs. Remove injector se rvo assembly (10) and remove gasket and spacer (5).

Magneto and harness removal

(1) Unscrew ignition wiring harness leads

(5, 10, Figure 02-00-00.10) from the top and bottom spark plugs (50). Remove harness attaching caps (5), two places, from the magneto. Remove spark plugs (50) from cylinder.

(2) Remove magneto (15, Figure 72-00-

09.40) attaching nut (30), washer (25), and clamp (20). Remove the magneto (15) and discard gasket (10). Remove the adapter (5) and gasket (1). Remove cotter pin (40), nut, and washer. Remove magneto gear (35) and install nut back on threads to prevent damage to drive shaft threads.

Oil level gage housing Removal

(1) Unscrew the oil gage (10, Figure 72-

00-09.28) and remove the oil gage housing (5). Discard seals (15, 20).

Fuel pump removal (as required)

(1) Remove fuel pump screws (15,

Figure 72-00-09.32) and washers (10). Remove fuel pump (5) and gasket (1). Remove elbows (25, 30) and discard o-rings (20).

Oil filter and Adapter removal

(1) Unscrew the oil filter (40, Figure 72-

00-09.35). Remove the vernatherm (temperature control valve) (35). Remove screws (30), washers (15,

20), and nut (25) that secure the oil filter adapter (10) to the accessory housing. Discard gasket (5). Remove cooler bypass plug (55), and discard gasket (50).

Vacuum pump or cover removal

(1) Remove the vacuum pump (or

cover) attaching nuts (40, Figure 7200-09.31), lockwashers (35) and flat washers (30). Remove pump (or cover (20) as appropriate) and discard gasket (15). Remove adapter assembly (25). Discard gasket (10) and remove vacuum gear (1) and thrust washer (5) from housing. Remove oil seal (55) and discard.

Propeller governor removal (as required)

(1) Remove the propeller governor oil line.

Remove any clamps. Remove elbows (10, 15) and any attaching hardware, as required, to allow hose removal, discard o-ring (20).

(2) Remove the cover nuts (30) as required,

(Figure 72-00-09.33), lockwashers (25), and flat washers (20). Remove cover (65) and discard gasket (60). Remove retaining ring (55) and thrust washer (5). Remove adapter nuts (30), lockwashers (25), and flat washers (20). Remove propeller governor adapter (15). Discard gasket (10). Tag and save thrust washer (5). Remove gear shaft (1) from housing.

Accessory Housing Assembly Removal

(1) Remove the accessory housing

assembly by removing the bolts (15, Figure 72-00-09.23), lockwashers (10), and flat washers (5). Remove bolt (20), washer (10), and nut (25) two places. Remove accessory housing (40) and gasket (35). Remove fuel pump plunger (1, Figure 72-00-09.24). (a) Remove nuts (90) and washers

(85) to remove oil pump housing assembly (80). Remove oil pump drive shaft (115) and impeller gears (105, 110).

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O-360 and IO-360 Series Engines

Idler gears and shaft removal

(1) Remove idler gears (15,20, Figure

72-00-09.20). Remove idler shaft mount screws (5) and nut (10). Remove idler shafts (1) from crankcase.

Starter and alternator attaching hardware removal

(1) Remove starter mount bolt (15,

Figure 72-00-09.42), nuts (20), lockwashers (10), and flat washers (5). Remove starter (1) from crankcase. (a) Remove alternator mount bolt

(10, Figure 72-00-09.43) and washer (5) to loosen drive belt. Remove cotter pin (45), slotted nut (40), support bolt (25), and shims (35). Remove cotter pin (45), slotted nut (40), shims (35), and support bolt (30). Remove bolts (20, 90) and flat washers (15, 85) from strut bracket (80). Remove strut support (80) and remove alternator.

(b) Remove alternator bracket (55)

by removing bolts (60) and lock plate (50). Remove bolt (75), flat washer (70), and adjusting link (65). Visually inspect hardware and bag for reuse if not damaged.

Oil sump and induction disassembly

(1) Remove screws (25, Figure 72-00-

09.29), lockwashers (20), and flat washers (15) from intake pipe flange (10). Discard gaskets (1).

(2) Remove clamps (35), intake hoses (30),

and intake tubes (5) from oil sump assembly.

(3) Remove oil screen plug (85, Figure 72-

00-09.27), discard gasket (80), and remove oil suction screen (75). Inspect for debris.

(4) Remove bolts (15,20), flat washers (25,

30), lockwashers (25), and nuts (35) from sump assembly flange. Discard gasket (11) and remove intake connection pipes (12) from sump assembly.

Cylinder drain tubes removal

(1) Loosen hose clamps (85, Figure 72-00-

09.17) on hose (80) at drain nipple (75). Slide away from drain nipple (75). Loosen gland nut at cylinder head fitting and remove tube assembly (90) from cylinder.

Intercylinder cooling baffle removal

(1) Remove the intercylinder cooling baffles

(1, Figure 72-00-09.26) using intercylinder baffle tool. Turn the baffle retaining hook (10) so that it disengages the retainer (5). Remove the baffle (1) and hook (10) from between the cylinders.

Cylinder removal

(1) Remove the valve cover screws (130,

Figure 72-00-09.15) and cover (125) and discard gasket (120). Rotate the crankshaft to place the piston of the No. 1 cylinder at top center of the compression stroke.

NOTE:

CAUTION SUPPORTED TO PREVENT DAMAGE TO THE ROD AND CRANKCASE. SUPPORT EACH

With the piston in this position both

valves will be closed and the piston extended away from the crankcase to avoid damage when the cylinder is removed.

(2) Remove the valve rocker shaft caps

(20), the valve rocker shaft (15), valve rocker arms (5), and the exhaust valve stem cap (115) from cylinder assembly. Remove the pushrod (1) by grasping the rod end and pulling it through the rod tube (40). Remove nut (60), spring (55), and lockplate (50). Pull rod tube through cylinder head and discard tube seals (35, 45). (a) Remove cylinder assembly by

: THE CONNECTING ROD MUST BE

removing nuts from cylinder base. Remove cylinder by pulling straight away from crankcase. As the cylinder is being pulled away, hold the piston to prevent damaged. Discard cylinder base seal.

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O-360 and IO-360 Series Engines

CONNECTING ROD WITH HOLD DOWN PLATES TOOL OR RUBBER BANDS (OR DISCARDED CYLINDER BASE SEALS) LOOPED AROUND THE CYLINDER BASE STUD.

(3) Remove the piston pin (35, Figure 72-

00-09.6) using a piston pin drive tool. Drive pin (35) from piston to remove piston (30) from the connecting rod (5).

NOTE:

CAUTION THROUGH THE GUIDES.

CAUTION OR SCORE PISTONS WHEN REMOVING THE RINGS.

Removal of the remaining cylinders

and pistons may be done in any sequence, but less turning of the crankshaft is involved if the cylinders are removed in firing order 1-3-2-4.

(4) Compress valve springs (90, 95, Figure

72-00-09.15) with spring compressor tool, while supporting cylinder, far enough to remove the valve cylinder keys (105, 110).

If the valve keys are stuck in the spring

seat, a light blow with a leather mallet on top of the compressor tool will release keys.

: DO NOT DRIVE THE VALVES

(a) Remove upper valve spring seats

(95, 100), inner and outer springs (85, 90), and lower valve spring seats (75, 80) from rocker box. Keep parts for each valve (65, 70) separate. Hold valves by the stems to keep them from dropping out of the cylinder and remove cylinder from the holding block. Reach inside and remove valves. If valves are difficult to remove, push valves back in and clean carbon from stems.

: BE CAREFUL NOT TO SCRATCH

(b) Using the piston ring expander tool,

remove the rings (40, 45, Figure 7200-09.6) from all pistons. Remove

the rings in order starting with the top ring and work down.

(5) Remove and disassemble the hydraulic

lifter assembly.

CAUTION TAPPET ASSEMBLY TOGETHER DURING ALL OVERHAUL OPERATIONS. ALL COMPONENT PARTS ARE TO BE REASSEMBLED WITH THEIR ORIGINAL MATING PARTS AND EACH ASSEMBLY REINSERTED IN ITS ORIGINAL LOCATION.

Crankcase Disassembly

NOTE:

: MAINTAIN THE PARTS OF EACH

(a) Using hydraulic tappet tool, remove

the pushrod socket (30, Figure 7200-09.15) by placing heavy grease on ball end of the "T". By inserting the ball end in the tappet and withdrawing, the socket will adhere to the grease.

(b) Using the hollow end of the tool,

push it over the plunger and withdraw the plunger. If the tool is not available, remove the pushrod socket with fingers or by using needle nose pliers. Insert a piece of wire bent at a right angle into the plunger between the plunger and the lifter body. Turn 90 degrees to engage a coil of spring and draw out the plunger assembly.

(1) Remove nuts (25, 45, 70, 85, Figure 72-

00-09.11 and 72-00-09.12), bolts (5, 30, 55, 90, 95), and washers (15, 20, 35, 40, 60, 65, 80). Draw or pull the thrubolts (1) from the crankcase using cylinder base nuts and washers and/or spacers.

(2) Separate crankcase using care not to

allow camshaft to fall to floor. Caution should be used to keep the right case thru-studs from becoming misaligned when separating the crankcase halves (60, Figure 72.00-09.5).

Carefully pull crankshaft nose seal

from crankcase forward on crankshaft to aid in crankcase half separation.

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O-360 and IO-360 Series Engines

(3) Remove the bearing inserts (5, 10,

Figure 72-00-09.2), lifter bodies (20), and camshaft. Remove and discard oring seals (10, 75).

NOTE:

Crankshaft Disassembly

Place each lifter body in its proper

location in a cleaning basket. The lifter bodies must be assembled in their original locations if reused.

(4) Remove all threaded plugs and discard

oil seals.

(1) With the crankshaft firmly supported at

the front and rear main bearing journals (or secured on a nose stand), remove rod nuts (15, Figure 72-00-09.6). Remove the rods (5) by tapping on the

rod bolts (10) with a soft hammer. Discard the connecting rod bearing (1), bolts (10), and nuts (15).

NOTE:

Maintain each cap and rod as an

assembly. Rods and caps are not interchangeable.

(2) To remove the crankshaft gear (5,

Figure 72-00-09.3), flatten the lockplate (10) and remove screw (15). Tap the gear lightly with a soft mallet or brass drift. Remove the crankshaft oil seal and discard.

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CLEANING

General

Cleanliness of the aircraft engine is crucial to its optimum performance. This section provides information on materials, tools, and guidelines for cleaning.

After the initial visual inspection of internal engine parts, it is necessary to thoroughly clean the engine components for detailed inspection. Since this visual inspection is made during and after disassembly, the components should be cleaned afterwards and tagged to facilitate further non-destructive inspection methods. This identification procedure will also help prevent these components from being overlooked.

It is important to remember to visually inspect an engine prior to cleaning. Residue from the engine’s operation can provide information as to hidden defects or other dangerous conditions.

Tools and Materials

For tools required during cleaning, refer to Table 72-00-07.1. For consumable materials required during cleaning, refer to Table 72-00-07.2.

Table 72-00-07.1

Equipment Required for Cleaning

Item Vendor

Brush (soft and stiff bristles)

Immersing tank

Scraper (wood)

Grit blaster

NOTE: Equivalent substitutes may be used.

Cleaning Instructions

Two (2) processes are used in cleaning engine parts; degreasing to remove dirt and sludge (soft carbon) and the removal of hard carbon by decarbonizing, brushing or scraping and grit blasting.

Commercially Available

CAUTION ABRASIVES WITH THE GRIT BLASTING EQUIPMENT.

Degreasing

Degreasing is accomplished by immersing or spraying the part in solution of white furnace oil (38-40 specific gravity) or another suitable solvent such as Varsol or Perm-A-Chlor.

Item Vendor

Cleaning solvent or degreaser such as white furnace oil, Varsol, or Perm-A-Chlor

Decarbonizing solutions such as Gunk, Penetrol, Carbrax, Super-Chemco, or Gerlach #70

Isopropyl Alcohol Aerosol electrical contact

cleaner Lubricating Oil (SAE 20)

Corrosion preservative oil

Abrasive cloth (crocus cloth)

NOTE

WARNING PROTECTION. SOME CHEMICAL SOLUTIONS CAN CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR EACH CLEANING SOLUTION.

CAUTION DEGREASING SOLUTIONS CONTAINING CAUSTIC COMPOUNDS OR SOAP ARE USED, EXTREME CARE MUST BE EXERCISED. THESE COMPOUNDS IN

: DO NOT USE SAND OR METALLIC

Table 72-00-07.2

Materials Required for Cleaning

Commercially Available

: Residue from the solvent washing must

be captured and contained to prevent contamination of the surrounding environment.

: USE THE CORRECT PERSONAL

: IF ANY WATER-MIXED

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Cleaning

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O-360 and IO-360 Series Engines

ADDITION TO BEING POTENTIALLY DANGEROUS TO ALUMINUM AND MAGNESIUM, MAY BECOME IMPREGNATED IN THE PORES OF THE METAL AND CAUSE OIL FOAMING WHEN THE ENGINE IS RETURNED TO SERVICE. WHEN USING THESE WATER-MIXED SOLUTIONS ALWAYS THOROUGHLY RINSE THE PART IN CLEAN BOILING WATER. REGARDLESS OF METHOD OR SOLUTION USED ALWAYS COAT AND SPRAY ALL PARTS WITH LUBRICATING OIL IMMEDIATELY AFTER CLEANING IN ORDER TO PREVENT CORROSION.

CAUTION PROTECTION. HEATED PARTS WILL CAUSE BURNS.

Decarbonizing

Decarbonizing is usually accomplished by immersion of the part in a decarbonizing solution (usually heated). Decarbonization solutions such as Gunk, Penetrol, Carbrax, SuperChemco, Gerlach No. 70 or any suitable solution. Refer to the above caution for watersoluble decarbonizers. Remove hard carbon deposits after degreasing by brushing, scraping or grit blasting. After cleanin g, rinse the parts in petroleum solvent, dry, and remove loose particles by blowing the particles out with compressed air. Use a shop air supply with an appropriate water trap.

Decarbonizing solutions will usually remove most of the enamel from machined surfaces. All remaining enamel should be removed by grit blasting particularly in the narrow areas between cylinder cooling fins.

Valve seats may be left unprotected during decarbonizing processes. This will facilitate the reconditioning of the valve seat in later procedures.

CAUTION EXERCISED WHEN USING A DECARBONIZING SOLUTION. IT IS RECOMMENDED THAT THE USE OF HEATED SOLUTIONS BE AVOIDED UNLESS THE OPERATOR IS THOROUGHLY FAMILIAR WITH THE PARTICULAR SOLUTION BEING USED. IN ADDITION THE OPERATOR IS

: USE THE CORRECT PERSONAL

: EXTREME CAUTION SHOULD BE

STRONGLY ADVISED AGAINST IMMERSING STEEL AND MAGNESIUM PARTS IN THE SAME DECARBONIZING TANK, BECAUSE THIS PRACTICE OFTEN RESULTS IN DAMAGE TO THE MAGNESIUM PARTS FROM CORROSION.

CAUTION SURFACES. MASK ALL MACHINE SURFACES PLUG ALL DRILLED OIL PASSAGES TO PREVENT DAMAGE OR ENTRY OF FOREIGN MATTER.

CAUTION AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 20 PSI. DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. THIS WILL HELP PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQ UIPMENT. IF YOU GE T AN EYE INJURY, SEEK MEDICAL ATTENTION

CAUTION BRUSHES OR METAL SCRAPERS ON ANY BEARING, MACHINED OR CONTACT SURFACES.

CAUTION THE PISTON RING GROOVES. USE A WOODEN SCRAPER.

Scratch and Corrosion Removal

Remove corroded or pitted surfaces on the fillets at the edges of crankshaft main and crankpin journal surfaces, and thrust bearing races by polishing with crocus cloth or other mild abrasive material. Refer to the Fits and Clearances section of this manual for limits.

Shallow or small scratches, minor abrasions, or pitting on gears or screwed fittings may be dressed out with a fine abrasive (crocus) cloth, small file, or polishing stone. Refer to the Fits and Clearances section of this manual for limits.

Accessory Mounts

Clean mounting pads and studs by wiping with a clean cloth moistened with solvent. Use care to remove sludge and debris from around the bases of the studs.

: DO NOT DAMAGE MACHINED

: WHEN YOU USE COMPRESSED

: DO NOT USE WIRE BRISTLE

: DO NOT USE GRIT BLASTING ON

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Cleaning

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O-360 and IO-360 Series Engines

NOTE:

WARNING WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

Fuel Injector and Primer Nozzles

Remove the nozzle. Submerge in a cleaning solvent such as Stoddard Solvent or MEK or equivalent. Allow soaking for several hours. Remove from solvent and dry with dry and clean compressed air. Ultra-sound cleaning methods may also be used.

WARNING WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 PSI. DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. IF YOU GET AN EYE INJURY, GET MEDICAL ATTENTION.

CAUTION CLEAN OR DISASSEMBLE FUEL OR AIR BLEED NOZZLES.

Use care to not force debris into drilled

areas, passages, ports, or threaded receptacles.

: SOLVENT IS TOXIC. USE IN

: WHEN YOU USE COMPRESSED

: DO NOT USE A SHARP TOOL TO

Screens and Filters

A. Fuel system filters

(1) Fuel screens may be soaked and

rinsed in clean solvent and dried with compressed air.

B. Oil system filters

(1) Oil screens may be soaked and

rinsed in clean solvent and dried with compressed air.

(2) Disposable external oil filter

elements are not cleaned.

C. Air induction system filters

(1) Foam air filters may be rinsed in

clean solvent then washed with mild detergent and water and reinstalled.

Paper air filter elements are not cleaned

WARNING WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 PSI. DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. IF YOU GET AN EYE INJURY, GET MEDICAL ATTENTION.

Accessories

Refer to the various manufacturers’ manuals for information regarding the cleaning of these components.

: SOLVENT IS TOXIC. USE IN

: WHEN YOU USE COMPRESSED

NOTE: Under normal conditions, the shield

and screen are NOT removed from the nozzle assembly. If removal is necessary, both must be thoroughly cleaned prior to reassembly. The shield must have a tight fit on the body.

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O-360 and IO-360 Series Engines

Preservation and Corrosion Prevention

A. Upon conclusion of visual inspection

and all cleaning operations, rinse parts with petroleum solvent. Dry and remove any loose particles by air blast. Apply a liberal coating of preservative oil to all surfaces.

B. For parts that will be repainted, do the

following: (1) Be sure that the part is thoroughly

degreased, clean, and dry.

(2) Prime and paint in accordance with

Repair section.

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INSPECTION AND CHECK

General

The inspection of engine parts consists of three (3) categories: visual, structural, and dimensional. Visual and structural inspections deal primarily with structural defects. The dimensional checks are concerned with the size, shape, and fit of a given part. Upon successful completion of inspection, coat all steel parts with preservative oil.

Visual inspections should precede all other inspections. No cleaning operation should be permitted until a complete initial visual inspection is made of the part in question. Residue from the engine’s operation can provide additional information as to hidden defects or other dangerous conditions. Refer to the Cleaning section of this manual.

Structural inspections will include checking flatness, out-of-roundness, and passageway clearance. They may also include magnetic particle and dye penetrant procedures as well as eddy-current, ultra-sonic, or other nondestructive testing methods.

For dimensional inspections, refer to the tables set forth in the Fits and Clearances section of this manual.

For repairs required prior to a final inspection or dimensional check of a part, refer to th e Repairs section of this manual.

The use of a recording form is recommended during the inspection procedures. The form should be prepared so that all inspection and subsequent repair and reassembly procedures can be noted as they are completed. This usage will also help prevent the omission of components during the inspections and will provide a place to record findings and comments resulting from the inspections.

Materials and Tools

Materials required for inspection are listed Table 72-00-08.1. Special tools and equipment required for inspection are listed Table 72-00-

08.2.

Table 72-00-08.1

Inspection Materials

Item Source

Magnetic base oil

Preservative oil Dye penetrant and

developer Acetone

Mineral Spirits SAE #10 lubricating oil

(check fuel nozzle flow)

NOTE: Equivalent substitutes may be used.

Table 72-00-08.2

Special Tools and Equipment

Item Source

Calipers and micrometers: ID and OD

10X Magnifying Glass

Machinist’s Ruler

Small Flashlight

Vee Blocks

Dial Indicator

Spring Tension Tester Magnetic Particle

Inspection Equipment

NOTE: Equivalent substitutes may be used.

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

Commercially

Available

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Inspection and Check

Overhaul Manual

O-360 and IO-360 Series Engines

General Inspection Procedures

All journal surfaces must be checked for galling, scores, misalignment, and out-of-round condition. Pins and shafts must be inspected for straightness.

Examine gears for evidence of pitting and excessive wear. This evidence is of special importance when found on the involute of the gear teeth. Deep pit marks in this area are reason to reject the part. Bearing surfaces of all gears may have minor abrasions dressed out with fine abrasive cloth but should be free from deep scratches.

Excessively worn or mutilated threads should be rejected. Small defects (such as slight nicks or burrs) may be dressed out with a small file, fine abrasive cloth (crocus cloth), or oil stone. If distortion, galling, or mutilation resulting from over tightening is discovered, the part must be replaced.

Inspection of highly stressed areas for corrosion is necessary. These areas are susceptible to pitting and can cause failure of the part. The following are components requiring particular attention with respect to this issue: the fillets at the edges of crankshaft main and crankpin journal surfaces, and thrust bearing races. If pitting is discovered in these areas and cannot be removed by polishing with crocus cloth or other fine abrasive, the part must be replaced. For polishing procedures, see the Repairs section of this manual.

Inspect all threaded inserts, fasteners, studs, fittings, plugs, etc., for condition of threads.

General Non-Destructive Testing

All parts must be thoroughly clean and dry prior to the start of the test and again upon completion of the test procedures. Refer to Cleaning section of this manual. It is important to carefully consider the results of the test to provide accurate interpretation.

All Ferro-magnetic steel parts should be inspected using a magnetic particle inspection method, such as MIL-STD-1949, performed by appropriately qualified personnel. This inspection is especially effective when used on highly stressed parts such as keyways, gear teeth, splines, roots of threads, small holes, and fillets.

NOTE:

Tests using the dye penetrant method must be thoroughly cleaned of all penetrant and developer residue upon completion of the test. Any oils or other fluids used for other nondestructive procedures must be thoroughly cleaned from the part upon completion of the test.

NOTE:

Perform the magnetic particle

inspection strictly in accordance with the manufacturer’s guidelines. Failure to do so can result in erroneous readings and the reuse of critical components with hidden damage that may cause engine failure.

Care must be taken to prevent

overheating or burning of the part as a result of the applied electricity during this test.

Upon completion of any cleaning

procedure, be sure to coat all steel parts with preservative oil. Do not handle cleaned parts any more than necessary prior to their reassembly into the engine as this handling reintroduces dirt and corrosive substances to the parts.

2

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Inspection and Check

Overhaul Manual

O-360 and IO-360 Series Engines

Accessory Housing

Initially inspect accessory housing as illustrated in Figure 72-00-08.2. Remove all accessories (magnetos, pumps, valves, etc.) for separate inspection.

•

Obvious excessive damage

Visually inspect accessory housing.

(1) Inspect accessory housing flange and

drive pad surfaces.

•

Deep scratches Reject

•

Minor scratches

(2) Inspect accessory case threaded and

drilled areas and passages.

•

Worn or mutilated, distorted, galled

•

Slight nicks or burrs

•

Obstructions or plugs

Crankcase Assembly

Perform initial inspection of crankcas e assembly per Figure 72-00-08.3.

•

Obvious excessive damage or wear

(1) Inspect all crankcase bearing bores

and journals, saddle supports, support webs, tang slots, and flange surfaces.

•

Deep scratches Reject

•

Fretting, heavy wear, flat spots

Reject

Blend/hand polish per Repair No.2

Reject Blend/hand

polish per Repair No.1

See Cleaning section of this manual

Reject

Blend/hand

•

Minor scratches

polish per Repair No.2

•

Misalignment of mating surfaces

•

Out of round conditions on

Reject

journals

(2) Inspect crankcase threaded studs and

drilled holes and passages.

•

Worn, mutilated, distorted, or

Reject/See Repair No. 1

galled

•

Slight nicks or burrs

Blend/hand polish per Repair No.1

NOTE:

Surfaces may be checked visually and

by feel for roughness, flaking, and pitting of races and for scoring on the outside of the bearing races. Shafts, pins, etc., may be checked using vee blocks and dial indicators.

NOTE:

Aluminum surfaces can withstand

considerable scratching and light scoring without harming the engine integrity or performance provided these problems fall within the limits set forth in the Fits and Clearances section of this manual.

NOTE:

Fretting on the saddle supports in the

crankcase has a frosted appearance and tiny pit holes. This usually indicates a change in the size of the bearing saddles that can be sufficient to cause an excessively tight crankshaft bearing fit.

3

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Inspection and Check

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-08.2 • Accessory Housing

4

72-00-08

Inspection and Check

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-08.3 • Crankcase Bearing and Flange Surfaces

5

72-00-08

Inspection and Check

Overhaul Manual

O-360 and IO-360 Series Engines

Cylinder Head

Initially inspect cylinder head. Refer to Figure 72-00-08.4.

Obvious

•

excessive damage to

Reject

cylinder head

Visually inspect cylinder head.

(1) Inspect cylinder head valve seats.

•

Loose, scored, or pitted valve

Reject

seats

(2) Inspect cylinder for loose or damaged

studs.

•

Loose or damaged studs

Reject

NOTE:

Loose or damaged studs must be

replaced with oversized studs using

0.003, 0.007, or 0.012 inch.

(3) Inspect cylinder head spark plug

helical coil inserts.

• Loose or

damaged

Reject

inserts

NOTE:

Loose or damaged helical coil inserts

must be replaced with oversized insert. See Repair No. 1.

(4) Inspect cylinder rocker box covers,

intake and exhaust ports.

•

Nicked, scored or dented mounting pads

Blend/hand polish per Repair No.2

(5) Inspect cylinder head cooling fins for

cracks.

•

Fin adjacent to the exhaust port flange

•

Physically damaged, broken, or bent

See Repair No.10

fins

Cylinder Head Dimensional Inspections

Inspect the rocker shaft bushings.

•

Check the ID of the rocker shaft bushings a minimum of two (2) positions, 90 degrees apart. Several check locations are

Refer to Fits and Clearances

preferred.

Cylinder Barrel Inspections

Visually inspect cylinder barrel for general condition. Refer to Figure 72-00-08.4.

•

Cracks. Reject

Visually inspect cylinder barrel cooling fins.

Blend with hand grinder

•

Notches and nicks

or file. See Repair No. 10

Visually inspect cylinder barrel skirt.

•

Bent, cracked, or broken

Reject

Visually inspect cylinder barrel mounting flange.

Blend with

•

Nicks

file or crocus cloth. See Repair No. 2

Visually inspect cylinder barrel interior.

•

Minor scoring or corrosion

•

Deep scoring or pitting

Repair by honing. See Repair No. 9

Reject

Visually inspect cylinder barrel interior.

•

Glazing or possible barrel wear

Repair by honing. See Repair No. 9

6

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Inspection and Check

Overhaul Manual

O-360 and IO-360 Series Engines

Cylinder Barrel Dimensional Inspections

Visually inspect cylinder barrel dimensions. Refer to Figure 72-00-08.4.

Fit between piston

•

skirt and cylinder Maximum taper of

•

cylinder walls Maximum out of

•

roundness

Bore diameter

•

NOTE:

All cylinder barrel diameter

measurements must be taken at a two (2) locations, 90 degrees apart at the plane specifically being measured.

Cylinder Assembly Inspection

Perform a fluorescent dye penetrant inspection of the cylinder head.

•

Cracks Reject

Piston Inspections

Visually inspect piston general condition. Refer to Figures 72-00-08.5 and 72-00-08.6.

•

Inspect the top of the piston for excessive pitting, cavities or surface distortion.

•

Inspect the piston lands, piston pin holes, and bosses for excessive wear or damage.

•

Inspect the piston ring in grooves clearances in excess of limits.

Refer to Fits and Clearances Refer to Fits and Clearances Refer to Fits and Clearances Refer to Fits and Clearances

Reject

Refer to Fits and Clearances

Piston Dimensional Inspections

Inspect pistons for correct dimensions. Refer to Figure 72-00-08.5.

•

Side clearance between piston and ring

Refer to Fits and Clearances

NOTE:

These pistons are ground with a slight

taper from the skirt to the head. The exception is the lands between the top compression and oil control rings, which are ground parallel. The clearance on wedge type compression rings must be measured with ring flush to outside edge of piston as shown in Figure 72-00-08.6 in order to obtain a true check of the side clearance.

Inside diameter of

•

piston pin hole

Refer to Fits and Clearances

NOTE:

No pitting or corrosion is permitted in

this area.

Clearance between

•

piston skirt and cylinder and piston diameter at top and

Refer to Fits and Clearances

bottom

7

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Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-08.4 • Cylinder Assembly

8

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Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-08.5 • Piston Assembly

9

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O-360 and IO-360 Series Engines

Figure 72-00-08.6 • Piston Rings and Lands

10

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O-360 and IO-360 Series Engines

Valve Rockers

Inspect valve rocker for damage. Refer to Figure 72-00-08.7.

•

Check for damaged, badly worn, pitted or scored tips and rod sockets.

•

Check rocker bushing ID at two (2) locations 90° apart. Refer to Fits and Clearances.

Pushrod Inspection

Inspect pushrods for wear, fit, and alignment. Refer to Figure 72-00-08.8.

•

Inspect for excessive wear or damage.

•

Rod must be straight within 0.010 inch

Reject

Replace bushing per Repair No. 13

Reject if in excess Reject if in excess

Valve Springs Inspection

Check valve springs using a spring tester. Refer to Figure 72-00-08.7.

•

Reference spring load and deflection limits in Fits and Clearances

Replace if weak

section of this manual.

11

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O-360 and IO-360 Series Engines

Figure 72-00-08.7 • Valve Train

12

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O-360 and IO-360 Series Engines

Crankshaft

NOTE:

Visually inspect the shaft.

Visually inspect the bearing surfaces.

Dimensionally inspect the bearing surfaces.

Visually inspect the ID of the forward end of the shaft.

Measure the run-out of the crankshaft center main bearings and flange by supporting the crankshaft on a flat surface in vee blocks on the front and rear main bearing.

A magnetic particle inspection should

be performed whenever the crankshaft is removed from the engine.

•

Scoring, galling, pitting, corrosion,

Reject

cracks

•

Scoring, scratching, etching

•

Refer to Fits and Clearances of this manual

•

Deterioration of the cadmium plating

Reject

Reject if beyond acceptable limits

See Repair No. 7

Reject if run-

•

Measure run-out of the crankshaft center main bearing

out exceeds limits of the Fits and Clearances. Reject if run-

•

Measure run-out of crankshaft prop flange

out exceeds limits of the Fits and Clearances

Crankshaft Counterbore Face Inspection

Inspection of the counterbored gear mounting flange surface.

•

Fretting, galling, scoring, pitting

•

Check threads in gear

Reject

retaining hole for nicks or burrs Check for hole depth by measuring with a gear retaining bolt threaded all the way in. Compare the

See Repair

No. 8 exposed length of the bolt with the thickness of the gear and lockplate.

•

Inspect dowel for damage, out of roundness. Refer to

Replace Repair No. 4.

•

Inspect pilot diameter of the counterbore for size and damage. The diameter should not exceed 2.1262

Repair inches at any place. Refer

to Repair No. 4.

CAUTION

: IF THE DOWEL MUST BE REMOVED, BE CAREFUL NOT TO DAMAGE THE CRANKSHAFT HOLE. DRILL A 1/8 INCH DIAMETER HOLE THROUGH THE CENTER OF THE DOWEL. FILL THE HOLE WITH OIL AND INSERT A PIECE OF 1/8 INCH DIAMETER DRILL ROD IN THE HOLE. STRIKE THE END OF THE DRILL ROD WITH A SHARP BLOW. THE RESULTING HYDRAULIC PRESSURE SHOULD FORCE THE DOWEL OUT.

NOTE:

If the crankshaft requires repairs other

than those specified above, measure the crankshaft counterbore face. If the crankshaft measures more than the minimum dimension shown, the surface may be reworked to the dimensions shown (do not plate the surface). The surface must be true within 0.001 inch T.I.R. The surface finish must be held to 45 to 90 microns.

13

72-00-08

Inspection and Check

Camshaft Inspection

Visual inspection.

Entire shaft for fretting,

•

galling, scoring, pitting, cracks, pitting, or other damage Cam lobes for

•

indications of distress, surface irregularity, or feathering along the edges.

NOTE:

If the hydraulic lifter bodies have been

rejected for spalling, inspect the corresponding cam lobe(s).

Dimensional inspection.

NOTE:

Refer to Fits and Clearances section

of this manual.

•

Runout at center bearing in excess of

0.001 T.I.R.

•

Difference between camshaft bearing journals and crankcase bore 0.002 minimum to 0.004 in. maximum

Connecting Rods Inspection

Overhaul Manual

O-360 and IO-360 Series Engines

Visual inspection.

•

Inspect bore in large

Reject

Reject if outside

end of connecting rod.

•

Inspect bushing bore in small end of connecting rod.

•

Check connecting rod parallelism. Refer to Fits and Clearances. Refer to Figure 72-00-

08.13

•

Check connecting rod squareness. Refer to Fits and Clearances. Refer to Figure 72-00-

08.15.

Replace or repair if tolerances are outside the limits Replace bushing per Repair No 11

Replace rod if tolerances are outside the limits

Replace if tolerances are outside the limits

14

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Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-08.8 • Camshaft Assembly

15

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O-360 and IO-360 Series Engines

THIS

PAGE

INTENTIONALLY

LEFT

BLANK

16

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O-360 and IO-360 Series Engines

ENGINE ASSEMBLY

General

This section has the procedures and illustrations necessary to assemble the Vantage O-360 and IO-360 series engine.

Fits, Clearances and Torque Values

Fits, clearances and torque values to be established during repair or assembly are listed in the applicable paragraph so that the unit can be assembled without reference to another section of the manual.

Table 72-00-09.1 • Assembly Materials

Material Source

Acetone or Methyl Ethyl Ketone (MEK) Commercially Available Assembly Grease – LubriplateTM No. 105 Commercially Available Cleaning Solvent Commercially Available Copper Based Anti-seize, Fel-ProTM C5-A Commercially Available Fuelube LoctiteTM 241, P/N 27183 Commercially Available LoctiteTM No. 2 Gasket Sealant P/N 30514 Commercially Available Oil, Aviation Grade (Mineral, Non-detergent) Commercially Available PermatexTM, P/N 27100 Commercially Available Pre-Lube Mixture – approx. 15% STPTM and 85% Aviation Mineral Oil Mixed Locally RTVTM 102 Silicon Sealant Commercially Available Safety Wire (0.032 in.) Type 304 Stainless, P/N MS20995 C32 Commercially Available Safety Wire (0.041 in.) Type 304 Stainless, P/N MS20995 C41 Commercially Available Silk Thread #50 (100% Silk) Commercially Available STPTM High Viscosity Oil Treatment Commercially Available TitesealTM No. 2 Gasket and Joint Compound P/N T2-01 Commercially Available

Special Tools and Equipment

Special tools and equipment required for assembly are listed in Table 72-00-09.2 below.

NOTE:

TM

Equivalent substitutes may be used for

listed items.

NOTE:

Materials Required for Assembly

Materials required for assembly are listed in Table 72-00-09.1 below.

NOTE:

NOTE: Standard reciprocating engine aviation

NOTE:

Limits followed by a letter “T” indicate

“tight”, i.e., interference fit. An example is the valve guide in the cylinder head. Where no “T” exists, the fit is a clearance dimension.

Equivalent substitutes may be used for

listed items.

Commercially Available

shop tools and equipment are used, unless otherwise specified.

Unless otherwise specified, all gaskets

are installed dry.

1

72-00-09

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Overhaul Manual

O-360 and IO-360 Series Engines

Table 72-00-09. 2 • Special Tools and Equipment

Description Source

Compressor, Valve Spring & Bar Commercially Available Piston Ring Expander Commercially Available Puller Set, Oil Seal Commercially Available Puller, Slide Hammer – Medium Commercially Available Puller, Valve Guide Commercially Available Socket, Connecting Rod Nut Commercially Available Stand, Engine Commercially Available Tool, Crankcase Separating Commercially Available Tool, Intercylinder Baffle Commercially Available Cylinder Base Wrenches, 3/4” and 9/16” Commercially Available Piston Ring Grinder Commercially Available Piston Ring Compressor Commercially Available Nose Seal Installation Tool Commercially Available Snap Ring Pliers Commercially Available

Engine Assembly WARNING

WHEN INSTALLING OR REMOVING SAFETY WIRE.

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE:

: PUT ON SAFETY GOGGLES

: LUBRICANTS ARE TOXIC AND

Unless otherwise specified, all torque

loads listed for nuts, bolts, and screws are for use with pre-lube oil.

Crankcase Inspection and Preparation for Assembly.

(1) Place crankcase halves on workbench.

Check for handling damage. Inspect for slight nicks and burrs surface finish, split lines, bearing and cam bores, mating surfaces, and tappet bores.

(2) Inspect studs for thread damage, bent

condition.

(3) Inspect tang slots for deformation.

Install center and aft main bearings in case halves.

(4) Check front main bearing retention

dowel installation for correct height of

0.070-0.090 in. Refer to Figure 72-00-

09.1.

WARNING AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30 PSI. DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES. IF YOU GET AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Inspect oil galleys in each crankcase

: WHEN YOU USE COMPRESSED

half to ensure they are clean and that

2

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

they properly intersect. Compressed air may be used.

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(6) Apply a light coat of pre-lube oil to main

(7) Using a feeler gage, check thrust and

(8) Repeat steps 6 and 7 in the left (9) Lightly lubricate camshaft bore journals

(10) Check threaded areas of crankcase

(11) Install piston cooling nozzle, if furnished,

NOTE:

: LUBRICANTS ARE TOXIC AND

bearings (5, Figure 72-00-09.2). Install crankshaft (25, Figure 72-00-09.3) in right crankcase half.

slinger clearances. Clearances must be within limits per Fits and Clearances section of this manual. Rotate crankshaft 360 degrees to ensure adequate cheek to case clearance and record. Refer to Figure 72-00-09.4.

crankcase half and record clearances. and temporarily install the camshaft and

rotate in each crankcase half. Using feeler gage measure and record end clearance in each half. Clearances must be within limits per Fits and Clearances section of this manual.

halves. Install external pipe plugs using Titeseal™ thread sealant. Torque plug (40, Figure 72-00-09.5) to 40 in-lbs.

using Locktite™ (95, Figure 72-00-09.5) torque nozzle to 100 in-lbs.

Plug(s) MS27769-1 may be used in

place of piston nozzle(s) as required by the engine model. Torque plug(s) to 40 in-lbs.

Crankshaft Inspection and Preparation for Assembly

(1) Visually inspect crankshaft for handling

damage. Check bearing, slinger and thrust face surfaces.

(2) Measure and record main journal

dimensions with micrometer. Dimensions must be within limits per Fits and Clearances section of this manual.

(3) Measure and record rod journal

dimensions with micrometer. Dimensions must be within limits per Fits and Clearances section of this manual.

Crankshaft Front Oil seal Installation

1. Remove spring from new front oil seal (15,

Figure 72-00-09.2). Apply pre-lube oil mixture to the crankshaft propeller flange and I.D. of oil seal. Install oil seal with flat side out to prop flange. Use tool to carefully stretch seal over flange.

2. Re-install the spring in seal (15) groove.

3. Clean oil from the prop flange.

4. Apply oil to crankshaft and front oil seal (15)

at their fit locations.

5. If required, apply pre-lube and install the

propeller flange bushings (50, 55, 60, Figure 72-00-09.3). Pull through with puller tool. Refer to Figure 72-00-09.3 for bushing positions.

6. Install and secure the crankshaft to a vertical

support stand.

WARNING: LUBRICANTS ARE TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

3

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.1 • Crankcase Bearing Retention Dowel

4

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.2 • Crankshaft Bearing and Oil Pressure Relief Valve

5

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.3 • Crankshaft Assembly

6

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.4 • Crankshaft Thrust and Slinger Clearance

7

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.5 • Crankcase Assembly

8

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O-360 and IO-360 Series Engines

Connecting Rod Assembly Inspection

(1) Visually inspect the rod assembly (5,

Figure 72-00-09.6) for handling damage, defects, and corrosion.

(2) Inspect the bore finish. This must be

smooth and free of burrs. (3) Verify correct rod part number. (4) Verify the serial number match for each

rod and cap assembly. (5) Verify and record each rod assembly

weight.

NOTE:

Subassembly of Connecting Rods to Crankshaft

Difference in rod assembly weights

must not exceed 2 grams in opposing pairs.

(6) Check each piston pin (35) in each rod

(5) for fit. The pins must slide freely

through the rod.

(1) Visually inspect the rod bolts and nuts

(10, 15 Figure 72-00-09.6). Lightly

lubricate bolt shanks and threads with

pre-lube oil. (2) Verify bearing part number and size for

crankshaft and model application. (3) Install the connecting rod bearing shell

(1) in each rod and cap (5). (4) Apply pre-lube oil to the bearing shell

(1). (5) Apply pre-lube oil to the rod bearing

journals of crankshaft. (6) Insert 2 rod bolts through each rod cap.

Begin with the lowest serial number rod

cap and install it to the crankshaft with

its matching rod (5) at the #1 (most

forward) rod location.

(a) Install with serial numbers in same

plane and down towards oil sump. Refer to Figure 72-00-09.7.

(b) Install the nuts with flat side to

connecting rod. Refer to Figure 7200-09.7. Tighten moderately to check fit prior to torque.

(7) Tighten each rod nut to bolt (10,15,

Figure 72-00-09.6) evenly to 480 in-lb.

torque. (8) Rotate each connecting rod (5) after

torque to check for smooth and free

rotation.

(9) Measure and record connecting rod to

crankshaft side clearance. Clearance must be within limits per Fits and Clearances section of this manual.

WARNING: LUBRICANTS ARE TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

Installation of Crank Gear to Crankshaft

(1) Inspect the crank gear (5, Figure 72-00-

09.3), bolt (15), and lockplate (10) for defects.

(2) Lightly lubricate with pre-lube crank bolt

threads and install the gear (5) to crankshaft with bolt (15) and new lockplate (10). Ensure that the gear (5) fits evenly in crank recess, aligns with dowel, and sits flat when torqued. Tapping the gear with a soft aluminum or brass drift will help ensure the seal is properly seated. Torque crankshaft gear bolt (15) to 204 in-lb. Attempt to insert a pointed 0.001 in. feeler gage or piece of shim stock between the gear and the crankshaft at each of the three scallops. There is no allowable clearance between crankshaft and gear. Bend lockplate (10) tab up to secure bolt head.

WARNING: LUBRICANTS ARE TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

9

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Assembly of Case and Crankshaft Assembly

(1) With crankcase halves lying on bench

with interior sides up, ensure that center

and rear main bearings (5, Figure 72-

00-09.2) are installed and lubricated

with pre-lube. (2) Lubricate tappet bore holes and tappet

bodies (20) (shank) and install bodies in

case. (3) Apply cam pre-lube liberally to tappet

(20) faces and camshaft lobes. (5,

Figure 72-00-09.8). A moly-graphite

grease is recommended. (4) Place camshaft (5) on bench beside

case halves. (5) Clean mating surfaces of both case

halves including nose seal area with fast

dry solvent. (6) Clean nose seal OD with fast dry

solvent. (7) Place front main (10, Figure 72-00-09.2)

bearing temporarily in place in the left

crankcase half making sure the bearing

is properly seated on the 2 locator

dowels.

NOTE:

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK

The front main bearing (10), unlike the

center and rear main bearings, splits on the horizontal centerline of the engine.

(8) Use a felt marker to trace on the front

bearings halves at the intersection

between the crankcase parting flanges

and the bearing. Make a vertical

reference mark on both the bearing half

and each case half at a convenient point

along the line of intersection. This

locates the bearing both radially and

axially. Make two parallel marks across

both bearing shells at their intersection

for alignment reference. Refer to Figure

72-00-09.9.

: LUBRICANTS ARE TOXIC AND

MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(9) Remove front main bearings. Lubricate

bearing surfaces liberally with pre-lube oil and fit to crankshaft aligning the two parallel marks. Refer to Figure 72-00-

09.10.

(10) Install two 3/8 in. bolts with their

corresponding flat washers through the right case half and install 2 O-rings (10, Figure 72-00-09.11).

(11) Install 2 O-rings (75) on rear through

studs of right case half.

(12) Lubricate crankshaft main bearing

journals and cam bores with pre-lube oil.

(13) Lay out crankcase assembly hardware

per Figure 72-00-09.11 and 72-00-09.12 together with appropriate hand tools.

- STOP -

PERFORM IN-PROCESS QUALITY

INSPECTION #1. REFER TO APPENDIX A.

(14) Assure that case mating surfaces are

clean and dry.

WARNING AND FLAMMABLE. DO NOT BREATHE VAPORS. AVOID EYE AND SKIN CONTACT. USE PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(15) Apply an even, thin coat of approved

(16) When using RTV 102 the coating must

: ADHESIVE SEALANT IS TOXIC

sealant to the backbone and breastbone surfaces of the left case half only and to the front nose seal bore (both case halves) as well as the nose seal OD.

not be too thick. A thin translucent coating is sufficient. Wipe off any excess on the inside and outside edges. Refer to Figure 72-00-09.13. Because this sealant will dry quickly when applied this thinly, it is important to proceed quickly until case halves are together and snug. A helper is required during this assembly process.

10

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

(17) Lay a single line of silk thread on the

RTV sealant at the centerline of the

sealing surface and loop the inside of

each bolt hole. The tail of the thread

should extend beyond the mating

surface approximately 0.25 in. to the

accessory gasket surface at the rear,

the nose seal surface at the front and

the sump gasket surface at the bottom.

Refer to Figure 72-00-09.13. (18) A helper places the left case half up to

the crank assembly with the connec ting

rods protruding through their appropriate

cylinder holes and allows the assembler

to align the front main bearing inserts

with the dowels in the crankcase. The

helper uses light pressure against case

half as the assembler adjusts front main

bearing until it snaps in place.

NOTE:

Using a tool to gently lift up on bearing

while holding case half-tight to crankshaft will aid in determining if bearing is properly seated. When properly seated, the bearing and case will move slightly up and down together as the front of the bearing is pried up and down.

(19) With the left case half and bearing

properly seated, the helper places a tool

inserted through the #4 connecting rod

piston pin hole. The case is rotated to

wedge the tool against the case half.

Firm pressure is maintained on

crankcase. Refer to Figure 72-00-

09.14.

It is imperative that the helper

maintains constant pressure on the left case half throughout the assembly process until case halves are snugged together. Enough case assembly hardware must be installed to not allow the front main bearing to shift from the locating dowels.

(20) Check thread and nose seal (15, Figure

72-00-09.2) for proper placement.

(21) Install camshaft in left case half and

have helper hold in place.

(22) Mate the right case half to the left case

half by carefully aligning rear through studs and front 3/8 in. nose bolts.

NOTE:

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE: Care should be taken not to

push out the 3/8 in. nose bolts (5, Figure 72-00-09.11) causing the orings (10) to fall out.

(23) Ensure that nose seal is properly in

place.

(24) Install backbone bolts (30), breastbone

bolts (90, 95), and nose bolts (5) with appropriate hardware. Snug all uniformly. Check for free case to crank rotation.

: LUBRICANTS ARE TOXIC AND

(25) Lightly lubricate shank and threads of

the ½ in. Dia. through bolts (1, Figure 72-00-09.12), with pre-lube oil. Install using a soft faced (dead blow) hammer as far as possible. Finish installation with sufficiently sized ball-peen hammer or equivalent using a nut or threaded cap to protect the threads and thru-bolt end. Thru bolts are properly installed when an equal number of threads protrude from each case half.

11

72-00-09

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O-360 and IO-360 Series Engines

Figure 72-00-09.6 • Connecting Rod and Piston Assembly

12

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.7 • Connecting Rod Installation

13

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.8 • Camshaft Assembly

14

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.9 • Main Bearing Reference Marks

15

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.10 • Main Bearing Installation

16

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.11 • Crankcase Attaching Hardware

17

72-00-09

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O-360 and IO-360 Series Engines

Figure 72-00-09.12 • Crankcase Attaching Hardware (cont’d.)

18

72-00-09

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Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.13 • Sealant Compound and Silk Thread Application

19

72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.14 • Crankcase Halves Assembly

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Cylinder Assembly Inspection

(1) Verify cylinder part number and serial

number. (2) Visually inspect general condition of

cylinder for handling or shipping

damage. (3) Verify the valve, spring, and key (65, 70,

85, 90, 105, 110, Figure 72-00-09.15)

installations. (4) Visually check threaded holes for thread

integrity and helical coil insert if

required. Ensure the absence of foreign

matter.

WARNING WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(5) Wipe cylinder bores clean with lint-free (6) Inspect piston (30, Figure 72-00-09.6)

NOTE:

(7) Clean piston pins (35) with fast dry

NOTE:

: SOLVENT IS TOXIC. USE IN

rag saturated with fast dry solvent.

part number and weight.

Piston weight differences should not

exceed 2 grams in opposing pairs.

solvent and check fit to each piston.

Piston pins are a push fit with light

lubrication. Refer to Figure 72-00-

09.16.

(8) Verify piston ring (40, 45) part numbers. (9) Check ring gaps of compression rings

(45, Figure 72-00-09.6) and oil control ring (40) with feeler gauge. End gap at 1”-4” from flange and gap at top of piston stroke must be within limits per Fits and Clearances section of this manual.

(10) Insert piston rings, one at a time in their

respective grooves.

(11) Using a ring expander, install rings to

piston with the lower ring first, then middle and top.

NOTE:

Numbers on the ring face indicate top

of the piston or up.

(12) Check side clearance of each ring.

Piston compression ring (45) in top groove is 0.0025 to 0.0055 in. Piston compression ring (45) in 2nd groove is

0.000. to 0.0040 in. Piston oil control ring (40) in 3rd groove is 0.0020 to

0.0040 in.

Side clearance is checked with ring in

its respective groove and flush with outside edge of piston.

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.15 • Cylinder Valve Train and Spring Assembly

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.16 • Piston Assembly to Connecting Rod

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Cylinder Assembly Installation to Engine

(1) Lubricate the rings and ring grooves on

the piston with straight weight, non-

detergent (mineral) aviation grade oil. (2) Stagger the ring gaps as follows: Top

ring gap is at approximately the 10

o’clock position, 2nd ring gap is at

approximately 2 o’clock; and the oil

control ring gap is at approximately 11

o’clock.

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE:

(3) Lubricate the cylinder bores, piston pins

(4) Lubricate the cylinder base o-ring (5,

(5) Lightly lubricate cylinder deck studs and (6) Rotate the engine so that the #1

: LUBRICANTS ARE TOXIC AND

Oil control expander spring is installed

in piston groove underneath the oil control ring and with its split line 180° from the ring gap.

and piston pin bushing in connecting rod

with straight weight, non-detergent

(mineral) aviation grade oil.

Figure 72-00-09.17) with oil and install

over the cylinder base.

through bolts with pre-lube oil.

connecting rod is at the top of the

stroke. Install the #1 piston to the #1

connecting rod with the piston pin.

Refer to Figure 72-00-09.16.

NOTE:

WARNING WHEN INSTALLING OR REMOVING SAFETY WIRE.

Ensure that piston is installed with ring

gaps towards the top of the engine.

(7) Slide the ring compressor tool over the

piston and rings far enough to allow the cylinder bore to fit over the piston top.

(8) Install cylinder #1: Position the top of

cylinder facing the top of the engine over the piston. Push on until the ring compressor is pushed off the piston skirt and can be removed at notch over the connecting rod. Continue to slide the cylinder over the cylinder base studs until flush with the case deck. Refer to Figure 72-00-09.18.

(9) Secure the cylinder assembly with the

cylinder base nuts (15, 20, Figure 7200-09.17) as required and tighten to snug.

(10) Continue process with cylinders #2, then

#3, and #4 in that order. Rotate the case and crank so that the connecting rod of the cylinder to be installed is at top dead center.

(11) Torque the large cylinder hold down

nuts (15, Figure 72-00-09.17) to 600 inlbs. Torque the small hold down nuts (20) to 300 in-lbs. Do this in the sequence shown in Figure 72-00-09.19.

(12) Torque all crankcase assembly

hardware in accordance with Fits and Clearances Table 72-00-11.2. Do this in the sequence shown in Figure 72-00-

09.19.

: PUT ON SAFETY GOGGLES

(13) Torque slotted 0.38 in. nut (85) to 300

in-lbs. Install safety wire (0.041 in.) at accessory location by cam gear.

(14) Torque the three, drilled-shank, 0.25 in.

belly bolts (95) and slotted nuts (100) to 55-60 in-lbs. Install safety wire (0.032 in.).

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.17 • Cylinder Assembly and Head Oil Drain Line

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.18 • Piston Assembly with Ring Compressor Tool

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Figure 72-00-09.19 • Cylinder Base Nuts Sequence of Tightening

(Left Side Shown)

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72-00-09

Engine Assembly

Overhaul Manual

O-360 and IO-360 Series Engines

Installation of Idler Shafts and Gears and Internal Gear Timing

(1) Install 2 each idler shafts (1, Figure 72-

00-09.20) with 3 bolts (5) and one nut (10). Torque the bolts (5) and nut (10) in accordance with the torque specifications per the Fits and Clearances section of this manual. Safety the nuts and bolts with 0.032 in. safety wire to idler shaft flange holes. Refer to Figure 72-00-09.21.

WARNING WHEN INSTALLING OR REMOVING SAFETY WIRE.

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

NOTE:

: PUT ON SAFETY GOGGLES

(2) Inspect idler gears and for handling

damage, burrs, and general condition.

: LUBRICANTS ARE TOXIC AND

(3) Apply pre-lube oil to idler shafts (1) and

gear bushing (25).

(4) Highlight with a marker the timing

marks on the camshaft, crank gear, and fuel pump drive idler gear (15).

(5) Place the left-hand idler gear (fuel

pump drive idler gear) over the left idler shaft aligning its timing marks with the corresponding timing marks on cam and crank. Rotate cam and crank as needed to align with marks on the idler gear. See Figure 72-00-09.22.

(6) Install the right hand idler gear (20) on

the right side idler shaft.

It is not necessary to align timing

marks on this gear.

(7) Check gear backlash of both idler gears

with feeler gauge or dial indicator. Backlash limits must be within limits

specified in Fits and Clearances section of this manual.

(8) Install tachometer shaft assembly (15,

Figure 72-00-09.8) with retaining ring (25) in camshaft (5) at gear end.

- STOP -

PERFORM IN-PROCESS QUALITY

INSPECTION #2. REFER TO APPENDIX A.

Cleaning, Inspection, and Installation of Hydraulic Plunger and Cup Assembly

(1) Visually inspect and clean hydraulic

plunger assemblies (25, Figure 72-00-

09.15) with fast dry solvent.

WARNING WELL-VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(2) Depress hydraulic plunger piston with

WARNING FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(3) Apply a light coat of pre-lube oil to the (4) Insert plunger, small tube end first, into

(5) Insert tappet cup or socket (30) into

: SOLVENT IS TOXIC. USE IN

thumb to ensure proper spring action. (a) If unit does not compress, use blunt

end of a 3/32 in. diameter rod to dislodge check ball allowing trapped air, oil, or solvent to escape.

(b) Remove rod and try depressing

piston again.

: LUBRICANTS ARE TOXIC AND

OD of each plunger. tappet body in crankcase. Refer to

Figure 72-00-09.15. tappet body on top of plunger assembly.

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72-00-09

Engine Assembly

Superior O-360 SERIES, IO-360 SERIES, Vantage Engine O-360 SERIES, Vantage Engine IO-360 SERIES Overhaul Manual

Specifications and Main Features

Frequently Asked Questions

User Manual