O-360 & IO-360 SERIES ENGINES

OVERHAUL
0.MANUAL

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

www.superiorairparts.com

Manual P/N SVOHM01 Revision C October, 2014

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© October 2014 Superior Air Parts Inc. RevisionR

 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Manual Number SVOHM01

Revision History

Revision Effective Pages

Description
Letter Date Revised
A 05/13/05 Initial Release All
Added Data For Models 360-C, -D and -E 72-00-11 pg. 2
Added Celsius Temperatures 72-00-04 All
B 02/28/07
" 72-00-12 All
" 72-00-13 pgs 10-32
Added Effective Page List Pgs. iv-vii

Added information for Front Prop Governor model 02-00-00 pgs. 1-6

Moved Torque Values & Fits and Clearances to App. C pgs. 1-7
Appendix C, SSD001 Table of limits; Oil Crush
Gasket angular value was 90°

Revised Airworthiness Limitations Section to 04-00-00 pgs. 1-2

reference Maint. Manual No. SVMM01

Revised Testing and Fault Isolation Section to 72-00-03 pg. 1

refer to Maint. Manual SVMM01

Revised Special Procedures Section, Break-in 72-00-04 pg. 1

Procedure
C 10/20/14 72-00-05
Revise Engine Removal Section to reference use
of specific aircraft maint. Manual

Revise Engine Installation Section to reference 72-00-10 pg. 1

use of specific aircraft maint. Manual

Revise Preservation and Storage Section to apply 72-00-11 pgs. 1-3

to o’hauled engines only.

Revise Testing Section to provide engine

acceptance testing after o’haul only. Remove 72-00-13 pgs. 1-5
break-in procedure, refer to SVMM01

Add stud driving torque and install height Appendix C, pgs. 4-5

Editorial changes to clarify and add missing

All
information

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© October 2014 Superior Air Parts Inc. RR
General Information
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

The following pages list the Effective Pages in this Manual with the effective Revision and Date.
EFFECTIVE PAGE LIST
Section/Page Number Title Revision Date
i Title Page C Oct. 2014
ii Editorial Blank C Oct. 2014
iii Revision History C Oct. 2014
iv Effective Page List C Oct. 2014
v Effective Page List C Oct. 2014
vi Effective Page List C Oct. 2014
vii Effective Page List C Oct. 2014
viii Editorial Blank C Oct. 2014
ix Safety Advisory C Oct. 2014
x Safety Advisory C Oct. 2014
xi Table of Contents C Oct. 2014
xii Table of Contents C Oct. 2014
xiii Table of Contents C Oct. 2014
xiv Table of Contents C Oct. 2014
xv List of Figures C Oct. 2014
xvi List of Figures C Oct. 2014
xvii List of Tables C Oct. 2014
01-00-00/1 Introduction C Oct. 2014
01-00-00/2 Introduction C Oct. 2014
01-00-00/3 Introduction C Oct. 2014
01-00-00/4 Editorial Blank C Oct. 2014
02-00-00/1 Description and Oper. C Oct. 2014
02-00-00/2 Description and Oper. C Oct. 2014
02-00-00/3 Description and Oper. C Oct. 2014
02-00-00/4 Description and Oper. C Oct. 2014
02-00-00/5 Editorial Blank C Oct. 2014
04-00-00/1 Airworthiness Limit. C Oct. 2014
04-00-00/2 Editorial Blank C Oct. 2014
70-00-03/1 Testing and Fault Det. C Oct. 2014
72-00-04/1 Special Processes C Oct. 2014
72-00-05/1 Engine Removal C Oct. 2014
72-00-05/2 Editorial Blank C Oct. 2014
72-00-06/1 Engine Disassembly C Oct. 2014
72-00-06/2 Engine Disassembly C Oct. 2014
72-00-06/3 Engine Disassembly C Oct. 2014
72-00-06/4 Engine Disassembly C Oct. 2014
72-00-06/5 Engine Disassembly C Oct. 2014
72-00-06/6 Engine Disassembly C Oct. 2014
72-00-07/1 Cleaning C Oct. 2014
72-00-07/2 Cleaning C Oct. 2014
72-00-07/3 Cleaning C Oct. 2014
72-00-07/4 Cleaning C Oct. 2014
72-00-08/1 Inspection and Check C Oct. 2014
72-00-08/2 Inspection and Check C Oct. 2014
72-00-08/3 Inspection and Check C Oct. 2014
72-00-08/4 Inspection and Check C Oct. 2014
72-00-08/5 Inspection and Check C Oct. 2014
72-00-08/6 Inspection and Check C Oct. 2014

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© October 2014 Superior Air Parts Inc. RR
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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

EFFECTIVE PAGE LIST

Section/Page Number Title Revision Date
72-00-08/7 Inspection and Check C Oct. 2014
72-00-08/8 Inspection and Check C Oct. 2014
72-00-08/9 Inspection and Check C Oct. 2014
72-00-08/10 Inspection and Check C Oct. 2014
72-00-08/11 Inspection and Check C Oct. 2014
72-00-08/12 Inspection and Check C Oct. 2014
72-00-08/13 Inspection and Check C Oct. 2014
72-00-08/14 Inspection and Check C Oct. 2014
72-00-08/15 Inspection and Check C Oct. 2014
72-00-08/16 Inspection and Check C Oct. 2014
72-00-08/17 Editorial Blank C Oct. 2014
72-00-09/1 Engine Assembly C Oct. 2014
72-00-09/2 Engine Assembly C Oct. 2014
72-00-09/3 Engine Assembly C Oct. 2014
72-00-09/4 Engine Assembly C Oct. 2014
72-00-09/5 Engine Assembly C Oct. 2014
72-00-09/6 Engine Assembly C Oct. 2014
72-00-09/7 Engine Assembly C Oct. 2014
72-00-09/8 Engine Assembly C Oct. 2014
72-00-09/9 Engine Assembly C Oct. 2014
72-00-09/10 Engine Assembly C Oct. 2014
72-00-09/11 Engine Assembly C Oct. 2014
72-00-09/12 Engine Assembly C Oct. 2014
72-00-09/13 Engine Assembly C Oct. 2014
72-00-09/14 Engine Assembly C Oct. 2014
72-00-09/15 Engine Assembly C Oct. 2014
72-00-09/16 Engine Assembly C Oct. 2014
72-00-09/17 Engine Assembly C Oct. 2014
72-00-09/18 Engine Assembly C Oct. 2014
72-00-09/19 Engine Assembly C Oct. 2014
72-00-09/20 Engine Assembly C Oct. 2014
72-00-09/21 Engine Assembly C Oct. 2014
72-00-09/22 Engine Assembly C Oct. 2014
72-00-09/23 Engine Assembly C Oct. 2014
72-00-09/24 Engine Assembly C Oct. 2014
72-00-09/25 Engine Assembly C Oct. 2014
72-00-09/26 Engine Assembly C Oct. 2014
72-00-09/27 Engine Assembly C Oct. 2014
72-00-09/28 Engine Assembly C Oct. 2014
72-00-09/29 Engine Assembly C Oct. 2014
72-00-09/30 Engine Assembly C Oct. 2014
72-00-09/31 Engine Assembly C Oct. 2014
72-00-09/32 Engine Assembly C Oct. 2014
72-00-09/33 Engine Assembly C Oct. 2014
72-00-09/34 Engine Assembly C Oct. 2014
72-00-09/35 Engine Assembly C Oct. 2014
72-00-09/36 Engine Assembly C Oct. 2014
72-00-09/37 Engine Assembly C Oct. 2014

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O-360 and IO-360 Series Engines
Revision C

EFFECTIVE PAGE LIST

Section/Page Number Title Revision Date
72-00-09/38 Engine Assembly C October 2014
72-00-09/39 Engine Assembly C October 2014
72-00-09/40 Engine Assembly C October 2014
72-00-09/41 Engine Assembly C October 2014
72-00-09/42 Engine Assembly C October 2014
72-00-09/43 Engine Assembly C October 2014
72-00-09/44 Engine Assembly C October 2014
72-00-09/45 Engine Assembly C October 2014
72-00-09/46 Engine Assembly C October 2014
72-00-09/47 Engine Assembly C October 2014
72-00-09/48 Engine Assembly C October 2014
72-00-09/49 Engine Assembly C October 2014
72-00-09/50 Engine Assembly C October 2014
72-00-09/51 Engine Assembly C October 2014
72-00-09/52 Engine Assembly C October 2014
72-00-09/53 Engine Assembly C October 2014
72-00-09/54 Engine Assembly C October 2014
72-00-09/55 Engine Assembly C October 2014
72-00-09/56 Engine Assembly C October 2014
72-00-09/57 Engine Assembly C October 2014
72-00-09/58 Engine Assembly C October 2014
72-00-09/59 Engine Assembly C October 2014
72-00-09/60 Engine Assembly C October 2014
72-00-09/61 Engine Assembly C October 2014
72-00-09/62 Editorial Blank C October 2014
72-00-10/1 Engine Installation C October 2014
72-00-11/1 Engine Installation C October 2014
72-00-11/2 Engine Installation C October 2014
72-00-11/3 Editorial Blank C October 2014
72-00-12/11 Repair C October 2014
72-00-12/2 Repair C October 2014
72-00-12/3 Repair C October 2014
72-00-12/4 Editorial Blank C October 2014
72-00-12/5 Repair C October 2014
72-00-12/6 Editorial Blank C October 2014
72-00-12/7 Repair C October 2014
72-00-12/8 Editorial Blank C October 2014
72-00-12/9 Repair C October 2014
72-00-12/10 Editorial Blank C October 2014
72-00-12/11 Repair C October 2014
72-00-12/12 Repair C October 2014
72-00-12/13 Repair C October 2014
72-00-12/14 Editorial Blank C October 2014
72-00-12/15 Repair C October 2014
72-00-12/16 Repair C October 2014
72-00-12/17 Repair C October 2014
72-00-12/18 Repair C October 2014
72-00-12/19 Repair C October 2014

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© October 2014 Superior Air Parts Inc. RR
General Information
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

EFFECTIVE PAGE LIST

Section/Page Number Title Revision Date
72-00-12/20 Repair C October 2014
72-00-12/21 Repair C October 2014
72-00-12/22 Repair C October 2014
72-00-12/23 Repair C October 2014
72-00-12/24 Editorial Blank C October 2014
72-00-12/25 Repair C October 2014
72-00-12/26 Editorial Blank C October 2014
72-00-12/27 Repair C October 2014
72-00-12/28 Editorial Blank C October 2014
72-00-12/29 Repair C October 2014
72-00-12/30 Editorial Blank C October 2014
72-00-13/1 Post Overhaul Test C October 2014
72-00-13/2 Post Overhaul Test C October 2014
72-00-13/3 Post Overhaul Test C October 2014
72-00-13/4 Post Overhaul Test C October 2014
72-00-13/5 Engine Run Sheet Form C October 2014
1 Appendix A C October 2014
2 Appendix A C October 2014
3 Appendix A C October 2014
4 Editorial Blank C October 2014
1 Appendix B C October 2014
2 Appendix B C October 2014
3 Appendix B C October 2014
1 Appendix C C October 2014
2 Appendix C C October 2014
3 Appendix C C October 2014
4 Appendix C C October 2014
5 Appendix C C October 2014
6 Appendix C C October 2014
7 Appendix C C October 2014

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

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© October 2014 Superior Air Parts Inc. RR
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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

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
Revision C

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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© October 2014 Superior Air Parts Inc. RR
General Information
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

TABLE OF CONTENTS

Sub-Section
Chapter
Section

Page Number

General Information
Revision History and Effective Page List iii
Safety Advisory ix
Table of Contents xi
List of Figures xv
List of Tables xvii

01 00 00 Introduction
About This Manual 1
Related Publications 1
Obtaining Service Information 1
Abbreviations 1
Consumable Materials List 3

02 00 00 Description and Operation

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

04 00 00 Airworthiness Limitations
Mandatory Intervals and Procedures 1

72 00 03 Testing and Fault Isolation

General 1

04 Special Procedures
General 1
Special Tools and Equipment 1

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

TABLE OF CONTENTS (cont’d)

Sub-Section
Chapter
Section

Page Number

72 00 05 Engine Removal
General 1

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

07 Cleaning
General 1
Tools and Materials 1
Cleaning Instructions 1
Degreasing 1
Decarbonizing 2
Scratch and Corrosion Removal 2
Accessory Mounts 2
Fuel Injector and Primer Nozzles 3
Screens and Filters 3
Accessories 3
Preservation and Corrosion Prevention 4

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O-360 and IO-360 Series Engines
Revision C

TABLE OF CONTENTS (cont’d)

Sub-Section
Chapter
Section

Page Number

72 00 08 Inspection and Check

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

09 Engine Assembly
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 47
Storage After Assembly 59

10 Engine Installation
General 1

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O-360 and IO-360 Series Engines
Revision C

TABLE OF CONTENTS (cont’d)

Sub-Section
Chapter
Section

Page Number

72 00 11 Preservation and Storage

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

12 Repair
General 1
Repair Procedures 1
Repair 1 – Threaded Area Repair and Stud Replacement 5
Repair 2 – Nick and Scratch Repair 7
Repair 3 – Crankshaft or Crankpin Repair 9
Repair 4 – Painted Parts 11
Repair 5 – Crankshaft Oil Seal Surface 13
Repair 6 – Cylinder Interior Surface 15
Repair 7 – Cylinder Head Cooling Fins 17
Repair 8 – Valve, Valve Seat, and Valve Guide 19
Repair 9 – Spark Plug Threaded Insert 25
Repair 10 – Rocker Bushing Replacement 27
Repair 11 – Connecting Rod Bushing Replacement 29

13 Testing
General 1
Special Tools and Equipment 1
Engine Installation and Testing Procedures 1
Engine preservation and Storage After Testing 4

Appendix A Assembly In Process Quality Inspections

Appendix B Approved Assembly Materials

Appendix C Table of Limits

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General Information
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

LIST OF FIGURES

Sub-Section
Chapter

Section

Page
Figure

02-00-00.1 Engine Model Number Designation 02 00 00 1

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

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 and Front Prop. Gov. Gear 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
Revision C

LIST OF FIGURES (cont’d.)

Sub-Section
Chapter

Section

Page
Figure

72-00-09.15 Cylinder Related Parts 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 in Crankcase 30
72-00-09.21 Idler Gear in Crankcase (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

72-00-12.1 Cylinder Interior Resurface Crosshatch 12 16

72-00-12.2 Cooling Fin Removal Maximum 18
72-00-12.3 Valve Seat Dimensions 23
72-00-12.4 Valve to Seat Fit Acceptable Criteria 24

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O-360 and IO-360 Series Engines
Revision C

LIST OF TABLES

Sub-Section
Chapter

Section

Page
Table

01-00-00.1 Abbreviations 01 00 00 2
01-00-00.2 Consumable Materials 3

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

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 Special Tools and Equipment 09 2

72-00-10.1 Equipment and Materials List 10 1

72-00-11.1 Storage Materials 14 1
72-00-12.1 List of Repairs 13 2
72-00-12.2 List of Materials 2
72-00-12.3 List of Equipment 3
72-00-12.4 List of Repair Codes 3
72-00-12.5 Reserved -
72-00-12.6 Consumable Materials for Paint Procedures 11

xvii
© October 2014 Superior Air Parts Inc. RR
General Information
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

INTRODUCTION

About This Manual Series Engines. Superior Air Parts values your
“Information contained in this Engine input regarding revisions and additional
Maintenance Manual fulfills the content information for our manuals. Please forward
requirements of FAR 33.4 Appendix A33.3(a)” your comments and input to:
and has been found “Acceptable to the Federal
Aviation Administration (FAA)”. The purpose of Superior Air Parts
this Overhaul Manual is to provide the Attn: Engineering Department
necessary instructions for major repair and 621 South Royal Lane Suite 100
replacement of Superior Vantage O-360 and Coppell, Texas 75019
IO-360 series engines. Maintenance information
may be found in the Maintenance Manual,
SVMM01. Related Publications
The following are related engine and accessory
The information in this publication is based on publications.
data available at the time of publication and is
updated, supplemented, and automatically O & IO-360 Installation and Operation Manual,
amended by Service Bulletins and Publication SVIOM01
Revisions that are issued by Superior Air Parts O & IO-360 Maintenance Manual, SVMM01
Inc.

This manual is divided into separate sections Obtaining Service Information

relating to the general and specific overhaul All Vantage Series Engine manuals and service
instructions required for the engine. These information may be downloaded at:
general and specific instructions are generally www.superiorairparts.com
organized and numbered per the
recommendations of the General Aviation All Vantage Series Engine manuals and service
Manufacturers Association (GAMA). In this way, information may be purchased by contacting:
information may be located in a conventional
manner to aid in both accuracy and timeliness. Superior Air Parts
621 South Royal Lane, Suite 100
Page numbering is organized within each Coppell, Texas 75019
section. The section number (e.g., 72-00-01) is
displayed in the right hand section of the footer or call: 972-829-4600
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 Abbreviations

information available for those who maintain, A list of abbreviations used in this manual is
own and repair the Vantage O-360 and IO-360 shown in Table 01-00-00.1 below.

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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 Revolutions Per Minute
SAE Society of Automotive Engineers
TIR Total Indicator Reading
UNF Unified National Fine
° Degree

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Consumable Materials List

Refer to Table 01-00-00.2 below for consumable NOTE: Equivalent substitutes may be used.
materials used during repair of the Vantage O-
360 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 Commercially Available
TM
Copper Based Anti-seize, Fel-Pro C5-A Commercially Available
TM
Fuelube Ohio Industrial Lubricants
Isopropyl alcohol Commercially Available
TM
Loctite 271, P/N 27183 Commercially Available
TM
Loctite 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
TM
Permatex , P/N 27100 Commercially Available
TM
Pliobond #20 Commercially Available
Pre-Lube Mixture – approx. 15% pre-lubricant
TM
(STP brand or equivalent) plus 85% SAE 50 Locally Prepared Mixture
straight weight mineral oil
Preservative oil mix (MIL-C-6529, type 1 plus
Locally Prepared Mixture
MIL-L-6082)
TM
RTV 102 Silicon Sealant General Electric
Safety Wire (0.032) Type 304 Stainless Steel,
Commercially Available
P/N MS20995 C32
Safety Wire (0.041) Type 304 Stainless Steel,
Commercially Available
P/N MS20995 C41
TM
Silastic 140 Sealant Commercially Available
Silk thread, size 00 (100% Silk) Commercially Available
TM
STP High Viscosity Oil Treatment Commercially Available
TitesealTM No. 2 Gasket and Joint Compound
Commercially Available
P/N T2-01
Phthalate resin-type enamel AMS3125C or
Commercially Available
equivalent MIL-E-7729 Randolph Black (#303)
Toluene or equivalent AMS3180 (or equivalent
Commercially Available
Federal Spec TT-T-548)
Zinc Chromate Primer Commercially Available

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DESCRIPTION AND OPERATION

General Description Continued Airworthiness

Superior Vantage Engines are four-cylinder, Vantage Engines discussed in this document
horizontally opposed, air-cooled, direct drive must be installed and operated in accordance
powerplants incorporating a wet sump, bottom with the limitations, conditions and operating
mounted induction, bottom exhaust with either procedures described in the Installation and
carbureted or port injected fuel systems. Operation Manual (SVIOM01). They must also
Provisions exist for both front and rear mounted be maintained in accordance with this manual
accessories. All engine components will be and the applicable Maintenance Manual
referenced as they are installed in the airframe. (SVMM01). For RSA-5 Fuel Servo, refer to
Therefore, the “front” of the engine is the Precision Airmotive Operation and Service
propeller end and the “rear” of the engine is the Manual (15-338E). For the carburetor, refer to
accessory mounting drive area. The oil sump is Marvel-Schebler Carburetor Service Manual
on the “bottom” of the engine and the cylinder (MSACSM). Sky-Tec starters and Slick
shroud tubes are on the “top”. The terms “left” magnetos must be returned to their mfr. for
and “right” are defined as being viewed from the service or overhaul. The engine’s time between
rear of the engine looking toward the front. overhaul (TBO) period is currently defined as
Cylinder numbering is from the front to the rear 1500 hours. A TBO extension program is in
with odd numbered cylinders on the right side of process.
the engine. The direction of crankshaft rotation
is clockwise as viewed from the rear of the Model Designations
engine looking forward unless otherwise The model number designation is defined in a
specified. Accessory drive rotation direction is way that the digits of the model number can
defined as viewed from the rear of the engine easily identify the basic configuration of the
looking forward. engine as described in Figure 02-00-00.1.

Figure 02-00-00.1 • Engine Model Number Designation

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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 Denotes detail engine configuration

1st Digit Crankshaft & Propeller Type

A Fixed-Pitch, Thin-wall front main

B Constant-Speed, Thin-wall front main
C Fixed-Pitch, Heavy-wall front main
D Constant-Speed, Heavy-wall front main
E Fixed-Pitch, Solid front main

2nd Digit Crankcase & Engine Mount Type

1 #1 Dynafocal Mount
2 #2 Dynafocal Mount
3 Conical Mount
4 #1 Dynafocal Mount, Front Propeller Governor
5 #2 Dynafocal Mount, Front Propeller Governor
6 Conical Mount, Front Propeller Governor

3rd Digit Accessory Package

Ignition System Fuel System

Carbureted (O-360) Fuel Injected (IO-360)
A Unison Magnetos Precision Carburetor Precision Fuel Injection

4th Digit Power Rating: Piston Compression Ratio

Cylinder Type
360
CR HP
1 7.2:1 168
2 8.5:1 180

Engine Components General Description

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The O-360 and IO-360 series engines are air- Features and Operating Mechanisms
cooled, four cylinder, horizontally opposed,
direct drive engines. See Installation & Crankshaft - The crankshaft is made from high
Operation Manual (SVIOM01) for Manufacturer’s quality, aerospace grade steel. All bearing
General Specifications. journal surfaces are nitrided. There are 3 kinds
of crankshafts: thin-wall, thick-wall, and solid
The complete engine (and engine overhaul) front mains which can be identified by looking at
includes the following components and the center of the front of the crankshaft or prop
assemblies (note that the fuel system oil cavity. The thin-wall and thick-wall
components, ignition components and starter crankshafts are each available as fixed-pitch or
must be overhauled by an approved FAA Repair constant-speed. Fixed-pitch versions have a
Station or the manufacturer): plug installed in the inner diameter of the front
main, or prop oil, cavity which prevents escape
Crankcase Assembly of oil out the front, since there isn’t a prop
Crankshaft Assembly governor or constant-speed prop for the oil
Camshaft Assembly pressure to act upon.
Valve Train Assembly
Cylinder Assemblies Connecting Rods - The connecting rods are
Connecting Rod Assemblies made from aerospace grade, high quality steel.
Oil Sump Assembly They have replaceable bearing inserts in the
Intercylinder Baffles crankshaft ends and bronze bushings in the
Starter piston ends. The bearing caps on the
Lubrication System (Includes Oil Filter) crankshaft ends are retained by two bolts with
Accessory Drive self locking nuts per cap. Caps are tongue and
Ignition System (Includes Spark Plugs) groove type for improved alignment and rigidity.
Fuel System
Starter Support Assembly Camshaft - Valve Operating Mechanism - The
Oil Gage camshaft is located above and parallel to the
Induction System crankshaft. The camshaft actuates hydraulic
Accessories lifters that operate the valves through pushrods
and valve rockers.
NOTE: Complete engine does not include outer
cylinder baffles, propeller governor, and airframe Crankcase - The crankcase is made from
to engine control cables, attaching hardware, aerospace grade, stabilized structural aluminum
hose clamps, vacuum pump, exhaust system, or alloy. The assembly consists of two reinforced
fittings. Fuel pump is included, unless otherwise aluminum alloy castings fastened together by
specified, on carbureted engines. Alternator means of studs, bolts, and nuts. The main
may be included, if specified. bearing bores are machined for use with
precision type main bearing inserts.
Specifications
The manufacturer’s physical specifications, Accessory Housing - The accessory housing is
Accessory Drive Specifications, Physical made from an aluminum casting and is fastened
Specifications for the engines and Accessories to the rear of the crankcase and the top rear of
and the Model Specification Data (MSD) are the sump.
available in the Installation & Overhaul Manual
(SVIOM01) available from Superior Air Parts, Oil Sump - The sump incorporates an oil drain
Inc. plug, oil suction screen, mounting pad for
carburetor or fuel injector, the intake riser, and
Illustrated views of the O-360 and IO-360 intake pipe connections.
engines identifying key components and sub-
assemblies, the engine wiring diagram and oil
system schematic are shown in the installation &
Overhaul Manual (SV10M01) available from
Superior Air Parts.

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Cylinders - Millennium Cylinders are used type pump. It is contained within the accessory
exclusively. These air-cooled cylinders are housing.
manufactured by screwing and shrinking the two
major parts, head and barrel, together. The cast Priming System - A manual primer system is
heads are made from a special aluminum alloy. provided on all engines using a carburetor. Fuel
All barrels are made from forgings produced to injected engines do not require a manual
aerospace specifications. They are internally priming system, relying instead on the fuel
choked and honed to allow optimal operating injectors for priming.
conditions for the rings and pistons at operating
temperatures. Ignition System - Dual ignition is furnished by
two Unison magnetos with two spark plugs per
Pistons - The pistons are made from an cylinder.
aluminum alloy. The piston pin is a full floating
type with a plug located in each end of the pin. Electrical System – Engines may be furnished
The piston is a 3-ring type with 2 compression with an alternator, if provided for in the model
rings and 1 oil control ring. specification. If an alternator is furnished,
installation brackets, hardware and belt are
Cooling System – Superior Vantage Engines provided. Alternators are available in either 12
are designed to be air-cooled. Baffles are or 24 volt systems and a range of amperages.
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 - Superior Air Parts O-360 engines

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 - IO-360 series engines are

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.

Lubrication System - The full pressure wet

sump lubrication system is supplied by a gear

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AIRWORTHINESS LIMITATIONS SECTION

Mandatory Intervals or Procedures

Refer to the Superior Vantage O/IO-360
Maintenance Manual, SVMM01 for
Airworthiness Limitations information.

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TESTING AND FAULT ISOLATION

Please refer to the Superior O/IO-360 Maintenance Manual No. SVMM01 for detailed instructions
for Testing and Fault Isolation.

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Revision C

SPECIAL PROCEDURES
Break-In Procedures
Break-In Procedures after the overhauled engine has been installed in the aircraft may be found in the
Superior Vantage O/IO-360 Maintenance Manual No. SVMM01. Information on acceptance testing after
overhaul is provided in this manual in section 72-00-13.

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Special Procedures
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O-360 and IO-360 Series Engines
Revision C

ENGINE REMOVAL
General
Due to the complexity and variation in aircraft
design, instructions for the removal of the engine
from the airframe are not provided here. The
airframe Maintenance Manual instructions for
engine removal must always be closely adhered
to, in order to avoid damage to the engine and
aircraft and injury to personnel. Refer to
Superior Vantage Maintenance Manual
SVMM01 for additional information.

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ENGINE DISASSEMBLY
General Disassembly Materials
This section contains disassembly procedures. The materials required for disassembly are listed
When necessary, disassembly illustrations are in Table 72-00-06.1.
also provided. All item number references in the
text are specific to this manual and the figures NOTE: Equivalent substitutes may be used.
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

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
Connecting Rod and Crankshaft Gear Bolts
Intake and Exhaust Valves, Valve Guides and Valve Keepers
Crankshaft Gear Attaching Bolt
Connecting Rod Nuts and Bolts
All Lock Washers, 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 NOTE: Standard reciprocating engine aviation
disassembly are listed in Table 72-00-06.3. shop tools and equipment are used
unless otherwise specified.

Table 72-00-06.3 • Special Tools and Equipment

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Nomenclature Source
Compressor, Piston Ring Commercially Available
Expander, Piston Ring Commercially Available
Puller, Slide Hammer-Medium Commercially Available
Compressor, Valve Spring Bar Commercially Available
Inter cylinder 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 Disassembly

 Place engine in horizontal position on a
transfer cart. WARNING: FUEL IS TOXIC AND
FLAMMABLE. DO NOT BREATHE VAPORS.
WARNING: ENGINE OIL IS HAZARDOUS AVOID EYE AND SKIN CONTACT. USE
AND MAY CAUSE INJURY TO SKIN AND PROTECTIVE GEAR. IN CASE OF EYE
EYES. PUT ON PERSONNEL PROTECTIVE CONTACT, FLUSH WITH WATER FOR 15
GEAR. MINUTES AND SEEK MEDICAL ATTENTION.
IN CASE OF SKIN CONTACT, WASH WITH
 Remove the oil drain plug and drain the oil SOAP AND WATER.
from the engine, if not previously drained.
 Remove the starter ring gear support. WARNING: PUT ON SAFETY GOGGLES
 Perform visual inspection during WHEN INSTALLING OR REMOVING SAFETY
disassembly and immediately after WIRE.
disassembly. All individual parts should be
laid out in an orderly manner as they are Removal of Carburetor and Priming System
removed. (1) Remove engine fuel lines (30, Figure
 All loose studs, cracked baffles, and loose or 72-00-09.37) and all attaching
damaged fittings should be identified using a hardware.
card paper tag and tie wire to prevent being (a) Remove engine fuel priming system
overlooked during regular inspection. attaching hardware clamps, (25, 30,
 Paper Tag all components and parts as they 45 Figure 72-00-09.36) screws (35)
are removed using tie wire. Maintain identity and nuts, (40). Disconnect tube (1,
of loose assemblies or attaching hardware 5, 10, 15) coupling nuts at cylinder
by placing them together in a suitable bag or head and attaching tee tubes (20).
other container. (2) Remove the carburetor on O-360 series
 Prior to starting the component or parts engines as follows.
disassembly phase, engine may be placed (a) Remove nuts (1, Figure 72-00-
on a vertical nose support stand. 09.37), lockwashers (2) and flat
washers (3) from studs in 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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Fuel injection system removal filter adapter (10) to the accessory

(1) Remove engine fuel injection manifold housing. Discard gasket (5).
tubing clamps (70, 75 Figure 72-00- Remove cooler bypass plug (55),
09.39), nuts (85), and screws (80). and discard gasket (50).
(2) Disconnect injector tubing (55, 60), eight
places at fittings (40), elbow (25), and Vacuum pump or cover removal
injector nozzle assembly (90). Remove (1) Remove the vacuum pump (or
nozzle assemblies (90) four places. cover) attaching nuts (40, Figure 72-
(3) Remove fuel manifold bracket (1) 00-09.31), lockwashers (35) and flat
retaining nuts, washers, (5) and bolts washers (30). Remove pump (or
(10). Remove manifold (15) retaining cover (20) as appropriate) and
bolts (25) and washer (20). discard gasket (15). Remove
(4) Disconnect and remove fuel hoses (30, adapter assembly (25). Discard
35, Figure 72-00-09.38). Remove nuts, gasket (10) and remove vacuum
(25) lockwashers (20), and flat washers gear (1) and thrust washer (5) from
(15) from studs. Remove injector servo housing. Remove oil seal (55) and
assembly (10) and remove gasket and discard.
spacer (5).
Rear Propeller governor Adapter removal (as
Magneto and harness removal required)
(1) Unscrew ignition wiring harness leads (1) Remove the propeller governor oil line
(5, 10, Figure 02-00-00.10) from the top (Figure 72-00-09.34). Remove any
and bottom spark plugs (50). Remove clamps. Remove elbows (10, 15) and
harness attaching caps (5), two places, any attaching hardware, as required, to
from the magneto. Remove spark plugs allow hose removal, discard o-ring (20).
(50) from cylinder. (2) Remove the cover nuts (30) as required,
(2) Remove magneto (15, Figure 72-00- (Figure 72-00-09.33), lockwashers (25),
09.40) attaching nut (30), washer (25), and flat washers (20). Remove cover
and clamp (20). Remove the magneto (65) and discard gasket (60). Remove
(15) and discard gasket (10). Remove retaining ring (55) and thrust washer (5).
the adapter (5) and gasket (1). Remove Remove adapter nuts (30), lockwashers
cotter pin (40), nut, and washer. (25), and flat washers (20). Remove
Remove magneto gear (35) and install propeller governor adapter (15).
nut back on threads to prevent damage Discard gasket (10). Tag and save
to drive shaft threads. thrust washer (5). Remove gear shaft
(1) from housing.
Oil level gage housing Removal
(1) Unscrew the oil gage (10, Figure 72- Accessory Housing Assembly Removal
00-09.28) and remove the oil gage (1) Remove the accessory housing
housing (5). Discard seals (15, 20). assembly by removing the bolts (15,
Figure 72-00-09.23), lockwashers
Fuel pump removal (as required) (10), and flat washers (5). Remove
(1) Remove fuel pump screws (15, bolt (20), washer (10), and nut (25)
Figure 72-00-09.32) and washers two places. Remove accessory
(10). Remove fuel pump (5) and housing (40) and gasket (35).
gasket (1). Remove elbows (25, 30) Remove fuel pump plunger (1,
and discard o-rings (20). Figure 72-00-09.24).
(a) Remove nuts (90) and washers
Oil filter and Adapter removal (85) to remove oil pump housing
(1) Unscrew the oil filter (40, Figure 72- assembly (80). Remove oil
00-09.35). Remove the vernatherm pump drive shaft (115) and
(temperature control valve) (35). impeller gears (105, 110).
Remove screws (30), washers (15,
20), and nut (25) that secure the oil Idler gears and shaft removal

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(1) Remove idler gears (15,20, Figure (1) Loosen hose clamps (85, Figure 72-00-
72-00-09.20). Remove idler shaft 09.17) on hose (80) at drain nipple (75).
mount screws (5) and nut (10). Slide away from drain nipple (75).
Remove idler shafts (1) from Loosen gland nut at cylinder head fitting
crankcase. and remove tube assembly (90) from
cylinder.
Starter and alternator attaching hardware
removal Intercylinder cooling baffle removal
(1) Remove starter mount bolt (15, (1) Remove the intercylinder cooling baffles
Figure 72-00-09.42), nuts (20), (1, Figure 72-00-09.26) using
lockwashers (10), and flat washers intercylinder baffle tool. Turn the baffle
(5). Remove starter (1) from retaining hook (10) so that it disengages
crankcase. the retainer (5). Remove the baffle (1)
(a) Remove alternator mount bolt and hook (10) from between the
(10, Figure 72-00-09.43) and cylinders.
washer (5) to loosen drive belt.
Remove cotter pin (45), slotted Cylinder removal
nut (40), support bolt (25), and (1) Remove the valve cover screws (130,
shims (35). Remove cotter pin Figure 72-00-09.15) and cover (125)
(45), slotted nut (40), shims and discard gasket (120). Rotate the
(35), and support bolt (30). crankshaft to place the piston of the No.
Remove bolts (20, 90) and flat 1 cylinder at top center of the
washers (15, 85) from strut compression stroke.
bracket (80). Remove strut
support (80) and remove NOTE: With the piston in this position both
alternator. valves will be closed and the piston
(b) Remove alternator bracket (55) extended away from the crankcase to
by removing bolts (60) and lock avoid damage when the cylinder is
plate (50). Remove bolt (75), removed.
flat washer (70), and adjusting
link (65). Visually inspect (2) Remove the valve rocker shaft caps
hardware and bag for reuse if (20), the valve rocker shaft (15), valve
not damaged. rocker arms (5), and the exhaust valve
stem cap (115) from cylinder assembly.
Oil sump and induction disassembly Remove the pushrod (1) by grasping the
(1) Remove screws (25, Figure 72-00- rod end and pulling it through the rod
09.29), lock washers (20), and flat tube (40). Remove nut (60), spring (55),
washers (15) from intake pipe flange and lockplate (50). Pull rod tube
(10). Discard gaskets (1). through cylinder head and discard tube
(2) Remove clamps (35), intake hoses (30), seals (35, 45).
and intake tubes (5) from oil sump (a) Remove cylinder assembly by
assembly. removing nuts from cylinder base.
(3) Remove oil screen plug (85, Figure 72- Remove cylinder by pulling straight
00-09.27), discard gasket (80), and away from crankcase. As the
remove oil suction screen (75). Inspect cylinder is being pulled away, hold
for debris. the piston to prevent damaged.
(4) Remove bolts (15,20), flat washers (25, Discard cylinder base seal.
30), lockwashers (25), and nuts (35)
from sump assembly flange. Discard CAUTION: THE CONNECTING ROD MUST BE
gasket (11) and remove intake SUPPORTED TO PREVENT DAMAGE TO THE
connection pipes (12) from sump ROD AND CRANKCASE. SUPPORT EACH
assembly. CONNECTING ROD WITH HOLD DOWN
PLATES TOOL OR RUBBER BANDS (OR
Cylinder drain tubes removal DISCARDED CYLINDER BASE SEALS)

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LOOPED AROUND THE CYLINDER BASE (5) Remove and disassemble the hydraulic
STUD. lifter assembly.

(3) Remove the piston pin (35, Figure 72- CAUTION: MAINTAIN THE PARTS OF EACH
00-09.6) using a piston pin drive tool. TAPPET ASSEMBLY TOGETHER DURING
Drive pin (35) from piston to remove ALL OVERHAUL OPERATIONS. ALL
piston (30) from the connecting rod (5). COMPONENT PARTS ARE TO BE
REASSEMBLED WITH THEIR ORIGINAL
NOTE: Removal of the remaining cylinders MATING PARTS AND EACH ASSEMBLY
and pistons may be done in any REINSERTED IN ITS ORIGINAL LOCATION.
sequence, but less turning of the
crankshaft is involved if the cylinders (a) Using hydraulic tappet tool, remove
are removed in firing order 1-3-2-4. the pushrod socket (30, Figure 72-
00-09.15) by placing heavy grease
(4) Compress valve springs (90, 95, Figure on ball end of the "T". By inserting
72-00-09.15) with spring compressor the ball end in the tappet and
tool, while supporting cylinder, far withdrawing, the socket will adhere
enough to remove the valve cylinder to the grease.
keys (105, 110). (b) Using the hollow end of the tool,
push it over the plunger and
NOTE: If the valve keys are stuck in the spring withdraw the plunger. If the tool is
seat, a light blow with a leather mallet not available, remove the pushrod
on top of the compressor tool will socket with fingers or by using
release keys. needle nose pliers. Insert a piece of
wire bent at a right angle into the
CAUTION: DO NOT DRIVE THE VALVES plunger between the plunger and
THROUGH THE GUIDES. the lifter body. Turn 90 degrees to
engage a coil of spring and draw out
(a) Remove upper valve spring seats the plunger assembly.
(95, 100), inner and outer springs
(85, 90), and lower valve spring Crankcase Disassembly
seats (75, 80) from rocker box. (1) Remove nuts (25, 45, 70, 85, Figure 72-
Keep parts for each valve (65, 70) 00-09.11 and 72-00-09.12), bolts (5, 30,
separate. Hold valves by the stems 55, 90, 95), and washers (15, 20, 35,
to keep them from dropping out of 40, 60, 65, 80). Draw or pull the thru-
the cylinder and remove cylinder bolts (1) from the crankcase using
from the holding block. Reach cylinder base nuts and washers and/or
inside and remove valves. If valves spacers.
are difficult to remove, push valves (2) Separate crankcase using care not to
back in and clean carbon from allow camshaft to fall to floor. Caution
stems. should be used to keep the right case
thru-studs from becoming misaligned
CAUTION: BE CAREFUL NOT TO SCRATCH when separating the crankcase halves
OR SCORE PISTONS WHEN REMOVING THE (60, Figure 72.00-09.5).
RINGS.
NOTE: Carefully pull crankshaft nose seal
(b) Using the piston ring expander tool, from crankcase forward on crankshaft
remove the rings (40, 45, Figure 72- to aid in crankcase half separation.
00-09.6) from all pistons. Remove
the rings in order starting with the (3) Remove the bearing inserts (5, 10,
top ring and work down. Figure 72-00-09.2), lifter bodies (20),
and camshaft. Remove and discard o-
ring seals (10, 75).

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Engine Disassembly
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

NOTE: Place each lifter body in its proper (or secured on a nose stand), remove
location in a cleaning basket. The rod nuts (15, Figure 72-00-09.6).
lifter bodies must be assembled in Remove the rods (5) by tapping on the
their original locations if reused. rod bolts (10) with a soft hammer.
Discard the connecting rod bearing (1),
(4) Remove all threaded plugs and discard bolts (10), and nuts (15).
oil seals.
(5) Propeller Governor Drive (Located on NOTE: Maintain each cap and rod as an
the front left side of crankcase). See assembly. Rods and caps are not
Figure 72-00-09.5. Remove the hex interchangeable.
head plug(6) and gasket (5) from the
crankcase. Remove the idler shaft (4) (2) To remove the crankshaft gear (5,
through the opening in the crankcase at Figure 72-00-09.3), flatten the lockplate
the same time supporting the idler gear (10) and remove screw (15). Tap the
(9) to prevent dropping and damaging. gear lightly with a soft mallet or brass
The idler shaft is pinned and staked to drift. Remove the crankshaft oil seal
the housing. Pull the Governor driven and discard.
gear (8) from the crankcase
Crankshaft Disassembly
(1) With the crankshaft firmly supported at
the front and rear main bearing journals

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

CLEANING
General CAUTION: DO NOT USE SAND OR METALLIC
Cleanliness of the aircraft engine is crucial to its ABRASIVES WITH THE GRIT BLASTING
optimum performance. This section provides EQUIPMENT.
information on materials, tools, and guidelines
for cleaning.
Degreasing
After the initial visual inspection of internal Degreasing is accomplished by immersing or
engine parts, it is necessary to thoroughly clean spraying the part in solution of white furnace oil
the engine components for detailed inspection. (38-40 specific gravity) or another suitable
Since this visual inspection is made during and solvent such as Varsol or Perm-A-Chlor.
after disassembly, the components should be
cleaned afterwards and tagged to facilitate
further non-destructive inspection methods. Table 72-00-07.2
This identification procedure will also help Materials Required for Cleaning
prevent these components from being Item Vendor
overlooked.
Cleaning solvent or degreaser
Commercially
such as white furnace oil,
It is important to remember to visually inspect an Available
Varsol, or Perm-A-Chlor
engine prior to cleaning. Residue from the
engine’s operation can provide information as to Decarbonizing solutions such
Commercially
hidden defects or other dangerous conditions. as Gunk, Penetrol, Carbrax,
Available
Super-Chemco, or Gerlach #70
Tools and Materials Commercially
Isopropyl Alcohol
For tools required during cleaning, refer to Table Available
72-00-07.1. For consumable materials required Aerosol electrical contact Commercially
during cleaning, refer to Table 72-00-07.2. cleaner Available
Commercially
Lubricating Oil (SAE 20)
Table 72-00-07.1 Available
Equipment Required for Cleaning Commercially
Corrosion preservative oil
Available
Item Vendor Commercially
Brush (soft and stiff Commercially Abrasive cloth (crocus cloth)
Available
bristles) Available
Commercially NOTE: Residue from the solvent washing must
Immersing tank
Available be captured and contained to prevent
Commercially contamination of the surrounding
Scraper (wood) environment.
Available
Commercially
Grit blaster WARNING: USE THE CORRECT PERSONAL
Available
NOTE: Equivalent substitutes may be used. PROTECTION. SOME CHEMICAL
SOLUTIONS CAN CAUSE SKIN, EYE AND
LUNG DAMAGE. FOLLOW THE
Cleaning Instructions MANUFACTURER'S INSTRUCTIONS FOR
Two (2) processes are used in cleaning engine EACH CLEANING SOLUTION.
parts; degreasing to remove dirt and sludge (soft
carbon) and the removal of hard carbon by CAUTION: IF ANY WATER-MIXED
decarbonizing, brushing or scraping and grit DEGREASING SOLUTIONS CONTAINING
blasting. CAUSTIC COMPOUNDS OR SOAP ARE
USED, EXTREME CARE MUST BE
EXERCISED. THESE COMPOUNDS IN
ADDITION TO BEING POTENTIALLY

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Cleaning
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

DANGEROUS TO ALUMINUM AND SAME DECARBONIZING TANK, BECAUSE

MAGNESIUM, MAY BECOME IMPREGNATED THIS PRACTICE OFTEN RESULTS IN
IN THE PORES OF THE METAL AND CAUSE DAMAGE TO THE MAGNESIUM PARTS FROM
OIL FOAMING WHEN THE ENGINE IS CORROSION.
RETURNED TO SERVICE. WHEN USING
THESE WATER-MIXED SOLUTIONS ALWAYS CAUTION: DO NOT DAMAGE MACHINED
THOROUGHLY RINSE THE PART IN CLEAN SURFACES. MASK ALL MACHINE
BOILING WATER. REGARDLESS OF SURFACES PLUG ALL DRILLED OIL
METHOD OR SOLUTION USED ALWAYS PASSAGES TO PREVENT DAMAGE OR
COAT AND SPRAY ALL PARTS WITH ENTRY OF FOREIGN MATTER.
LUBRICATING OIL IMMEDIATELY AFTER
CLEANING IN ORDER TO PREVENT CAUTION: WHEN YOU USE COMPRESSED
CORROSION. AIR TO CLEAN OR DRY PARTS, MAKE SURE
THAT THE PRESSURE IS NOT MORE THAN
CAUTION: USE THE CORRECT PERSONAL 20 PSI. DO NOT DIRECT THE AIRSTREAM
PROTECTION. HEATED PARTS WILL CAUSE AT PERSONNEL OR LIGHT OBJECTS. PUT
BURNS. ON GOGGLES OR A FACE SHIELD TO
PROTECT YOUR EYES. THIS WILL HELP
Decarbonizing PREVENT INJURIES TO PERSONNEL OR
Decarbonizing is usually accomplished by DAMAGE TO THE EQUIPMENT. IF YOU GET
immersion of the part in a decarbonizing solution AN EYE INJURY, SEEK MEDICAL ATTENTION
(usually heated). Decarbonization solutions
such as Gunk, Penetrol, Carbrax, Super- CAUTION: DO NOT USE WIRE BRISTLE
Chemco, Gerlach No. 70 or any suitable BRUSHES OR METAL SCRAPERS ON ANY
solution. Refer to the above caution for water- BEARING, MACHINED OR CONTACT
soluble decarbonizers. Remove hard carbon SURFACES.
deposits after degreasing by brushing, scraping
or grit blasting. After cleaning, rinse the parts in CAUTION: DO NOT USE GRIT BLASTING ON
petroleum solvent, dry, and remove loose THE PISTON RING GROOVES. USE A
particles by blowing the particles out with WOODEN SCRAPER.
compressed air. Use a shop air supply with an
appropriate water trap.
Scratch and Corrosion Removal
Decarbonizing solutions will usually remove Remove corroded or pitted surfaces on the fillets
most of the enamel from machined surfaces. All at the edges of crankshaft main and crankpin
remaining enamel should be removed by grit journal surfaces, and thrust bearing races by
blasting particularly in the narrow areas between polishing with crocus cloth or fine grit abrasive
cylinder cooling fins. paper. Refer to the Table of Limits section of
this manual for size limits.
Valve seats may be left unprotected during
decarbonizing processes. This will facilitate the Shallow or small scratches, minor abrasions, or
reconditioning of the valve seat in later pitting on gears or screwed fittings may be
procedures. dressed out with a fine abrasive (crocus) cloth,
small file, or polishing stone. Refer to the Table
CAUTION: EXTREME CAUTION SHOULD BE of Limits Appendix C of this manual for limits.
EXERCISED WHEN USING A
DECARBONIZING SOLUTION. IT IS Note: If pits, scratches, corrosion, abrasions
RECOMMENDED THAT THE USE OF HEATED cannot be removed using crocus cloth or
SOLUTIONS BE AVOIDED UNLESS THE another specifically defined material, the part
OPERATOR IS THOROUGHLY FAMILIAR must be rejected. Reference Repair No. 2.
WITH THE PARTICULAR SOLUTION BEING
USED. IN ADDITION THE OPERATOR IS
STRONGLY ADVISED AGAINST IMMERSING
STEEL AND MAGNESIUM PARTS IN THE

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Accessory Mounts NOTE: Under normal conditions, the shield

Clean mounting pads and studs by wiping with a and screen are NOT removed from the
clean cloth moistened with solvent. Use care to nozzle assembly. If removal is
remove sludge and debris from around the necessary, both must be thoroughly
bases of the studs. cleaned prior to reassembly. The
NOTE: Use care to not force debris into drilled shield must have a tight fit on the
areas, passages, ports, or threaded body.
receptacles.

WARNING: SOLVENT IS TOXIC. USE IN Screens and Filters

WELL-VENTILATED AREA. PREVENT EYE A. Fuel system filters
AND SKIN CONTACT AND DO NOT (1) Fuel screens may be soaked and
BREATHE VAPORS. IN CASE OF EYE rinsed in clean solvent and dried
CONTACT, FLUSH WITH WATER FOR 15 with compressed air.
MINUTES AND SEEK MEDICAL ATTENTION. B. Oil system filters
IN CASE OF SKIN CONTACT, WASH WITH (1) Oil screens may be soaked and
SOAP AND WATER. rinsed in clean solvent and dried
with compressed air.
(2) Disposable external oil filter
Fuel Injector and Primer Nozzles elements are not cleaned.
Remove the nozzle. Submerge in a cleaning C. Air induction system filters
solvent such as Stoddard Solvent or MEK or (1) Foam air filters may be rinsed in
equivalent. Allow soaking for several hours. clean solvent then washed with mild
Remove from solvent and dry with dry and clean detergent and water and reinstalled.
compressed air. Ultra-sound cleaning methods Paper air filter elements are not cleaned
may also be used. Refer to Precision Airmotive
SIL RS-82 for approved cleaning methods. WARNING: SOLVENT IS TOXIC. USE IN
WELL-VENTILATED AREA. PREVENT EYE
WARNING: SOLVENT IS TOXIC. USE IN AND SKIN CONTACT AND DO NOT
WELL-VENTILATED AREA. PREVENT EYE BREATHE VAPORS. IN CASE OF EYE
AND SKIN CONTACT AND DO NOT CONTACT, FLUSH WITH WATER FOR 15
BREATHE VAPORS. IN CASE OF EYE MINUTES AND SEEK MEDICAL ATTENTION.
CONTACT, FLUSH WITH WATER FOR 15 IN CASE OF SKIN CONTACT, WASH WITH
MINUTES AND SEEK MEDICAL ATTENTION. SOAP AND WATER.
IN CASE OF SKIN CONTACT, WASH WITH
SOAP AND WATER. WARNING: WHEN YOU USE COMPRESSED
AIR TO CLEAN OR DRY PARTS, MAKE SURE
WARNING: WHEN YOU USE COMPRESSED THAT THE PRESSURE IS NOT MORE THAN
AIR TO CLEAN OR DRY PARTS, MAKE SURE 30 PSI. DO NOT DIRECT THE AIRSTREAM
THAT THE PRESSURE IS NOT MORE THAN AT PERSONNEL OR LIGHT OBJECTS. PUT
30 PSI. DO NOT DIRECT THE AIRSTREAM ON GOGGLES OR A FACE SHIELD TO
AT PERSONNEL OR LIGHT OBJECTS. PUT PROTECT YOUR EYES. IF YOU GET AN EYE
ON GOGGLES OR A FACE SHIELD TO INJURY, GET MEDICAL ATTENTION.
PROTECT YOUR EYES. IF YOU GET AN EYE
INJURY, GET MEDICAL ATTENTION.
Accessories
CAUTION: DO NOT USE A SHARP TOOL TO Refer to the various manufacturers’ manuals for
CLEAN OR DISASSEMBLE FUEL OR AIR information regarding the cleaning of these
BLEED NOZZLES. components.

• Precision Airmotive fuel injector components-
SIL RS-82
• Marvel-Schebler carburetor components-
Service Bulletin No. A1-76.

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

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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Cleaning
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

INSPECTION AND CHECK

General Methods to be used for inspection are listed
The inspection of engine parts consists of three Table 72-00-08.1. Special tools and equipment
(3) categories: visual, structural and required for inspection are listed Table 72-00-
dimensional. Visual and structural inspections 08.2.
deal primarily with structural defects. The
Table 72-00-08.1
dimensional checks are concerned with the size,
Inspection Methods
shape, and fit of a given part. Upon successful
completion of inspection, coat all steel parts with Item Method
preservative oil.
Magnetic Particle ASTM E1444 or
Inspection (MPI) MIL-STD-1947
Visual inspections should be accomplished
during teardown to isolate to identify ASTM E1417, AMS
Florescent Penetrant
components that are cracked, worn or otherwise 2647 or MIL-STD-
Inspection (FPI)
appear damaged. No cleaning operation should 1907
be permitted until a complete initial visual
inspection is made of the part in question. Table 72-00-08.2
Residue from the engine’s operation can provide Special Tools and Equipment
additional information as to hidden defects or
other dangerous conditions. Refer to the Item Source
Cleaning section of this manual for cleaning of Calipers and Commercially
parts prior to structural and dimensional micrometers: ID and OD Available
inspection Commercially
10X Magnifying Glass
Available
Structural inspections for structural failures will
Commercially
be accomplished using several common non- Machinist’s Ruler
destructive testing (NDT) processes. These Available
include magnetic particle (for steel parts) and Commercially
Small Flashlight
dye penetrant (for all non-magnetic alloys) Available
procedures as well as eddy-current, ultra-sonic, Commercially
Vee Blocks
or other NDT methods. Available
Commercially
Dimensional inspections must be accomplished Dial Indicator
Available
to determine the serviceability or the need for Commercially
repair or replacement of parts. Dimensions and Spring Tension Tester
Available
tolerances are provided in the Table of Limits
Appendix C of this manual. Magnetic Particle Commercially
For repairs required prior to a final inspection or Inspection Equipment Available
dimensional check of a part, refer to the Repairs NOTE: Equivalent substitutes may be used.
Section 72-00-11 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

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Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

General Inspection Procedures Qualification and Certification of Nondestructive

All journal surfaces must be checked for galling, Testing Personnel. This inspection is especially
scores, misalignment, and out-of-round effective when used on highly stressed parts
condition. Pins and shafts must be inspected for such as keyways, gear teeth, splines, roots of
straightness. Detailed instructions and threads, small holes, and fillets.
acceptance criteria are in the following pages for
Crankshafts, camshafts, connecting rods, etc. NOTE: Perform the magnetic particle
inspection strictly in accordance with
Examine gears for evidence of pitting and the MPI specification guidelines.
excessive wear. This evidence is of special Failure to do so can result in
importance when found on the involute of the erroneous readings and the reuse of
gear teeth. Deep pit marks in this area are critical components with hidden
reason to reject the part. Bearing surfaces of all damage that may cause engine failure.
gears may have minor abrasions dressed out
with fine abrasive cloth but should be free from NOTE: Care must be taken to prevent
deep scratches. overheating or burning of the part as a
result of the applied electricity during
Excessively worn or mutilated threads should be this test.
rejected. Small defects (such as slight nicks or
burrs) may be dressed out with a small file, fine All aluminum and other non-magnetic alloy parts
abrasive cloth (crocus cloth), or oil stone. If should be inspected using a fluorescent
distortion, galling, or mutilation resulting from penetrant (inspection (FPI) method (Refer to
over tightening is discovered, the part must be Table 72-00-08.1), performed by qualified
replaced. personnel in accordance with ANSI/ASNT-CP-
189 Standard for Qualification and Certification
Inspection of highly stressed areas for corrosion of Nondestructive Testing Personnel.
is necessary. These areas are susceptible to
pitting and can cause failure of the part. The Parts subjected to MPI or FPI must be
following are components requiring particular thoroughly cleaned of all penetrant and
attention with respect to this issue: the fillets at developer residue upon completion of the test.
the edges of crankshaft main and crankpin Any oils or other fluids used for other non-
journal surfaces, and thrust bearing races. If destructive procedures must be thoroughly
pitting is discovered in these areas and cannot cleaned from the part upon completion of the
be removed by polishing with crocus cloth or test.
other fine abrasive, the part must be replaced.
For polishing procedures, see the Repairs NOTE: Upon completion of any cleaning
section of this manual. procedure, be sure to coat all steel
parts with preservative oil. Do not
Inspect all threaded inserts, fasteners, studs, handle cleaned parts any more than
fittings, plugs, etc., for condition of threads. necessary prior to their reassembly
into the engine as this handling
General Non-Destructive Testing reintroduces dirt and corrosive
All parts must be thoroughly clean and dry prior substances to the parts.
to the start of the test and again upon
completion of the test procedures. Refer to
Cleaning Section 72-00-07 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
(MPI) method (Refer to Table 72-00-08.1),
performed by qualified personnel in accordance
with ANSI/ASNT-CP-189 Standard for

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

wear
Accessory Housing (1) Inspect all crankcase bearing bores
Initially inspect accessory housing as illustrated and journals, saddle supports, support
in Figure 72-00-08.2. Remove all accessories webs, tang slots, and flange surfaces.
(magnetos, pumps, valves, etc.) for separate  Deep scratches Reject
inspection.  Fretting, heavy
Reject
 Obvious wear, flat spots
excessive Reject Blend/hand
damage  Minor scratches polish per
Repair No.2
Visually inspect accessory housing.  Misalignment of
Reject
(1) Inspect accessory housing flange and mating surfaces
drive pad surfaces.  Out of round
 Deep scratches Reject conditions on Reject
journals
Blend/hand (2) Inspect crankcase threaded studs and
 Minor scratches
polish per drilled holes and passages.
Repair No.2  Worn,
(2) Inspect accessory case threaded and mutilated, Reject/See
drilled areas and passages. distorted, or Repair No. 1
 Worn or galled
mutilated, Reject/Repair Blend/hand
 Slight nicks or
distorted, galled polish per
burrs
Blend/hand Repair No.1
 Slight nicks or
polish per
burrs
Repair No. 2 NOTE: Surfaces may be checked visually and
by feel for roughness, flaking, and
See Cleaning pitting of races and for scoring on the
 Obstructions or
section of this outside of the bearing races. Shafts,
plugs
manual pins, etc., may be checked using vee
blocks and dial indicators.
See Repair No.
 Stud damage
1 NOTE: Aluminum surfaces can withstand
considerable scratching and light
FPI accessory housing scoring without harming the engine
 Cracks Reject integrity or performance provided
these problems fall within the limits set
Dimensionally inspect accessory housing. forth in the Table of Limits section of
(1) Inspect accessory housing bearing this manual.
bores.
 Inside See Table of NOTE: Fretting on the saddle supports in the
diameters Limits crankcase has a frosted appearance
and tiny pit holes. This usually
(2) Inspect accessory housing flange for indicates a change in the size of the
flatness bearing saddles that can be sufficient
See Table of to cause an excessively tight
 Flat
Limits crankshaft bearing fit.

Crankcase Assembly FPI Crankcase Halves

Perform initial inspection of crankcase assembly  Cracks Reject
per Figure 72-00-08.3.
 Obvious Dimensionally inspect assembled crankcase.
excessive Reject See Table of Limits for thru bolt torque.
damage or

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

(1) Inspect crankcase main and camshaft (2) Inspect crankcase front propeller
bearing bores. governor (if applicable) idler shaft and
 Inside See Table of drive gear bores.
diameters Limits  Inside See Table of
diameters Limits

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72-00-08
Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Figure 72-00-08.2 • Accessory Housing

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Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

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

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Cylinder Head Visually inspect cylinder barrel for general

Initially inspect cylinder head. Refer to Figure condition. Refer to Figure 72-00-08.4.
72-00-08.4.  Cracks. Reject
 Obvious
excessive Visually inspect cylinder barrel cooling fins.
Reject
damage to Blend with
cylinder head hand grinder
 Notches and nicks or file. See
Visually inspect cylinder head. Repair No.
(1) Inspect cylinder head valve seats. 10
 Loose, scored,
or pitted valve Reject Visually inspect cylinder barrel to head junction
seats area for evidence of leakage
(2) Inspect cylinder for loose or damaged  Dark Stains Reject
studs.
 Loose or See Repair No. Visually inspect cylinder barrel skirt.
damaged studs 1  Bent, cracked, or
Reject
broken

(3) Inspect cylinder head spark plug Visually inspect cylinder barrel mounting flange.
helical coil inserts. Blend with
 Loose or file or crocus
See Repair No.  Nicks
damaged cloth. See
12
inserts Repair No. 2

Visually inspect cylinder barrel interior.

(4) Inspect cylinder rocker box covers, Repair by
 Minor scoring or
intake and exhaust ports. honing. See
corrosion
 Nicked, scored Blend/hand Repair No. 6
or dented polish per  Deep scoring or
Reject
mounting pads Repair No.2 pitting
(5) Inspect cylinder head cooling fins for Repair by
 Glazing or possible
cracks. honing. See
barrel wear
 Fin adjacent to Repair No. 6
See Repair
the exhaust
No.10
port flange
 Physically
damaged, See Repair
broken, or bent No.10
fins

Cylinder Head Dimensional Inspections

Inspect the rocker shaft bushings.

 Check the ID of the rocker
shaft bushings a minimum
Refer to
of two (2) positions, 90
Table of
degrees apart. Several
Limits
check locations are
preferred.

Cylinder Barrel Inspections

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Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Cylinder Barrel Dimensional Inspections Inspect pistons for correct dimensions. Refer to
Visually inspect cylinder barrel dimensions. Figures 72-00-08.5 and 72-00-08-6.
Refer to Figure 72-00-08.4 and 72-00-12.1.  Side clearance Refer to
between piston and Table of
Refer to ring Limits
 Fit between piston
Table of
skirt and cylinder
Limits
Refer to NOTE: These pistons are ground with a slight
 Maximum taper of
Table of taper from the skirt to the head. The
cylinder walls
Limits exception is the lands between the top
Refer to compression and oil control rings,
 Maximum out of
Table of which are ground parallel. The
roundness
Limits clearance on wedge type compression
Refer to rings must be measured with ring flush
 Bore diameter Table of to outside edge of piston as shown in
Limits Figure 72-00-08.6 in order to obtain a
true check of the side clearance.

NOTE: All cylinder barrel diameter Refer to

measurements must be taken at a two  Inside diameter of
Table of
(2) locations, 90 degrees apart at the piston pin hole
Limits
plane specifically being measured.

Cylinder Assembly Inspection NOTE: No pitting or corrosion is permitted in

Perform a fluorescent penetrant inspection of this area.
the cylinder heads.
 Cracks Reject  Clearance between
piston skirt and Refer to
cylinder and piston Table of
Piston Inspections diameter at top and Limits
Visually inspect piston general condition. Refer bottom
to Figure 72-00-08.5.
Perform a fluorescent penetrant inspection of
 Inspect the top of
the pistons.
the piston for
 Cracks Reject
excessive pitting, Reject
cavities or surface
distortion.
 Inspect the piston
lands, piston pin
holes, and bosses Reject
for excessive wear
or damage.

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Inspection and Check
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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-08.4 • Cylinder Assembly

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Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Figure 72-00-08.5 • Piston Assembly

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Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Figure 72-00-08.6 • Piston Rings and Lands

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Inspection and Check
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

Valve Rockers Pushrod Inspection

Inspect valve rocker for damage. Refer to Inspect pushrods for wear, fit, and alignment.
Figure 72-00-08.7. Refer to Figure 72-00-08.8.
 Check for damaged,  Inspect for excessive Reject if in
badly worn, pitted or wear or damage. excess
scored tips and rod Reject  Rod must be straight Reject if in
sockets. within 0.010 inch excess

Dimensionally inspect valve rocker bushing bore Valve Springs Inspection

See Table Check valve springs using a spring tester. Refer
of Limits. to Figure 72-00-08.7.
 Inside Diameter Replace
bushing per  Reference spring load
Repair and deflection limits in
Replace if
No. 13 Table of Limits
weak
Appendix C of this
MPI valve rocker assembly manual.
 Cracks
Reject

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Revision C

Figure 72-00-08.7 • Valve Train

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O-360 and IO-360 Series Engines
Revision C

Crankshaft
Inspection of the counterbored gear mounting
Visually inspect the shaft. flange surface.
 Scoring, galling,  Fretting, galling, scoring,
Reject
pitting, corrosion, Reject pitting
cracks  Check threads in gear
retaining hole for nicks or
Visually inspect the bearing surfaces. burrs Check for hole depth
 Scoring, scratching, by measuring with a gear See
Reject
etching retaining bolt threaded all Repair
the way in. Compare the No. 1
Dimensionally inspect the bearing surfaces. exposed length of the bolt
Reject if with the thickness of the
 Refer to Table of beyond gear and lockplate.
Limits of this acceptable  Inspect dowel for damage,
manual limits. See out of roundness. Refer to Replace
Repair No. 3 Caution Note below.
 Inspect pilot diameter of the
Visually inspect the ID of the forward end of the counterbore for size and See
shaft. damage. The diameter Repair
 Deterioration of the See Repair should not exceed 2.1262 No. 4
cadmium plating No. 7 inches atcannot
any place
be cleaned cannot b

Measure the run-out of the crankshaft center

main bearings and flange by supporting the CAUTION: IF THE DOWEL MUST BE
crankshaft on a flat surface in vee blocks on the REMOVED, BE CAREFUL NOT TO DAMAGE
front and rear main bearing. THE CRANKSHAFT HOLE. DRILL A 1/8 INCH
Reject if run- DIAMETER HOLE THROUGH THE CENTER
 Measure run-out of out exceeds OF THE DOWEL. FILL THE HOLE WITH OIL
the crankshaft limits of the AND INSERT A PIECE OF 1/8 INCH
center main bearing Table of DIAMETER DRILL ROD IN THE HOLE.
Limits. cannot
STRIKE THE END be cleaned
OF THE DRILL ROD WITH cannot b
Reject if run- A SHARP BLOW. THE RESULTING
 Measure run-out of out exceeds HYDRAULIC PRESSURE SHOULD FORCE
crankshaft prop limits of the THE DOWEL OUT.
flange Table of
Limits NOTE: If the crankshaft requires repairs other
MPI the crankshaft. than those specified above, measure
 Cracks Reject 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.

Camshaft Inspection pitting, cracks, pitting,

Visual inspection. or other damage
 Entire shaft for fretting,  Cam lobes for
Reject cannot be cleanedReject cannot b
galling, scoring, indications of distress,

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Revision C

surface irregularity, or Connecting Rods Inspection

feathering along the
edges. Visual inspection.
 Inspect for wear or
fretting on the rod and Reject
NOTE: If the hydraulic lifter bodies have been cap mating surfaces.
rejected for spalling, inspect the See Repair
 Inspect for nicks and
corresponding cam lobe(s). No. 2 in this
similar damage
manual
Dimensional inspection.

Dimensional inspection.
NOTE: Refer to Table of Limits section of this
manual. NOTE: Refer to Table of Limits , Appendix C,
of this manual.
 Runout at center
bearing in excess of Reject cannot be cleanedReplace or cannot b
0.001 T.I.R. repair if
 Inspect bore in large
 Difference between tolerances
end of connecting rod.
camshaft bearing are outside
journals and Reject if the limits
crankcase bore 0.002 outside Replace
 Inspect bushing bore
minimum to 0.004 in. bushing per
in small end of
maximum Repair
connecting rod.
No 11
MPI the Camshaft. Replace rod
 Cracks Reject  Check connecting rod if tolerances
parallelism. Refer to are outside
Replace if tolerances
the limits
Replace if
 Check connecting rod
tolerances
squareness. Refer to
are outside
Figure 72-00-08.15. Replace if tolerances
the limits

MPI Connecting Rods.

 Cracks Reject

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Revision C

igure 72-00-08.8 • Camshaft Assembly

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Revision C

THIS

PAGE

INTENTIONALLY

LEFT

BLANK

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Revision C

ENGINE ASSEMBLY
General Special Tools and Equipment
This section has the procedures and illustrations Special tools and equipment required for
necessary to assemble the Vantage O-360 and assembly are listed in Table 72-00-09.1 below.
IO-360 series engine.

Fits, Clearances and Torque Values NOTE: Standard reciprocating engine aviation
Fits, clearances and torque values to be shop tools and equipment are used,
established during repair or assembly are listed unless otherwise specified.
in the Table of Limits appendix C at the back of
this manual. NOTE: Unless otherwise specified, all gaskets
NOTE: Limits followed by a letter “T” indicate are installed dry.
“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.

Materials Required for Assembly

Materials required for assembly are listed in
SSD0002. See attached appendix B

NOTE: Equivalent substitutes may be used for

listed items.

Table 72-00-09. 1 • 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

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Revision C

Engine Assembly (5) Inspect oil galleys in each crankcase

half to ensure they are clean and that
WARNING: PUT ON SAFETY GOGGLES they properly intersect. Compressed air
WHEN INSTALLING OR REMOVING SAFETY may be used.
WIRE.
WARNING: LUBRICANTS ARE TOXIC AND
WARNING: LUBRICANTS ARE TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS.
FLAMMABLE. DO NOT BREATHE VAPORS. BEFORE YOU USE, READ THE MATERIAL
BEFORE YOU USE, READ THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE
SAFETY DATA SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER. USE IN A
MANUFACTURER OR SUPPLIER. USE IN A WELL-VENTILATED AREA FREE FROM
WELL-VENTILATED AREA FREE FROM SPARKS. WEAR PROTECTIVE GEAR. IN
SPARKS. WEAR PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
CONTACT, WASH WITH SOAP AND WATER.
(6) Apply a light coat of pre-lube oil to main
NOTE: Unless otherwise specified, all torque bearings (5, Figure 72-00-09.2). Install
loads listed for nuts, bolts, and screws crankshaft (25, Figure 72-00-09.3) in
are for use with pre-lube oil. right crankcase half.
(7) Using a feeler gage, check thrust and
Crankcase Inspection and Preparation for slinger clearances. Clearances must be
Assembly. per the table of limits (SSD001)
(1) Place crankcase halves on workbench. appendix C of this manual. Rotate
Check for handling damage. Inspect for crankshaft 360 degrees to ensure
slight nicks and burrs surface finish, split adequate cheek to case clearance and
lines, bearing and cam bores, mating record. Refer to Figure 72-00-09.4.
surfaces, and tappet bores. (8) Repeat steps 6 and 7 in the left
(2) Inspect studs for thread damage, bent crankcase half and record clearances.
condition. (9) Lightly lubricate camshaft bore journals
(3) Inspect tang slots for deformation. and temporarily install the camshaft and
Install center and aft main bearings in rotate in each crankcase half. Using
case halves. feeler gage measure and record end
(4) Check front main bearing retention clearance in each half. Clearances must
dowels for correct installation height. be within limits per table of limits
See Table of Limits Appendix C (SSD001) appendix C of this manual.
(SSD001) for value. Refer to Figure 72- (10) Check threaded areas of crankcase
00-09.1. halves. Install external pipe plugs using
Titeseal™ thread sealant. Torque plug
WARNING: WHEN YOU USE COMPRESSED (40, Figure 72-00-09.5) per SSD001
AIR TO CLEAN OR DRY PARTS, MAKE SURE (Appendix C). Torque is based on plug
THAT THE PRESSURE IS NOT MORE THAN thread size.
30 PSI. DO NOT DIRECT THE AIRSTREAM (11) Install piston cooling nozzle, if furnished,
AT PERSONNEL OR LIGHTWEIGHT (95, Figure 72-00-09.5) using Loctite™
OBJECTS. PUT ON GOGGLES OR A FACE and torque to value found in the Table of
SHIELD TO PROTECT YOUR EYES. IF YOU Limits appendix C (SSD001).
SUFFER AN EYE INJURY, GET MEDICAL
ATTENTION.

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Revision C

NOTE: Plug(s) MS27769-1 may be used in Crankshaft Inspection and Preparation

place of piston nozzle(s) as required for Assembly
by the engine model. Install the same (1) Visually inspect crankshaft for handling
as previous external pipe plugs (40, damage. Check bearing, slinger and
Figure 72-00-09.5). thrust face surfaces.
(2) Measure and record main journal
Propeller Governor Drive (Located on the dimensions with micrometer.
Left crankcase half). Dimensions must be within limits per
See figure 72-00-09.5. This drive assembly must Table of limits Appendix C of this
be installed before the crankcase halves are manual.
assembled. This is accomplished in the following (3) Measure and record rod journal
manner. dimensions with micrometer.
(1) Lubricate the drive gear bore, gear Dimensions must be within limits per
teeth, and gear shaft with pre-lube oil Table of limits Appendix C of this
and install the governor drive gear (8) manual.
into the left crankcase half.
(2) Lubricate idler bores and shaft with pre- Crankshaft Front Oil seal Installation
lube oil and insert the idler shaft (4) part 1. Remove spring from new front oil seal (15,
of the way through the hole in the Figure 72-00-09.2). Apply pre-lube oil
crankcase. mixture to the crankshaft propeller flange
(3) Select the .060 inch thick thrust washer and I.D. of oil seal. Install oil seal with flat
(2). Lubricate the washer and gear side out to prop flange. Use tool to carefully
assembly (9) with pre-lube oil and place stretch seal over flange.
them onto the idler shaft (4). 2. Re-install the spring in seal (15) groove.
(4) Insert the shaft into the crankcase until it 3. Clean oil from the prop flange.
bottoms and check the end clearance 4. Apply oil to crankshaft and front oil seal (15)
using a feeler gage. The end gap must at their fit locations.
be within range per the Table of Limits 5. If required, apply pre-lube and install the
Appendix C of this manual. If the propeller flange bushings (50, 55, 60, Figure
measured clearance is more that this 72-00-09.3). Pull through with puller tool.
value, select the washer thickness that Refer to Figure 72-00-09.3 for bushing
provides the proper clearance. positions.
(5) Once the gap is correct with the 6. Install and secure the crankshaft to a vertical
appropriate thrust washer, rotate the support stand.
idler shaft until the countersunk hole is
aligned with the threaded hole in the WARNING: LUBRICANTS ARE TOXIC AND
crankcase. Place a drop of Loctite® FLAMMABLE. DO NOT BREATHE VAPORS.
271 on the set screw threads and insert BEFORE YOU USE, READ THE MATERIAL
the set screw (7). Tighten to tighten per SAFETY DATA SHEET (MSDS) FROM THE
Table of limits Appendix C of this MANUFACTURER OR SUPPLIER. USE IN A
manual and stake the crankcase with a WELL VENTILATED AREA FREE FROM
pointed tool such as an awl to secure SPARKS. WEAR PROTECTIVE GEAR. IN
screw. CASE OF EYE CONTACT, FLUSH WITH
(6) Assemble gasket (5) and hex head plug WATER FOR 15 MINUTES AND SEEK
(6) into the crankcase. Torque plug per MEDICAL ATTENTION. IN CASE OF SKIN
table of Limits Appendix C of this CONTACT, WASH WITH SOAP AND WATER.
manual. Install safety wire (0.032 in.)
from the plug (6) to the hole provided in
the crankcase

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Revision C

Figure 72-00-09.1 • Crankcase Bearing Retention Dowel

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Revision C

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

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Figure 72-00-09.3 • Crankshaft Assembly

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Revision C

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

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Revision C

1. GASKET 7. SET SCREW 40. PLUG

2. THRUST WASHER 8. PROP. GOVERNOR DRIVEN GEAR 60. STUD
3. COVER 9. PROP. GOVERNOR GEAR 75. INSERT
4. IDLER GEAR SHAFT 10. WASHER 85. DOWEL
5. GASKET 11. LOCK WASHER 95. PLUG OR PISTON COLLING NOZZLE
6. HEX HEAD PLUG 12. NUT (AS REQUIRED)

Figure 72-00-09.5 • Crankcase Assembly and Front Prop. Gov. Gear Assembly

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Revision C

Connecting Rod Assembly Inspection (9) Measure and record connecting rod to
(1) Visually inspect the rod assembly (5, crankshaft side clearance. Clearance
Figure 72-00-09.6) for handling damage, must be within limits per Table of Limits
defects, and corrosion. Appendix C of this manual.
(2) Inspect the bore finish. This must be
smooth and free of burrs. WARNING: WEAR PROTECTIVE GEAR.
(3) Verify correct rod part number. LUBRICANTS ARE TOXIC AND FLAMMABLE.
(4) Verify the serial number match for each DO NOT BREATHE VAPORS. BEFORE YOU
rod and cap assembly. USE, READ THE MATERIAL SAFETY DATA
(5) Verify and record each rod assembly SHEET (MSDS) FROM THE MANUFACTURER
weight. OR SUPPLIER. USE IN A WELL-
VENTILATED AREA FREE FROM SPARKS.
NOTE: Difference in rod assembly weights IN CASE OF EYE CONTACT, FLUSH WITH
must not exceed 2 grams in opposing WATER FOR 15 MINUTES AND SEEK
pairs. MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.
(6) Check each piston pin (35) in each rod
(5) for fit. The pins must slide freely Installation of Crank Gear to Crankshaft
through the rod. (1) Inspect the crank gear (5, Figure 72-00-
09.3), bolt (15), and lockplate (10) for
Subassembly of Connecting Rods to defects.
Crankshaft (2) Lightly lubricate with pre-lube crank bolt
(1) Visually inspect the rod bolts and nuts threads and install the gear (5) to
(10, 15 Figure 72-00-09.6). Lightly crankshaft with bolt (15) and new
lubricate bolt shanks and threads with lockplate (10). Ensure that the gear (5)
pre-lube oil. fits evenly in crank recess, aligns with
(2) Verify bearing part number and size for dowel, and sits flat when torqued.
crankshaft and model application. Tapping the gear with a soft aluminum
(3) Install the connecting rod bearing shell or brass drift will help ensure the seal is
(1) in each rod and cap (5). properly seated. Torque crankshaft gear
(4) Apply pre-lube oil to the bearing shell bolt (15) per Table of Limits section 6.0
(1). Appendix C (SSD01) of this manual.
(5) Apply pre-lube oil to the rod bearing Attempt to insert a pointed 0.001 in.
journals of crankshaft. feeler gage or piece of shim stock
(6) Insert 2 rod bolts through each rod cap. between the gear and the crankshaft at
Begin with the lowest serial number rod each of the three scallops. There is no
cap and install it to the crankshaft with allowable clearance between crankshaft
its matching rod (5) at the #1 (most and gear. Bend lockplate (10) tab up to
forward) rod location. secure bolt head.
(a) Install with serial numbers in same
plane and down towards oil sump. WARNING: WEAR PROTECTIVE GEAR.
Refer to Figure 72-00-09.7. LUBRICANTS ARE TOXIC AND FLAMMABLE.
(b) Install the nuts with flat side to DO NOT BREATHE VAPORS. BEFORE YOU
connecting rod. Refer to Figure 72- USE, READ THE MATERIAL SAFETY DATA
00-09.7. Tighten moderately to SHEET (MSDS) FROM THE MANUFACTURER
check fit prior to torque. OR SUPPLIER. USE IN A WELL VENTILATED
(7) Tighten each rod nut to bolt (10,15, AREA FREE FROM SPARKS. WEAR
Figure 72-00-09.6) evenly per Table of PROTECTIVE GEAR. IN CASE OF EYE
Limits section 6.0 Appendix C. CONTACT, FLUSH WITH WATER FOR 15
(8) Rotate each connecting rod (5) after MINUTES AND SEEK MEDICAL ATTENTION.
torque to check for smooth and free IN CASE OF SKIN CONTACT, WASH WITH
rotation. SOAP AND WATER.

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Revision C

ATTENTION. IN CASE OF SKIN CONTACT,

Assembly of Case and Crankshaft Assembly WASH WITH SOAP AND WATER.
(1) With crankcase halves lying on bench
with interior sides up, ensure that center (9) Remove front main bearings. Lubricate
and rear main bearings (5, Figure 72- bearing surfaces liberally with pre-lube
00-09.2) are installed and lubricated oil and fit to crankshaft aligning the two
with pre-lube. parallel marks. Refer to Figure 72-00-
(2) Lubricate tappet bore holes and tappet 09.10.
bodies (20) (shank) and install bodies in (10) Install two 3/8 in. bolts (5, Figure 72-00-
case. 09.11) with their corresponding flat
(3) Apply cam pre-lube liberally to tappet washers(15) through the right case half
(20) faces and camshaft lobes. (5, and install 2 O-rings (10).
Figure 72-00-09.8). A moly-graphite (11) Install 2 O-rings (75) on rear through
grease is recommended. studs of right case half.
(4) Place camshaft (5) on bench beside (12) Lubricate crankshaft main bearing
case halves. journals and cam bores with pre-lube oil.
(5) Clean mating surfaces of both case (13) Lay out crankcase assembly hardware
halves including nose seal area with fast per Figure 72-00-09.11 and 72-00-09.12
dry solvent. together with appropriate hand tools.
(6) Clean nose seal OD with fast dry
solvent. - STOP -
(7) Place front main (10, Figure 72-00-09.2) PERFORM IN-PROCESS QUALITY
bearing temporarily in place in the left INSPECTION #1. REFER TO APPENDIX A.
crankcase half making sure the bearing
is properly seated on the 2 locator (14) Ensure that case mating surfaces are
dowels. clean and dry.

NOTE: The front main bearing (10), unlike the WARNING: ADHESIVE SEALANT IS TOXIC
center and rear main bearings, splits AND FLAMMABLE. WEAR PROTECTIVE
on the horizontal centerline of the GEAR. DO NOT BREATHE VAPORS. AVOID
engine. EYE AND SKIN CONTACT. IN CASE OF
EYE CONTACT, FLUSH WITH WATER FOR
(8) Use a felt marker to trace on the front 15 MINUTES AND SEEK MEDICAL
bearings halves at the intersection ATTENTION. IN CASE OF SKIN CONTACT,
between the crankcase parting flanges WASH WITH SOAP AND WATER.
and the bearing. Make a vertical
reference mark on both the bearing half (15) Apply a thin, even coat of approved
and each case half at a convenient point sealant to the backbone and breastbone
along the line of intersection. This surfaces of the left case half only and to
locates the bearing both radially and the front nose seal bore (both case
axially. Make two parallel marks across halves) as well as the nose seal OD. Do
both bearing shells at their intersection not apply sealant to the seal surface
for alignment reference. Refer to Figure itself.
72-00-09.9. (16) A thin translucent coating is sufficient.
Wipe off any excess on the inside and
WARNING: WEAR PROTECTIVE GEAR. outside edges. Refer to Figure 72-00-
LUBRICANTS ARE TOXIC AND FLAMMABLE. 09.13. Because this sealant will dry
DO NOT BREATHE VAPORS. BEFORE YOU quickly when applied this thinly, it is
USE, READ THE MATERIAL SAFETY DATA important to proceed quickly until case
SHEET (MSDS) FROM THE MANUFACTURER halves are together and snug. A
OR SUPPLIER. USE IN A WELL-VENTILATED assistant is required during this
AREA FREE FROM SPARKS. IN CASE OF assembly process.
EYE CONTACT, FLUSH WITH WATER FOR
15 MINUTES AND SEEK MEDICAL

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Revision C

(17)Lay a single line of silk thread on the (20) Check thread and nose seal (15, Figure
sealant at the centerline of the sealing 72-00-09.2) for proper placement.
surface and loop each bolt hole on the (21) Install camshaft in left case half and
interior side. The tail of the thread have the assistant hold in place.
should extend beyond the mating (22) Mate the right case half to the left case
surface approximately 0.25 in. to the half by carefully aligning rear through
accessory gasket surface at the rear, studs and front 3/8 in. nose bolts.
the nose seal surface at the front and
the sump gasket surface at the bottom. NOTE: NOTE: Care should be taken not to
Refer to Figure 72-00-09.13. push out the 3/8 in. nose bolts (5,
(18)The assistant places the left case half Figure 72-00-09.11) causing the o-
up to the crank assembly with the rings (10) to fall out.
connecting rods protruding through their
appropriate cylinder holes and allows (23) Ensure that nose seal is properly in
the assembler to align the front main place.
bearing inserts with the dowels in the (24) Install backbone bolts (30), breastbone
crankcase. The assistant uses light bolts (90, 95), and nose bolts (5) with
pressure against case half as the appropriate hardware. Snug all
assembler adjusts front main bearing uniformly. Check for free case to crank
until it snaps in place. rotation.

NOTE: Using a tool to gently lift up on bearing WARNING: LUBRICANTS ARE TOXIC AND
while holding case half-tight to FLAMMABLE. DO NOT BREATHE VAPORS.
crankshaft will aid in determining if BEFORE YOU USE, READ THE MATERIAL
bearing is properly seated. When SAFETY DATA SHEET (MSDS) FROM THE
properly seated, the bearing and case MANUFACTURER OR SUPPLIER. USE IN A
will move slightly up and down WELL VENTILATED AREA FREE FROM
together as the front of the bearing is SPARKS. WEAR PROTECTIVE GEAR. IN
pried up and down. CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK
(19)With the left case half and bearing MEDICAL ATTENTION. IN CASE OF SKIN
properly seated, the assistant places a CONTACT, WASH WITH SOAP AND WATER.
tool inserted through the #4 connecting
rod piston pin hole. The case is rotated (25) Lightly lubricate shank and threads of
to wedge the tool against the case half. the ½ in. Dia. through bolts (1, Figure
Firm pressure is maintained on 72-00-09.12), with pre-lube oil. Install
crankcase. Refer to Figure 72-00- using a soft faced (dead blow) hammer
09.14. as far as possible. Finish installation
with sufficiently sized ball-peen hammer
NOTE: It is imperative that the assistant or equivalent using a nut or threaded
maintains constant pressure on the left cap to protect the threads and thru-bolt
case half throughout the assembly end. Thru bolts are properly installed
process until case halves are snugged when an equal number of threads
together. Enough case assembly protrude from each case half.
hardware must be installed to not
allow the front main bearing to shift
from the locating dowels.

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O-360 and IO-360 Series Engines
Revision C

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

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.7 • Connecting Rod Installation

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.8 • Camshaft Assembly

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.9 • Main Bearing Reference Marks

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.10 • Main Bearing Installation

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.11 • Crankcase Attaching Hardware

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Revision C

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

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O-360 and IO-360 Series Engines
Revision C

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

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Revision C

Figure 72-00-09.14 • Crankcase Halves Assembly

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O-360 and IO-360 Series Engines
Revision C

Cylinder Assembly Inspection (8) Verify piston ring (40, 45) part numbers.
(1) Verify cylinder part number and serial (9) Check ring gaps of compression rings
number. (45, Figure 72-00-09.6) and oil control
(2) Visually inspect general condition of ring (40) with feeler gauge. End gap at
cylinder for handling or shipping 1”-4” from flange and gap at top of
damage. piston stroke must be within limits per
(3) Verify the valve, spring, and key (65, 70, the Table of Limits Appendix C of this
85, 90, 105, 110, Figure 72-00-09.15) manual.
installations. (10) Insert piston rings, one at a time in their
(4) Visually check threaded holes for thread respective grooves.
integrity and helical coil insert if (11) Using a ring expander, install rings to
required. Ensure the absence of foreign piston with the lower ring first, then
matter. middle and top.

WARNING: SOLVENT IS TOXIC. USE IN NOTE: Numbers on the ring face indicate top
WELL-VENTILATED AREA. PREVENT EYE of the piston or up.
AND SKIN CONTACT AND DO NOT
BREATHE VAPORS IN CASE OF EYE (12) Check side clearance of each ring.
CONTACT, FLUSH WITH WATER FOR 15 Piston compression ring (45) in top
MINUTES AND SEEK MEDICAL ATTENTION. groove, Piston compression ring (45) in
nd
IN CASE OF SKIN CONTACT, WASH WITH 2 groove and piston oil control ring
rd
SOAP AND WATER. (40) in 3 groove per specifications in
the Table of Limits Appendix C of this
(5) Wipe cylinder bores clean with lint-free manual.
rag saturated with fast dry solvent.
(6) Inspect piston (30, Figure 72-00-09.6) NOTE: Side clearance is checked with ring in
part number and weight. its respective groove and flush with
outside edge of piston.
NOTE: Piston weight differences should not
exceed 2 grams in opposing pairs.

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

solvent and check fit to each piston.

NOTE: Piston pins are a push fit with light

lubrication. Refer to Figure 72-00-
09.16.

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Revision C

50
55
60

90
80 100

85 110

75 110

115 1. PUSH ROD 85. VALVE SPRING, OUTER

85
5. ROCKER ARMS 90. VALVE SPRING, INNER
90 95 10. BUSHING 95. SEAT, UPPER INTAKE VALVE
105 15. ROCKER ARM SHAFT 100. SEAT, UPPER EXHAUST
20. THUST BUTTON-ROCKER SHAFT VALVE
105. KEY, INTAKE VALVE
25. PLUNGER 110. KEY EXHAUST VALVE
30. PUSH ROD SOCKET 115. CAP, EXHAUST VALVE
35. SEAL - TUBE BOTTOM 120. GASKET-VALVE COVER
40. SHROUD TUBE 125. VALVE COVER
45. SEAL – TUBE TOP 130. SCREW
50. SPRING 135. GASKET-EXHAUST
55. LOCKPLATE 140. WASHER-FLAT
60. NUT, PLAIN (1/4-20) 145. WASHER-LOCK
75. SEAT, LOWER INTAKE VALVE 150. NUT-PLAIN
80. SEAT, LOWER EXHAUST VALVE

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

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Revision C

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

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O-360 and IO-360 Series Engines
Revision C

Cylinder Assembly Installation to Engine (7) Slide the ring compressor tool over the
(1) Lubricate the rings and ring grooves on piston and rings far enough to allow the
the piston with straight weight, non- cylinder bore to fit over the piston top.
detergent (mineral) aviation grade oil. (8) Install cylinder #1: Position the top of
(2) Stagger the ring gaps as follows: Top cylinder facing the top of the engine
ring gap is at approximately the 10 over the piston. Push on until the ring
o’clock position, 2nd ring gap is at compressor is pushed off the piston skirt
approximately 2 o’clock; and the oil and can be removed at notch over the
control ring gap is at approximately 11 connecting rod. Continue to slide the
o’clock. cylinder over the cylinder base studs
until flush with the case deck. Refer to
WARNING: LUBRICANTS ARE TOXIC AND Figure 72-00-09.18.
FLAMMABLE. DO NOT BREATHE VAPORS. (9) Secure the cylinder assembly with the
BEFORE YOU USE, READ THE MATERIAL cylinder base nuts (15, 20, Figure 72-
SAFETY DATA SHEET (MSDS) FROM THE 00-09.17) as required and tighten to
MANUFACTURER OR SUPPLIER. USE IN A snug.
WELL-VENTILATED AREA FREE FROM (10) Continue process with cylinders #2, then
SPARKS. WEAR PROTECTIVE GEAR. IN #3, and #4 in that order. Rotate the
CASE OF EYE CONTACT, FLUSH WITH case and crank so that the connecting
WATER FOR 15 MINUTES AND SEEK rod of the cylinder to be installed is at
MEDICAL ATTENTION. IN CASE OF SKIN top dead center.
CONTACT, WASH WITH SOAP AND WATER. (11) Torque the large cylinder hold down
nuts (15, Figure 72-00-09.17) and small
NOTE: Oil control expander spring is installed hold down nuts (20) per the Table of
in piston groove underneath the oil Limits Appendix C of this manual. Do
control ring and with its split line 180° this in the sequence shown in Figure 72-
from the ring gap. 00-09.19.
(12) Torque all crankcase assembly
(3) Lubricate the cylinder bores, piston pins hardware (Figure 72-00-09.11) in
and piston pin bushing in connecting rod accordance with the Table of Limits
with straight weight, non-detergent Appendix C of this manual. Do this in
(mineral) aviation grade oil. the sequence shown in Figure 72-00-
(4) Lubricate the cylinder base o-ring (5, 09.19.
Figure 72-00-09.17) with oil and install
over the cylinder base. WARNING: PUT ON SAFETY GOGGLES
(5) Lightly lubricate cylinder deck studs and WHEN INSTALLING OR REMOVING SAFETY
through bolts with pre-lube oil. WIRE.
(6) Rotate the engine so that the #1
connecting rod is at the top of the (13) Torque slotted 3/8in. nut (85, Figure 72-
stroke. Install the #1 piston to the #1 00-09.11)) per the Table of Limits
connecting rod with the piston pin. Appendix C section 6.0. Install safety
Refer to Figure 72-00-09.16. wire (0.041 in.) at accessory location by
cam gear.
(14) Torque the three, drilled-shank, 1/4in.
belly bolts (95) and slotted nuts (100)
NOTE: Ensure that piston is installed with ring per the Table of Limits Appendix C
gaps towards the top of the engine. section 6.0. Install safety wire (0.032
in.).

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

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Revision C

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

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Revision C

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

(Left Side Shown)

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O-360 and IO-360 Series Engines
Revision C

Installation of Idler Shafts and Gears and (8) Install tachometer shaft assembly (15,
Internal Gear Timing Figure 72-00-09.8) with retaining ring
(1) Install 2 each idler shafts (1, Figure 72- (25) in camshaft (5) at gear end.
00-09.20) with 3 bolts (5) and one nut
(10). Torque the bolts (5) and nut (10) - STOP -
in accordance with the torque PERFORM IN-PROCESS QUALITY
specifications per the Table of Limits INSPECTION #2. REFER TO APPENDIX A.
Appendix C section 6.0. Safety the
nuts and bolts with 0.032 in. safety wire Cleaning, Inspection, and Installation of
to idler shaft flange holes. Refer to Hydraulic Plunger and Cup Assembly
Figure 72-00-09.21. (1) Visually inspect and clean hydraulic
plunger assemblies (25, Figure 72-00-
WARNING: PUT ON SAFETY GOGGLES 09.15) with fast dry solvent.
WHEN INSTALLING OR REMOVING SAFETY
WIRE. WARNING: SOLVENT IS TOXIC. USE IN
WELL-VENTILATED AREA. PREVENT EYE
(2) Inspect idler gears and for handling AND SKIN CONTACT AND DO NOT
damage, burrs, and general condition. BREATHE VAPORS. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15
WARNING: LUBRICANTS ARE TOXIC AND MINUTES AND SEEK MEDICAL ATTENTION.
FLAMMABLE. DO NOT BREATHE VAPORS. IN CASE OF SKIN CONTACT, WASH WITH
BEFORE YOU USE, READ THE MATERIAL SOAP AND WATER.
SAFETY DATA SHEET (MSDS) FROM THE
MANUFACTURER OR SUPPLIER. USE IN A (2) Depress hydraulic plunger piston with
WELL-VENTILATED AREA FREE FROM thumb to ensure proper spring action.
SPARKS. WEAR PROTECTIVE GEAR. IN (a) If unit does not compress, use blunt
CASE OF EYE CONTACT, FLUSH WITH end of a 3/32 in. diameter rod to
WATER FOR 15 MINUTES AND SEEK dislodge check ball allowing trapped
MEDICAL ATTENTION. IN CASE OF SKIN air, oil, or solvent to escape.
CONTACT, WASH WITH SOAP AND WATER. (b) Remove rod and try depressing
piston again.
(3) Apply pre-lube oil to idler shafts (1) and
gear bushing (25). WARNING: LUBRICANTS ARE TOXIC AND
(4) Highlight with a marker the timing FLAMMABLE. DO NOT BREATHE VAPORS.
marks on the camshaft, crank gear, and BEFORE YOU USE, READ THE MATERIAL
fuel pump drive idler gear (15). SAFETY DATA SHEET (MSDS) FROM THE
(5) Place the left-hand idler gear (fuel MANUFACTURER OR SUPPLIER. USE IN A
pump drive idler gear) over the left idler WELL-VENTILATED AREA FREE FROM
shaft aligning its timing marks with the SPARKS. WEAR PROTECTIVE GEAR. IN
corresponding timing marks on cam CASE OF EYE CONTACT, FLUSH WITH
and crank. Rotate cam and crank as WATER FOR 15 MINUTES AND SEEK
needed to align with marks on the idler MEDICAL ATTENTION. IN CASE OF SKIN
gear. See Figure 72-00-09.22. CONTACT, WASH WITH SOAP AND WATER.
(6) Install the right hand idler gear (20) on
the right side idler shaft. (3) Apply a light coat of pre-lube oil to the
OD of each plunger.
NOTE: It is not necessary to align timing (4) Insert plunger, small tube end first, into
marks on this gear. tappet body in crankcase. Refer to
Figure 72-00-09.15.
(7) Check gear backlash of both idler gears (5) Insert tappet cup or socket (30) into
with feeler gauge or dial indicator. tappet body on top of plunger assembly.
Backlash limits must be within limits Put the cup side out (flat side against
specified in the Table of Limits plunger). Refer to Figure 72-00-09.15.
Appendix C section 5.0 of this manual.

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Revision C

PROTECT YOUR EYES. IF YOU GET AN EYE

Installation of Pushrod Tubes, Pushrods, and INJURY, GET MEDICAL ATTENTION.
Rocker Arms
(1) Visually inspect the pushrod tubes (40,
Figure 72-00-09.15) for handling
damage, dents, or burrs. Check I.D. of
each tube for debris.

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.

(2) Apply a light coat of Fuelube™ or

equivalent to 8 O-ring seals (45) and 8
bottom tube seals (35). Install O-rings
to pushrod tube (40) at top groove
locations.
(3) Insert pushrod tubes through holes at
the top of each cylinder then install
bottom seal (35). Seat each tube into its
crankcase lifter hole using a rotary or
twisting motion. Ensure that o-ring seal
and bottom seal are properly seated.
(4) Install spring clip (50) over stud in
cylinder and over the edge of each
pushrod tube.
(5) Secure spring clip with lock plate (55)
and 1/4in. nut (60).
(6) Torque nut (60) per Table of Limits
Appendix C of this manual. Bend lock
tab with screwdriver or pliers to secure
nut.
(7) Inspect pushrods for bends or damage.
(a) Blow clean, dry air through each
pushrod (1).
(b) Visually inspect I.D. of each pushrod
to verify each is clear, clean, and
open.

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

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(8) Install pushrods in pushrod tubes. (c) Lubricate the rocker arm socket and
oil feed hole to ensure clear
NOTE: There are different lengths of pushrods passage.
available for this engine model to aid (11) Rotate the engine until cylinder #1 is at
in adjusting the dry tappet clearance. top dead center (TDC).
Use the appropriate length to achieve (12) Apply a light film of pre-lube oil to the
proper clearance of 0.028 to 0.080 rocker shafts. Install rocker arms and
inch. shafts in the #1 cylinder head.
(13) Check dry tappet (lifter) clearance.
(9) Install exhaust valve rotator cap (115) Clearance must be within limits per the
on valve stem of each exhaust valve Table of Limits Appendix C of this
(65). manual. Check valve rocker side
clearance with a feeler gauge.
NOTE: A drop of pre-lube or spot of grease on Clearance must be within limits
the inside of each rotator cap will help specified in the Table of Limits Appendix
retain it in place until the rocker arms C of this manual.
are installed. (a) Repeat for all remaining cylinders.
(b) Install the rocker shaft thrust buttons
(10)Inspect rocker arms (5) for general (20) in each end of the rocker shaft
condition. (15) immediately before installing
(a) Ensure bushing (10) is properly rocker cover.
installed. NOTE: Change the pushrod length as
(b) Check rocker shaft (15) in bushing required to achieve proper clearance.
and shaft in cylinder head for correct
fit. Clearance must be within limits NOTE: A light coat of grease applied to the
specified in the Table of Limits thrust buttons will aid in retaining them
Appendix C of this manual. in position until the rocker covers (45,
Figure 72-00-09.17) are installed.

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Figure 72-00-09.20 • Idler Gear in Crankcase

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Figure 72-00-09.21 • Idler Gear in Crankcase (cont’d.)

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Figure 72-00-09.22 • Accessory Drive Gear Arrangement

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O-360 and IO-360 Series Engines
Revision C

Accessory Housing Inspection and NOTE: It may be necessary to twist or move

Subassembly the oil pump housing slightly to
(1) Inspect the accessory housing (1, achieve a smooth rotation of the oil
Figure 72-00-09.23) for damage. Check pump assembly gears.
the studs, threaded holes, and mating
surfaces for damage or debris. WARNING: PUT ON SAFETY GOGGLES
(2) Install new tachometer drive seal (30). WHEN INSTALLING OR REMOVING SAFETY
(3) Install the fitting (45, Figure 72-00- WIRE.
09.23) and/or oil pressure fitting
removed for cleaning. Tighten per (12) Tighten the slotted nuts (90) per torque
torque specifications in the Table of specifications in the Table of Limits
Limits Appendix C section 6.0 of this Appendix C of this manual. Install
manual. safety wire (0.032 in.). Refer to Figure
(4) Install plug (55) and crush gasket (50) 72-00-09.24.
per Figure 72-00-09.35 and tighten per (13) Check fuel pump plunger (Figure 72-00-
torque specifications in the Table of 92.24) to accessory case clearance.
Limits Appendix C section 6.0 of this Clearance must be within limits
manual. specified in the Table of Limits Appendix
(5) Inspect the oil pump housing (95, Figure C of this manual. Lubricate and install
72-00-09.23) for damage. Verify plug the fuel pump plunger in the accessory
(100) installation. housing.
(6) Inspect the oil pump gears (105, 110)
and oil pump drive shaft (115) for - STOP -
damage. PERFORM IN-PROCESS QUALITY
(7) Install the oil pump gears (105, 110) and INSPECTION #3. REFER TO APPENDIX A.
drive shaft (115) into oil pump housing.
Inspect gear backlash, gear to housing, Assembly of Accessory Housing to Engine
and shaft to accessory case clearance (1) Check tachometer drive shaft (Figure
per specifications in the Table of Limits 72-00-92.24) to accessory case
Appendix C of this manual. clearance. Clearance must be within
limits specified in the Table of Limits
WARNING: LUBRICANTS ARE TOXIC AND Appendix C of this manual. Apply pre-
FLAMMABLE. DO NOT BREATHE VAPORS. lube oil to the tach shaft (15, Figure 72-
BEFORE YOU USE, READ THE MATERIAL 00-09.8) as well as to the gear teeth of
SAFETY DATA SHEET (MSDS) FROM THE cam, crank and idler gears.
MANUFACTURER OR SUPPLIER. USE IN A
WELL-VENTILATED AREA FREE FROM
SPARKS. WEAR PROTECTIVE GEAR. IN WARNING: LUBRICANTS ARE TOXIC AND
CASE OF EYE CONTACT, FLUSH WITH FLAMMABLE. DO NOT BREATHE VAPORS.
WATER FOR 15 MINUTES AND SEEK BEFORE YOU USE, READ THE MATERIAL
MEDICAL ATTENTION. IN CASE OF SKIN SAFETY DATA SHEET (MSDS) FROM THE
CONTACT, WASH WITH SOAP AND WATER. MANUFACTURER OR SUPPLIER. USE IN A
WELL-VENTILATED AREA FREE FROM
(8) Apply pre-lube oil liberally to gears and SPARKS. WEAR PROTECTIVE GEAR. IN
shaft in housing. CASE OF EYE CONTACT, FLUSH WITH
(9) Install the oil pump assembly (80) over WATER FOR 15 MINUTES AND SEEK
studs in accessory housing. MEDICAL ATTENTION. IN CASE OF SKIN
(10)Install the flat washers (85) and slotted CONTACT, WASH WITH SOAP AND WATER.
nuts (90) to the studs. Tighten the
installation hardware to snug. (2) Ensure the mating surfaces of the
(11)Rotate the oil pump drive shaft (115) to crankcase and accessory housing are
ensure smooth fit. The gears must clean, flat, and free from burrs or
rotate smoothly. scoring.

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(3) Verify the dowels are installed in the Tighten the plug (85) until the plug body
proper location in the crankcase. contacts the gasket (80) then turn an
(4) Install the accessory housing gasket additional approx. 135 degrees. Install
(35, Figure 72-00-09.23) to the safety wire (0.032 in.) on the plug (85).
crankcase over the dowels. (3) Install the sump gasket over sump
(5) Install the accessory housing assembly studs.
(1) over the tach shaft taking care to (4) Install the sump with bolt (15, Figure 72-
align oil pump drive with the crankshaft 00-09.27) lock washers (30), washers
gear. (25), and nuts (35) 14 places. Install the
(a) Lightly tap the accessory housing in bolts (20), lock washers (30), washers
place over the dowels with a soft (25), and nuts (35) 2 places. Install the
face or dead blow hammer as lock washers (30), washers (25), and
required. nuts (35) on the sump studs 4 places.
(6) Secure the accessory housing with Torque the bolts (15, 20) and nuts (35)
washer (5), lock washer (10), and bolt per the Table of Limits Appendix C of
(15) 10 places. Secure with the bolt this manual.
(20), washer (5) and lock washer (10) 2
places. Tighten per the Table of Limits Installation of the Oil Pressure Relief Valve
Appendix C of this manual. Assembly
(7) Trim the protruding gasket ends flush (1) Apply pre-lube oil in the crankcase at
with the sump mating surfaces. See the oil pressure relief valve location.
Figure 72-00-09.25. (2) Insert the ball (40, Figure 72-00-09.2)
into the hole in the crankcase.
(3) Install the spring (35) into the oil
Installation of the Rocker Cover and Baffles pressure relief valve housing (25).
(1) Install the rocker box covers with the (4) Install the gasket (30) to the relief valve
gaskets (120,125, Figure 72-00-09.15) housing (25).
and screws (130). (5) Apply pre-lube oil to the threads of the
(2) Torque the rocker cover screws (130) in oil pressure relief valve housing and
accordance with torque specifications in install the housing in the crankcase.
the Table of Limits Appendix C of this (6) Tighten the relief valve assembly (25,
manual. Figure 72-00-09.2) until the valve body
(3) Install the inner cylinder baffles with the contacts gasket (30) then turn an
hooks and retainers. See Figure 72-00- additional approx. 90°. Install safety
09.26. wire (0.032 in.) from the relief valve
assembly (25) to the hole provided in
Inspection of the Sump and Subassembly the crankcase.
(1) Inspect the sump (5, Figure 72-00-
09.27) for general condition, handling Oil Level Gage and Housing
damage, stud damage, mating surface (1) Install the oil level gage housing (5,
condition, and security of the roll Figure 72-00-09.28) with the gasket into
swaged intake pipe extensions (70). the crankcase. Tighten per the Table of
Limits Appendix C of this manual. Install
WARNING: PUT ON SAFETY GOGGLES safety wire (0.032 in.) between the oil
WHEN INSTALLING OR REMOVING SAFETY level gage housing (5) and crankcase.
WIRE. (2) Install the oil level gage (10) with its O-
ring seal (15) into the housing.
(2) Install the oil suction screen (75) with its
gasket (80) and plug (85). Ensure the
gasket seam faces the sump (5).

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Figure 72-00-09.23 • Accessory Housing

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.24 • Oil Pump Assembly

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.25 • Accessory Housing Gasket Trimming

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O-360 and IO-360 Series Engines
Revision C

Installation of Intake Pipes

(1) Slide the intake flange (10, Figure 72-
00-09.29) onto the intake elbow (5).
Allow the flanged end of the elbow to
seat in the recessed flat side of the
intake flange.
(2) Install the rubber hose coupler (30) onto
other end of the elbow along with 2
clamps (35).
(3) Place the bolts (25) with the appropriate
lock washer (20) and flat washer (15)
through the holes in the intake flange.
Install the gasket (1) over the bolts.
(4) Attach the elbow assembly to the engine
with the hose connection to sump and
the flange coupling to the intake port of
the cylinder head. Refer to Figure 72-
00-09.30.
(5) Slide the hose coupler over the intake
extension in the sump. Center the hose
coupler over the joint and tighten the
bolts (25) into the cylinder head until
snug.
(6) Ensure that the flange end of the intake
elbow fits completely in the recess in the
aluminum hold down flange (10). This
must lay flat against the cylinder port.
Torque the bolts (25) per the Table of
Limits appendix C of this manual.
(7) Position the clamps (35) over the hose
coupler (30) to secure each side of the
connection. Tighten per the Table of
Limits Appendix C.

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Revision C

Figure 72-00-09.26 • Inner Cylinder Cooling Baffle

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.27 • Oil Sump and Induction System

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Revision C

Figure 72-00-09.28 • Oil Level Gage

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Revision C

Figure 72-00-09.29 • Induction System

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O-360 and IO-360 Series Engines
Revision C

Figure 72-00-09.30 • Intake Tube Assembly

Installation of Cylinder Drain Tubes

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Revision C

(1) Secure the cylinder drain tubes (90, (2) Apply pre-lube oil and thrust washer to
Figure 72-00-09.17) to their the shaft gear (1) and install the gear in
corresponding cylinders. Do this by the housing. Rotate the gear upon
installing the drain back hose (80) to the installation to ease it through the seal
case nipple (75) and the drain tube and to ensure it turns smoothly.
using the clamps (85). Fasten the B-nut (3) Install the gasket (10) over the studs in
end of the drain tube to 45º fitting in the accessory housing. Align holes in
cylinder head. Torque the 2 clamps (85) gasket to correspond with holes in the
to specification in the Table of Limits housing. Refer to Figure 72-00-09.31.
Appendix C of this manual. Torque the (4) Install the vacuum pump adapter (25)
drain tubes (90) B-nuts per the Table of and the gear assembly (1) over the
Limits Appendix C. studs in the accessory housing. Align
the holes and dowel pin. Ensure that
NOTE: Ensure that the cylinder drain fitting is the drive gear teeth mesh with the idler
tight and pointed in the correct position gear teeth.
for the drain tube (90) installation. The (5) Check the gear endplay and backlash.
tube should not touch the intake pipe, Values must be within limits per the
cylinder, or inner cylinder baffle. Table of Limits section of this manual.
(6) Install the gasket (15), and cover plate
Installation of Vacuum Pump Adapter (20) with the washer (30), lockwasher
(1) Install new oil seal (55, Figure 72-00- (35), and nuts (40). Torque the nuts
09.31) in the vacuum pump adapter (40) per the Table of Limits Appendix C.
(25).
(a) Lightly lubricate the seal OD with Installation of Accessories
Fuelube™ or equivalent. Press into (1) Install the engine accessories per
the adapter, flat side up, until it instructions given later in this section.
bottoms out.
- STOP -
WARNING: LUBRICANTS ARE TOXIC AND PERFORM IN-PROCESS QUALITY
FLAMMABLE. DO NOT BREATHE VAPORS. INSPECTION #4. REFER TO APPENDIX A.
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.

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Figure 72-00-09.31 • Vacuum Pump Drive

Engine Accessory Assembly Installation

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NOTE: Unless otherwise specified, all torque (1) This instruction applies to engine
loads listed for nuts, bolts, and screws models requiring a prop governor
are for use with pre-lube oil. installation.
(2) Lubricate the governor shaft gear (1,
Installation of Fuel Pump (if furnished) Figure 72-00-09.33) and the bore in the
(1) Verify new fuel pump part number. adapter (15) with pre-lube oil. Install the
shaft gear in the adapter.
WARNING: LUBRICANTS ARE TOXIC AND
FLAMMABLE. DO NOT BREATHE VAPORS. WARNING: LUBRICANTS ARE TOXIC AND
BEFORE YOU USE, READ THE MATERIAL FLAMMABLE. DO NOT BREATHE VAPORS.
SAFETY DATA SHEET (MSDS) FROM THE BEFORE YOU USE, READ THE MATERIAL
MANUFACTURER OR SUPPLIER. USE IN A SAFETY DATA SHEET (MSDS) FROM THE
WELL-VENTILATED AREA FREE FROM MANUFACTURER OR SUPPLIER. USE IN A
SPARKS. WEAR PROTECTIVE GEAR. IN WELL-VENTILATED AREA FREE FROM
CASE OF EYE CONTACT, FLUSH WITH SPARKS. WEAR PROTECTIVE GEAR. IN
WATER FOR 15 MINUTES AND SEEK CASE OF EYE CONTACT, FLUSH WITH
MEDICAL ATTENTION. IN CASE OF SKIN WATER FOR 15 MINUTES AND SEEK
CONTACT, WASH WITH SOAP AND WATER. MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.
(2) Apply pre-lube oil to threads of 90º
elbow (25, Figure 72-00-09.32) and o- (3) Place the thrust washer (5) on the shaft
ring (20). Install into fuel pump (5) outlet gear. Secure the shaft gear in the
port. Position elbow (25) to point adapter with snap ring (55). Refer to
straight back and torque lock nut per the Figure 72-00-09.33.
Table of Limits Appendix C. (4) Ensure free spin of the gear in the
(3) Apply pre-lube oil to the threads of the adapter and check the end clearance.
45º elbow (30) and o-ring (20). Install End clearance must be within limits
into the fuel pump (50) inlet port. specified in the Table of Limits Appendix
Position the elbow (30) to point up and C of this manual.
torque the lock nut per Table of Limits (5) Install the adapter assembly to the
Appendix C. accessory housing with the gasket (10),
(4) Rotate the engine to provide least washer (20), lock washer (25), and nut
amount of fuel pump plunger extension. (30) per Figure 72-00-09.33. Torque the
(5) Apply grease to the fuel pump arm and nuts (30) per the Table of Limits
plunger where they will make contact on Appendix C of this manual.
the wear surfaces. (6) Check the gear lash to the idler gear.
(6) Install the fuel pump (5) with the gasket Backlash must be within limits specified
(1), drilled sockethead screws(15), and in the Table of Limits Appendix C of this
flat washers (10). manual.
(7) Lightly lubricate the threads of the 45º
WARNING: PUT ON SAFETY GOGGLES elbow (15, Figure 72-00-09.34) and its
WHEN INSTALLING OR REMOVING SAFETY o-ring (20) with pre-lube oil and install in
WIRE. the propeller governor adapter. Torque
per the Table of Limits Appendix C of
(7) Torque the screws (15) per Table of this manual.
Limits Appendix C. Install safety wire
(0.032 in.).

Installation of Propeller Governor Adapter

Assembly

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Figure 72-00-09.32 • Fuel Pump

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WARNING: ADHESIVE SEALANT IS TOXIC

AND FLAMMABLE. DO NOT BREATHE
VAPORS. AVOID EYE AND SKIN CONTACT. INSTALLATION OF SPIN-ON OIL FILTER
USE PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 (1) Apply light coat of Dow Corning #4
MINUTES AND SEEK MEDICAL ATTENTION. lubricant or equivalent to the rubber seal
IN CASE OF SKIN CONTACT, WASH WITH at base of the oil filter (40, 72-00-09.35)
SOAP AND WATER. and lightly lubricate the filter threads
then install to the adapter (10) and
(8) Apply TiteSeal™ thread sealant or torque per the Table of Limits Appendix
equivalent to the threads of 90º elbow C of this manual. Reference SVMM01,
fitting (10) and install in the right Maintenance Manual. Install safety wire
crankcase half, forward of No.1 cylinder. (0.032 in.) from the oil filter to the
Refer to Figure 72-00-09.34. adapter.
(9) Position fittings per Figure 72-00-09.34
and install the propeller governor oil WARNING: PUT ON SAFETY GOGGLES
hose (1). Torque the oil hose (1) nuts WHEN INSTALLING OR REMOVING SAFETY
per the Table of Limits Appendix C of WIRE.
this manual.
WARNING: LUBRICANTS ARE TOXIC AND
Installation of Propeller Governor Cover FLAMMABLE. DO NOT BREATHE VAPORS.
Plate BEFORE YOU USE, READ THE MATERIAL
SAFETY DATA SHEET (MSDS) FROM THE
(1) This instruction applies to all engine MANUFACTURER OR SUPPLIER. USE IN A
models not requiring a prop governor, WELL-VENTILATED AREA FREE FROM
and models having the prop governor in SPARKS. WEAR PROTECTIVE GEAR. IN
the front of the engine. CASE OF EYE CONTACT, FLUSH WITH
(2) For the engine models where no WATER FOR 15 MINUTES AND SEEK
propeller governor is used, install cover MEDICAL ATTENTION. IN CASE OF SKIN
(65, Figure 72-00-09.33), gasket (60), CONTACT, WASH WITH SOAP AND WATER.
washer (30), and lockwasher (25).
Torque the 5/16 in. nuts (30) per the
Table of Limits Appendix C.

Installation of Oil Filter Adapter (if furnished)

(1) Install the Vernatherm valve (45, Figure
72-00-09.35) with the aluminum gasket
and torque per the Table of Limits
Appendix C of this manual. Install safety
wire (0.032 in.) from the Vernatherm to
the adapter.
(2) Install the oil filter adapter (10) to the
accessory housing with the gasket (5),
washers (15), lock washers (20), 1 nut
(25), and 3 screws (30). Torque per the
Table of Limits Appendix C.

WARNING: PUT ON SAFETY GOGGLES

WHEN INSTALLING OR REMOVING SAFETY
WIRE.

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Figure 72-00-09.33 • Propeller Governor Adapter

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Figure 72-00-09.34 • Propeller Governor Oil Line

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Figure 72-00-09.35 • Oil Filter Assembly

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Installation of Carburetor and Primer System

NOTE: Remove and reinstall the appropriate
NOTE: This section applies to carbureted backbone hardware to accommodate
engine models only. bracket

(1) Verify the correct part number of the (6) Install the bolt (10) with lock washer
carburetor. (5).
(2) Install the carburetor (5, Figure 72-00- (7) Apply anti-seize to the fuel injectors
09.37), gasket (1), washers (10), (90). Install in the cylinders. Torque
lockwashers (15), and nuts (20) per the injectors per the Table of Limits
Figure 72-00-09.37. Torque the nuts Appendix C.
(20) per the Table of Limits Appendix C. (8) Install the fuel lines (55) between the
(3) Apply anti-seize to the threads of the fuel injectors (90) and the flow divider
primer nozzles (1, Figure 72-00-09.36). (15). Tighten per the Table of Limits
(4) Install the primer nozzles in cylinder Appendix C. Install clamps.
numbers 1, 2, and 4 (lower ports, Fig. (9) Install the fuel hose (30, Figure 72-00-
72-00-09.36). Torque the nozzles (1) 09.38) between the fuel pump and fuel
per the Table of Limits Appendix C of servo. Install the fuel hose (35, Figure
this manual. 72-00-09.38) between the fuel servo
(5) Install the primer lines (1, 5, 10, 15) to and flow divider. Torque the hose (30,
nozzles and “T” junctions (20). Torque 35) B-nuts per the Table of Limits
nuts per Table of Limits Appendix C. Appendix C of this manual.
Clamp to the induction elbows and
sump flange.
Magneto and Harness Installation
Installation of Fuel Injection System (1) Verify the correct magneto part
numbers.
NOTE: This section applies to fuel injected (2) Assemble the magnetos as follows:
engines only. (a) Install the drive gear (35, Figure 72-
00-09.40) to the magneto (15) by
(1) Verify the correct part number of the removing the gear retaining nut,
fuel injection unit (servo), flow divider, washer, and cotter pin (40) from the
and nozzles. magneto.
(2) Install the servo to the sump with (b) Install the drive gear (35) with the
gaskets (1, Figure 72-00-09.38), washer and nut. Torque the nut per
spacer (5), washer (15), lock washers the Table of Limits Appendix C of
(20), and nuts (25). Torque the this manual. Secure with cotter pin
attaching nuts (25) per the Table of (40).
Limits Appendix C of this manual. (3) Repeat for the 2nd magneto’s assembly.
(3) Install the fuel injector fittings, (4) Install the magneto gasket (1) and
appropriate pipe plugs and nipples per spacer (5), as appropriate, to the
Figure 72-00-09.39 into the flow accessory housing at each magneto
divider. Use anti-seize on the male location.
threads and torque per the Table of (5) Remove the harness cover cap from
Limits Appendix C of this manual. each magneto as required. Retain
(4) Install the flow divider bracket (1) to the screws for harness installation.
flow divider with screws (25) and lock (6) Determine direction of rotation. Refer to
washers (20). Torque the screws per magneto data plate.
the Table of Limits Appendix C. (7) Insert the alignment pin in appropriate
(5) Install the flow divider and bracket hole “R” or “L” in magneto, as
assembly to the engine backbone (top) determined by the direction of rotation,
per Figure 72-00-09.39 and torque the and slowly rotate the magneto drive
attaching hardware to per the Table of shaft “backwards” until the alignment pin
Limits Appendix C.

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drops into position (to the first shoulder),

locking the shaft.

Figure 72-00-09.36 • Fuel Priming System

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Figure 72-00-09.37 • Carburetor Installation

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Figure 72-00-09.38 • Fuel Injection Servo Installation

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Figure 72-00-09.39 • Fuel Injection Manifold Installation

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WARNING: DO NOT ROTATE ENGINE OR

NOTE: While rotating the magneto shaft CRANKSHAFT BEFORE REMOVAL OF
backwards with alignment pin in hole, if TIMING LOCATOR PINS.
the shaft stops turning due to internal
interference against the alignment pin (12) Remove the timing locator pins from the
prior to pin seating, pull pin out just far magnetos (15) and install the harness.
enough to allow the shaft to continue to Ensure correct harness locations. Align
rotate. Re-insert the pin and continue the harness cover caps properly.
rotation until the pin seats as previously Secure with the screws removed from
described. This procedure locates the the cap removal.
magneto at the No.1 cylinder firing
position. Starter Installation
(1) Verify the starter part number.
(8) Repeat for the 2nd magneto’s (2) Install the starter IAW the starter
alignment. manufacturer’s installation instructions.
(9) Bring the engine to the compression Tighten the bolt and nuts per the Table
stroke on the No. 1 cylinder. of Limits Appendix C of this manual.
(10)Rotate engine to approx. 25º before top
dead center using a timing indicator Alternator Installation (if furnished)
installed in a spark plug hole of the No. (1) Verify the alternator part number is
1 cylinder or equivalent method. correct.
(2) Install pulley, as required, to alternator
IAW manufacturer’s installation
WARNING: LUBRICANTS ARE TOXIC AND instructions.
FLAMMABLE. DO NOT BREATHE VAPORS. (3) Attach mounting bracket (55, Figure 72-
BEFORE YOU USE, READ THE MATERIAL 00-09.43) to engine with bolts (60) and
SAFETY DATA SHEET (MSDS) FROM THE lock plate (50) and tighten until snug
MANUFACTURER OR SUPPLIER. USE IN A (finger tight).
WELL VENTILATED AREA FREE FROM (4) Attach alternator to mounting bracket
SPARKS. WEAR PROTECTIVE GEAR. IN (55) using drilled shank bolts (25, 30)
CASE OF EYE CONTACT, FLUSH WITH with shim washers (35) and hardware as
WATER FOR 15 MINUTES AND SEEK required for alternator pulley/belt
MEDICAL ATTENTION. IN CASE OF SKIN alignment to starter ring gear assembly.
CONTACT, WASH WITH SOAP AND WATER. (5) Attach strut support (80) to alternator
bracket in forward location using bolt
(11)Apply pre-lube oil to the idler gear teeth (25).
and magneto drive gear teeth (35) and (6) Install adjusting link (65) to crankcase
apply light coat of Dow Corning™ #4 or and alternator with drilled head bolts
Fuelube™, per Appendix B section 3.0, (75, 10). Use single washer (70) at the
to the magneto gasket (10). Install each crankcase attach point and two (2)
magneto with the clamp (20), lock washers (5) at slotted alternator attach
washers (25), and nut (30). Tighten point for strength.
moderately.
NOTE: Leave all attach hardware snug or
NOTE: Magnetos must be able to move for final finger tight as required to allow for
timing. This will be accomplished later alignment and belt tension adjustment.
with the engine horizontal, disconnected
from nose stand, and with the ring gear (7) Install alternator belt (not shown) to
and starter installed. starter ring gear assembly and install
starter ring gear assembly to crankshaft
flange. Reference SVMM01,
Maintenance Manual. A “slave” bolt
may be used to temporarily hold starter

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ring gear assembly in place if propeller (3) Align the correct timing mark on the ring
and spinner are to be installed later. gear with the mark on the starter
(8) Install new belt to alternator pulley and housing. See Figure 72-00-09.41.
adjust alternator and/or brackets to (4) Attach the timing indicator leads of the
achieve proper alignment. magneto synchronizer (timing box) to
(9) Adjust belt tension to allow a midspan the magneto P-lead connections and
deflection per the Table of Limits ground lead to an appropriate ground.
Appendix C of this manual. (5) Rotate or adjust the magnetos until each
magneto synchronizer lights indicate
NOTE: An alternate method of checking belt that the magneto points are just
tension is to measure the torque opening.
required to slip the belt at the small (6) Snug the magneto nut (30, Figure 72-
alternator pulley. A new belt is 00-09.40) and rotate the crankshaft
properly tensioned when alternate back a few degrees before the correct
value per the Table of Limits Appendix timing. Slowly rotate the crankshaft in
C is required to cause it to slip. the direction of rotation until the timing
lights simultaneously indicate the
(10)Torque and safety the 3/8-24 slotted magneto points are just opening.
nuts (40) per SSD001. (7) Repeat the process above for minor
(11)Torque and safety all other attaching adjustments as needed to achieve the
hardware in accordance with values correct timing.
listed in the Table of Limits Appendix C (8) Torque the magneto nut (30) per the
section of this manual. Table of Limits appendix C of this
manual.
(9) Remove the timing indicator leads of the
Engine Removal magneto synchronizer from the magneto
(1) Remove the engine from nose stand P-lead connections and ground lead.
and place horizontal on transfer cart. (10) Install the spark plugs into the top and
bottom spark plug ports of each
cylinder. Torque per Table of Limits
Final Magneto Timing and Adjustment Appendix C of this manual. Reference
SVMM01, Maintenance Manual.
NOTE: Magneto assembly to the engine is (11) Attach the harness leads. Refer to
outlined in the accessory installation wiring diagram Figure 02-00-00.10.
instructions of this section. Secure to each spark plug.
(12) Install the clamps provided with the
(1) Install the ring gear to the crankshaft harness kit to prevent wire chafing.
propeller flange and retain with one
slave bolt. NOTE: Assembly steps 10, 11 and 12 above
(2) Rotate the crankshaft, using ring gear, may be replaced by assembly of
to compression stroke of number one dehydrator plugs if the engine will be
cylinder. stored prior to engine test. In this
event, spark plug leads should be
NOTE: It may be necessary to rotate the neatly coiled and stowed with the
crankshaft just beyond top dead center clamps for later assembly.
to allow the magneto impulse
couplings to release. Upon release of Storage After Assembly
the couplings, rotate the crankshaft If not immediately proceeding to engine testing
back in the opposite direction, to section, preserve the engine for storage per
correct timing degree mark. instructions in the Preservation and Storage
section of this manual.

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Figure 72-00-09.40 • Magneto and Adapter Installation

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Figure 72-00-09.41 • Starter Ring Gear Alignment

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Figure 72-00-09.43 • Alternator Installation

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ENGINE INSTALLATION
General
Due to the complexity and variation in aircraft
design, instructions for the installation of the
engine in the airframe are not provided here.
The airframe Maintenance Manual instructions
for engine installation must always be closely
adhered to, in order to avoid damage to the
engine and aircraft and injury to personnel.
Refer to Superior Vantage Installation and
Operation Manual No. SVIOM01 for additional
information.

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PRESERVATION AND STORAGE

General WARNING: HOT OIL MAY CAUSE BURNS TO
This section provides preservation instructions EYES AND SKIN. PUT ON SPLASH
for the engine after overhaul and prior to GOGGLES AND INSULATED GLOVES, AND
installation in the aircraft and is suitable for OTHER PROTECTIVE GEAR. IN CASE OF
temporary storage. For preservation of the EYE CONTACT, FLUSH WITH WATER FOR
engine for long term storage or on the aircraft, 15 MINUTES AND SEEK MEDICAL
refer to the Superior Vantage Maintenance ATTENTION. IN CASE OF SKIN CONTACT,
Manual No. SVMM01. WASH WITH SOAP AND WATER.

WARNING: ENGINE OIL IS HAZARDOUS

AND MAY CAUSE INJURY TO SKIN AND
NOTE: Corrosion may reduce engine service EYES. PUT ON PERSONNEL PROTECTIVE
life. Primary wear concerns are GEAR.
cylinders, piston rings, camshaft and
lifters.

Table 72-00-11.1 • Storage Materials

NOMENCLATURE VENDOR

Preservative Oil MIL-L-46002, Grade 1, or equivalent Commercially Available

Cortec Corp.
Cortec VpCI-326 Preservative Oil Concentrate, or 4119 White Bear Pkwy
equivalent St. Paul, MN 55510
612-429-1100
Dehydrator plugs, AN4062-1 or MS27215-2 Commercially Available
Covers, as required Commercially Available
Moisture Resistant Caps Commercially Available
Moisture Resistant Tape Commercially Available

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Temporary Preservation NOTE: If the engine is not returned to flyable

The following preservation procedure should status on or before the 90 day
follow acceptance testing as soon as possible if expiration it must be preserved in
the engine is not to be immediately installed in accordance with “Indefinite Storage”
the aircraft and operated. procedures.

 Remove oil sump drain plug and drain oil,

preferably while engine is still warm. Returning an Engine to Aircraft Service After
Replace drain plug, torque and safety. Storage
Remove oil filter used for testing if not  Remove all seals and all desiccant bags.
already accomplished. Install new oil filter,  Remove cylinder dehydrators and plugs
torque and safety. from lower spark plug holes.
 Remove all spark plug leads and remove the  Rotate crankshaft by hand for several
top spark plugs. Protect the ignition lead revolutions to remove preservative oil.
ends with AN-4060 protectors or equivalent.  Remove oil sump drain plug and drain the
Rotate crankshaft so that all pistons are at corrosion preventive oil mixture. Replace
approximately mid stroke. Using a common drain plug, torque and safety. Temporarily
garden sprayer or equivalent, spray replace the cylinder dehydrators to prevent
approximately 2-3 ounces of atomized contamination of the cylinders. Allow any
preservative oil MIL-P-46002 Grade I, or preservative oil to drain away that is in the
Cortec VpCI-326, at room temperature intake port. Wipe away any excess oil.
through the upper spark plug hole of each  The engine is now ready to install on the
cylinder. aircraft in compliance with Superior Vantage
 Remove carburetor or fuel injection servo, Installation and Operation Manual, No.
drain all fuel from system and lines and cap SVIOM01 and the specific aircraft
lines. Spray 1-2 ounces of preservative Maintenance Manual instructions.
into the intake port, as described above.
Insert desiccant bag in intake port. Attach a
red “Remove Before Flight” streamer to
each bag of desiccant and seal the
openings.
 Re-pack the carburetor or fuel injection
servo in the manufacturer’s packaging to
avoid damage and contamination.
 Install dehydrator plugs in top spark plug
holes. Make sure each plug is blue in color
when installed. Install caps in bottom spark
plug holes
 Seal all engine openings exposed to the
atmosphere using suitable plugs and covers.
 Identify using red tag with tie wire, on the
propeller flange, with the following notation
on the tag, : “Do Not Turn Crankshaft –
Engine Preserved – (Preservation Date)”

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REPAIR
General
The following sections contain Minor repair
procedures required to return the Superior
Vantage O-360 and IO-360 series engine to
serviceable condition. Replace all parts that do
not meet requirements after repair. A list of
repairs is provided in Table 72-00-12.1.
 Materials required for repair are listed in
Table 72-00-12.2.
 Equipment used for repair is listed in Table
72-00-12.3.
 Codes used for repair are listed in Table 72-
00-12.4
 Symbols used for repair are listed in Table
72-00-12.5

Repair Procedures
Perform repair procedures as listed in Table 72-
00-12.1 when components do not meet
requirements specified in the Inspection and
Check section of this manual.

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Table 72-00-12.1 • List of Repairs

Repair
Title Description
Procedure
Threaded area repair and stud Repairs threaded areas and replaces
Repair No.1
replacement studs and threaded inserts.
Blends nicks, scratches in
Repair No.2 Nick and scratch repair mounting/mating flanges and other flat
surfaces.
Repairs crankshaft or crankpin bearing
Repair No.3 Crankshaft or crankpin repair
journals.
Repairs the gear mounting surface.
Crankshaft counterbored gear
Repair No.4 Contact Superior Air Parts for
mounting surface
Approved Repair Station.
Paints parts stripped during
Repair No.5 Painted parts
degreasing or inspection procedures.
Reconditions the oil seal area at the
Repair No.6 Crankshaft oil seal surface
prop flange surface.
Allows grinding of the flange area to
Repair No.7 Crankshaft flange reduce distortion. Contact Superior Air
Parts for Approved Repair Station.
Polishes and re-plates pilot diameter of
crankshaft forward end. Contact
Repair No.8 Crankshaft forward counterbore
Superior Air Parts for Approved Repair
Station.
Hones glazed interior surfaces of
Repair No.9 Cylinder interior surface
hardened cylinders.
Repair No.10 Cylinder head cooling fins Repairs nicks, chips, cracks
Valve, valve seat, and valve Reseats, polishes, re-faces valves and
Repair No.11
guide adjoining parts.
Replaces the spark plug threaded
Repair No.12 Spark plug threaded insert
insert.
Replaces the bushing in intake and
Repair No.13 Rocker bushing replacement
exhaust rockers.
Connecting Rod bushing Replaces the bushing in small end of
Repair No.14
replacement the connecting rod.

NOTE: Repair Nos. 4, 7 and 8 must be accomplished by an Approved FAA Repair Station. Contact
Superior Air Parts for approved sources at 866-845-7624.

Table 72-00-12.2 • List of Materials

Material Source
Dress wheel (polishing) Commercially Available
Thread lubricant Commercially Available
TM
Locktite Commercially Available
Abrasive (crocus) cloth Commercially Available

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Zinc chromate primer (AMS 3110 or equivalent per MIL-P-8585) Commercially Available
Sodium dichromate Commercially Available
Enamel paint (AMS 3125C or equivalent per MIL-E-7729) Commercially Available
Toluene (AMS 3180 or equivalent per TT-T-548) Commercially Available
Alodine (Mil-C-5541 Class 1A or equivalent) Commercially Available

Table 72-00-12.3 • List of Equipment

Material Source
Stud extractor Commercially Available
Lathe Commercially Available
Collet grip tool Commercially Available
Spray gun (paint) Commercially Available
Carborundum wheel (GA54-J5-V10 or equivalent) Commercially Available
Hand file Commercially Available
Reamer set Commercially Available
Bushing puller kit Commercially Available
Tap & die set Commercially Available
Extraction tool for threaded inserts Commercially Available
Insertion tool for threaded inserts Commercially Available

Table 72-00-12.4 • List of Repair Codes

Material Source
M03MP Main and crankpin journals 0.003 inch undersize
M03M Main bearing journals 0.003 inch undersize
M03P Crankpin bearing journals 0.003 inch undersize

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REPAIR NO. 1
THREADED AREA REPAIR AND STUD REPLACEMENT
Repair and Replacement WARNING: LUBRICANTS ARE TOXIC AND
(1) Repair defective threaded areas on studs FLAMMABLE. DO NOT BREATHE VAPORS.
with a suitable die or tap. Small nicks can BEFORE YOU USE, READ THE MATERIAL
be removed satisfactorily with files or small, SAFETY DATA SHEET (MSDS) FROM THE
edged stones. MANUFACTURER OR SUPPLIER. USE IN A
(2) Replace defective studs with a collet grip WELL VENTILATED AREA FREE FROM
tool, or other appropriate tool. SPARKS. WEAR PROTECTIVE GEAR. IN
(a) If stud is broken and tool cannot be CASE OF EYE CONTACT, FLUSH WITH
used, drill a hole into the stud to use a WATER FOR 15 MINUTES AND SEEK
pilot bushing. A stud extractor may then MEDICAL ATTENTION. IN CASE OF SKIN
be utilized to remove the stud. CONTACT, WASH WITH SOAP AND WATER.
(b) After defective stud is removed, check
hole threads for damage. Repair or (d) Coat threads of new stud with lubricant
reject as required. Also check thread or Loctite™ and drive stud to correct
size to determine replacement stud depth with suitable stud driver. Torque
thread size. IAW Table of Limits Appendix C of this
(c) Use compressed air to clean out manual.
shavings prior to installation of new
stud. Preservation
Coat threads of repaired threaded areas or
WARNING: WHEN YOU USE COMPRESSED studs with lubricant or preservative oil.
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.

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REPAIR NO. 2
NICK AND SCRATCH REPAIR
Repairs
(1) Using hand file or abrasive (crocus) cloth, (3) Clean to remove all abrasive dust and other
remove minor nicks and scratches on debris. If lapping was performed, check the
mating surfaces of accessory housing, part with its mate to assure that the
crankcase and accessory assemblies, and clearances are still within tolerances. Refer
mounting flanges or bodies of other to the Table of Limits Appendix C of this
components. manual for limits.

(2) If necessary, lap mating surfaces on a

surface plate to remove abnormal damage.

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REPAIR NO. 3
CRANKSHAFT OR CRANKPIN REPAIR
Repairs WARNING: IF ONE SURFACE IS POLISHED
Measure crankshaft main and crankpin journals. TO UNDERSIZE, ALL CORRESPONDING
(1) Determine if the components in question SURFACES MUST BE POLISHED TO THE
are standard or undersize bearing SAME SIZE.
journals. Determine this information
prior to beginning any polishing or WARNING: USE THE CORRECT PERSONAL
grinding operation. PROTECTION. POLISHING WILL CAUSE
LOOSE PARTICLES THAT CAN GET IN
(2) Measure the OD of the crankshaft main YOUR EYES.
and rod bearing journals and compare
results to the limits shown in the Table NOTE: Main bearing surfaces may be
of Limits Appendix C of this manual. If polished without affecting crankpin
dimensions do not fall within specified surfaces and likewise, the crankpin
limits, the shaft must be brought to bearing surfaces may be polished
undersize. without affecting the main bearing
surfaces.
(3) Check the crankshaft flange for a code
symbol stamped as a suffix to the part Inspection After Resurface Procedure
number. Possible code symbols are: (1) Upon completion of the polishing
M03MP (main and crankpin journals procedure, thoroughly clean the part. Buff
0.003 in. undersize); M03M (main the surface to a high finish.
bearing journals 0.003 in. undersize);
M03P (crankpin bearing journals 0.003 (2) After polishing operation, clean the part and
in. undersize). perform a complete magnetic particle
inspection of the shaft or pin. If any cracks
If the maximum service limits are or checks are found, the part must be
exceeded, standard shafts may be rejected.
polished to 0.003 in. undersize and fitted
with 0.003 in. undersize bearing inserts. (3) Coat the clean surfaces of approved parts
with preservative oil and store until ready
for reassembly.
CAUTION: DO NOT ALLOW LATHE SPEED TO
EXCEED 150 RPM DURING ANY POLISHING WARNING: USE CORRECT PERSONAL
OPERATION. PROTECTION. SOME CHEMICAL
SOLUTIONS CAN CAUSE SKIN, EYE AND
Polish crankshaft or crankpin journals as LUNG DAMAGE. FOLLOW THE
needed to reestablish proper fits and MANUFACTURER'S INSTRUCTIONS FOR
clearances. Refer to the Table of Limits EACH CLEANING SOLUTION.
Appendix C of this manual for size
limits.

WARNING: DO NOT DAMAGE THE NITRIDED

SURFACES OF THE CRANKSHAFT.

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REPAIR NO. 5
PAINTED PARTS
Painted Parts Repair
Some parts may have had paint removed from All paint used in these procedures should be
either normal operation or during the cleaning sprayed on. If it is necessary to brush the paint
and inspection procedures. The new crankcase on, extreme care must be exercised to prevent
and other aluminum cast components have excessive accumulation of paint in small corners
been alodined after machining and prior to any or void areas of the crankcase.
hardware installation per MIL-C-5541, Class 1A.
NOTE: All machined bosses should be
Parts requiring the use of paint for protection masked before painting. Do not paint
should be painted in accordance with the areas under hold-down nuts or bolt
following recommendations using material from heads where torque is required.
the list of approved materials. See Table 72-00-
12.6.

Table 72-00-12.6 • Consumable Materials for Paint Procedures

Material Source
Resin-type enamel, AMS 3125C or equivalent MIL-E-7729
Commercially Available
(such as Randolph Black #303)
Toluene or equivalent AMS3180 (or equivalent Federal
Commercially Available
Spec. TT-T-548)
Zinc chromate primer Commercially Available

A. Aluminum and steel parts WARNING: USE THE CORRECT PERSONAL

(1) Clean and degrease all parts prior to PROTECTION. HEATED PARTS WILL
paint procedures. CAUSE BURNS.

WARNING: SOLVENT IS TOXIC. USE IN B. Cylinder Barrels

WELL-VENTILATED AREA. PREVENT EYE (1) Thoroughly clean all old paint from the
AND SKIN CONTACT AND DO NOT cylinder. A vapor degreaser is well
BREATHE VAPORS. IN CASE OF EYE suited for this purpose.
CONTACT, FLUSH WITH WATER FOR 15 (2) Superior Air Parts does not recommend
MINUTES AND SEEK MEDICAL ATTENTION. painting of cylinder heads for optimum
IN CASE OF SKIN CONTACT, WASH WITH cooling. Only alodine is required for
SOAP AND WATER. cylinder head surface protection.
(3) Mask off the cylinder head, plug flange
(2) Apply one coat zinc chromate primer, bolt holes and cover cylinder bore.
thinned with approximately 2 parts
toluene, and allow to air dry. NOTE: Masking materials may include tape,
corks, plugs, foil, metal covers, etc.
NOTE: Parts from which the paint has not
been removed may be repainted (4) Spray a very light coat of zinc chromate
without the primer coat. primer (0.0005 in. maximum thickness)
on the cylinder flange. A correct
(3) Apply one coat of enamel and bake at thickness of paint will appear green with
250°F for ½ hour. If allowed to air dry, a yellow tint and allow the metal to show
an inferior finish will result.
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through. Paint that is too thick will (5) Mask off the flange area around nut
appear zinc chromate yellow. seating surface. Paint the cylinder with
an enamel resin or equivalent that has
CAUTION: THICKNESS OF PRIMER MUST BE been properly thinned with toluene or
NO MORE THAN 0.0005 IN. USE EITHER A equivalent.
TINSLEY THICKNESS GAGE OR A (6) Use a cloth wet with thinner to clean
MICROMETER TO MEASURE THE paint from any surfaces where
THICKNESS OF THE FLANGE BEFORE AND overspray paint may have adhered.
AFTER PAINTING. IF THE PRIMER IS TOO (7) Allow the cylinder to air dry for 15
THICK IT MUST BE REMOVED AND THE minutes then bake in an oven until
BARREL REPAINTED. completely dry.

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REPAIR NO. 6
CRANKSHAFT OIL SEAL SURFACE
Crankshaft Oil Seal Flange Recondition prevent the occurrence of spiral marks,
(1) If the crankshaft oil seal surface on the do not move the cloth while polishing.
shaft itself is damaged to the point that The surface roughness of the oil seal
the oil seal might leak, use the following area should not exceed 8 microinches
procedure to recondition this area. Ra. Clean the shaft so that all traces of
debris are removed.
WARNING: DO NOT DAMAGE THE NITRIDED
SURFACES OF THE CRANKSHAFT. Preservation
Coat steel parts with preservative oil per MIL-L-
(2) Use crocus cloth to polish the oil seal 6529.
area of the shaft while the shaft is
rotated counterclockwise (viewed from
the front or flange end of the shaft). To

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REPAIR NO. 9
CYLINDER INTERIOR SURFACE
Cylinder Interior Surface Reconditioning 3) Oversize allowance is determined by
The Superior Vantage O-360 and IO-360 series adding 0.004 in. to the barrel diameter
engines utilize cylinders constructed of through- at the point of greatest wear. This must
hardened steel. These do not include nitride- not exceed 0.002 in. per wall. Grind the
hardened or chrome plated interior surfaces. barrel to the oversize above this
amount.
WARNING: USE THE CORRECT PERSONAL 4) Grind the surface of the steel barrel to
PROTECTION. POLISHING AND GRINDING 25-35 microinches Ra. This can be
WILL CAUSE LOOSE PARTICLES THAT CAN obtained by grinding the barrel diameter
GET IN YOUR EYES. to within 0.0005 to 0.001 in. of the
desired ID with rough-in cuts.
CAUTION: DO NOT ALLOW THE HONING 5) Redress the wheel and make a finish
WHEEL TO RUN PAST THE BARREL MORE pass. Allow the wheel to run over the
THAN 1/8 IN. INTO THE COMBUSTION work up to five more times to ensure a
CHAMBER. proper surface finish.

1) Place the cylinder on a honing stand. If NOTE: The surface finish must be properly
the cylinder exceeds allowable service crosshatched along the entire length of
limits in taper, diameter, or out-of- the barrel. The crosshatch pattern
roundness, regrind to 0.010 oversize. must be 35°-37° from a line parallel
2) Recommended equipment information with the cylinder base. Refer to Figure
for honing is as follows: 72-00-12.1.
(a) Wheel:
 Friable bond material – 2A; 6) If oversizing must occur, the cylinder
grain size – 54; grade – K; must be fitted with P010 (.010 in.)
structure – 5 porous; vitrify bond oversize pistons and piston rings.
treatment – V92; diameter – 3 ½ These must be used in opposing pairs
to 4 inches. to maintain the dynamic balance of the
(b) Wheel speed: engine.
 3 ½ inch wheel: 5600 to 6000
surface feet per minute.
 4 inch wheel: 5350 to 5730
surface feet per minute.
(c) Work speed: 250 RPM.

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Figure 72-00-12.1 • Cylinder Interior Resurface Crosshatch

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REPAIR NO. 10
CYLINDER HEAD COOLING FINS
Cylinder Head Cooling Fin Repair (c) The minimum filet at the root of the
The Superior Vantage O-360 and IO-360 series removed portion of the fin is 0.25 in.
engines utilize cylinders constructed of through- radius. Minimum corner at top of fin
hardened steel and heads of cast aluminum. adjacent to the removed portion is
Only the fins on the aluminum head may be 0.50 in. radius.
repaired. Cooling fins on the steel barrels may (3) For damaged, cracked, or broken fins, it
NOT be repaired by this process. is permissible to perform the following
repairs:
The cooling fins on these cylinders are finely (a) A damaged area may be blended.
balanced to provide appropriate cooling to the The blended area for any one fin
overall cylinder assembly. shall not exceed 0.38 in. square
area or 0.38 in. depth.
CAUTION: REFER TO THE INSPECTION AND (b) There may be no more than two
CHECK SECTION OF THIS MANUAL TO blended areas on one fin.
DETERMINE DAMAGE LIMITS FOR COOLING (c) No more than four blended areas on
FINS ON ANY CYLINDER PRIOR TO the pushrod side of the cylinder
REPAIRS. head. No more than six blended
fins on the side opposite the
Perform repairs as follows: pushrod side of the cylinder head.
(1) For cracks in the fin, it is permissible to (4) It is recommended that a fluorescent
drill a 0.19 in diameter hole (a stop drill) penetrant inspection be performed upon
at the end of the crack provided the completion of any of these repairs.
crack is at least 0.25 in. from the root of (a) Pay special attention to the area on
the fin. exhaust port side of the cylinder.
(2) For fins cracked almost all the way (b) Pay special attention to the area
across, it is permissible to remove a around the lower spark plug
portion of the fin as follows. Refer to counterbore.
Figure 72-00-12.2.
(a) The maximum material removed is
no more than ½ the total fin width.
(b) No burrs or sharp edges remain.

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Figure 72-00-13.2 • Cooling Fin Removal Maximum

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REPAIR NO. 11
VALVE, VALVE SEAT, AND VALVE GUIDE
General order to achieve the specified
Valves and valve guides must be replaced at diameter, the seat must be
overhaul. The surfaces of the valves and their replaced.
seats can normally be resurfaced and
reconditioned if the engine is being repaired not Valve seat replacement
overhauled. (3) Valve seats that are damaged, worn, or
loose must be replaced. Use the
Valves must be removed from the cylinder and following procedure or an equivalent.
cleaned of all sludge and carbon build-up prior
to repairs. Refer to the Cleaning section of this NOTE: The valve guide must be replaced at
manual. Refer to the Inspection and Check the same time as a valve seat is
section of this manual for appropriate inspection replaced. This ensures concentric
procedures and limits on damage and wear. grinding of the valve seat. See
discussions later in this Repair for
Valve seat grinding guide replacement procedures.
(1) The ID of the valve guide is used as a
pilot for all valve seat reconditioning NOTE: For the purpose of removing valve
operations. seats, a tool may be fabricated from
threaded bar stock, hardware and
WARNING: USE THE CORRECT PERSONAL sponge material.
PROTECTION. POLISHING AND GRINDING
WILL CAUSE LOOSE PARTICLES THAT CAN NOTE: The valve seats are an interference fit
GET IN YOUR EYES. installation. The cylinder must be
heated and the valve seat cooled. The
(2) Grind valve seats with suitable grinding resulting difference in size will allow
equipment to a 30° angle on intake the seat to be removed from the
valve seats and a 45° angle on exhaust cylinder head.
valve seats. Grind valve seats to 16 RA
max. (ref) concentric to guide bore WARNING: USE THE CORRECT PERSONAL
within 0.002 in. PROTECTION. HEATED PARTS WILL
(a) On intake valve seats, use a 15° CAUSE BURNS.
grinding wheel to grind the top
surfaces of the valve seat to (4) Heat the cylinder to 575°F (302°C) and
produce the outer face diameter. secure to a fixture.
Bring the face of the intake valve (5) Soak the removal tool sponge in cold
seats to the specified width (refrigerated) water. Insert the tool
(Dimension “B”) by narrowing the through the valve seat. The seat should
throat with a 75° wheel. Refer to shrink slightly and stick to the sponge.
Figure 72-00-12.3. Pull the tool back out with the seat. Use
(b) On exhaust valve seats, use a 15° care to not tilt the seat during this
grinding wheel to grind the top process.
surface of the valve seats to
produce the outer face diameter. NOTE: This procedure must be performed as
The width of the exhaust valve seats quickly as possible.
should conform to dimension “D”.
Refer to Figure 72-00-12.3. (6) Measure the ID of the valve seat recess
(c) If the seat wear has progressed to to determine which oversize seat must
the extent that the entire face of the be installed. Refer to Tables in section
15° narrowing wheel must be 9.0 and 10.0 of the Table of Limits
brought into contact with the seat in Appendix C of this manual.
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the valve guide is out of the cylinder

WARNING: USE THE CORRECT PERSONAL head.
PROTECTION. POLISHING AND GRINDING (2) Install valve guides as follows:
WILL CAUSE LOOSE PARTICLES THAT CAN (a) Prior to installation of a new valve
GET IN YOUR EYES. guide, measure the guide hole to
determine if an oversize guide must
(7) Use an appropriately sized cutter be used. Refer to section 11.0 and
installed with its pilot and drive on a drill 12.0 of the Table of Limits Appendix
press. Cut the recess in the cylinder C of this manual. Use a hole plug
head to proper oversize. Remove no gage and measure each valve guide
more metal than required to clean the hole. Determine if a standard size
major diameter of the seat recess. or oversize guide must be used.
Refer to the Table of limits section
NOTE: The cutter pilot shall engage the ID of 11.0 and 12.0.
the valve guide hole in the cylinder (b) Fasten the cylinder in place on a
head. guide replacement tool. Set the tool
to the appropriate angle for the
(8) Place the new valve seat onto a guide being installed.
replacement drift. (c) If an oversize guide must be
installed, use an appropriate size
WARNING: USE THE CORRECT PERSONAL reamer in a drill press. Ream the
PROTECTION. HEATED PARTS WILL valve guide hole to the specified
CAUSE BURNS. size. Measure the hole again and
confirm proper size.
(9) Heat the cylinder to 575°F (302°C) and (d) Heat the cylinder to between 350°F-
secure to a fixture. Place the new seat 425°F (176°-218°C) for a minimum
on a replacement drift. Drive the new of 1 hour. Position the new guide
seat into the recess by tapping the drift onto the end of a valve guide
with a hammer. installation drift and insert the guide
in the hole in the cylinder head.
(10)Grind the face of the new seat as (e) Drive the guide into the hole with
described above in this Section. firm hammer blows on the end of
the drift.

Valve guide replacement WARNING: USE THE CORRECT PERSONAL

(1) Remove valve guides as follows: PROTECTION. USE OF A HAMMER CAN
(a) Use a valve guide puller to the head CAUSE LOOSE PARTICLES THAT CAN GET
of a ¾-16 bolt. Place the tool IN YOUR EYES.
retainer over the valve guide inside
the rocker box. Insert the ¾-16 bolt (f) Allow the cylinder to cool. Ream the
into the retainer and valve guide. valve guide with an appropriate ID
From inside the cylinder, insert the reamer. Check the finished ID with
3/8-24 bolt into the end of the larger a hole plug gage.
¾ bolt. Tighten the 3/8 bolt until it is
against the valve guide. Turn the
nut in the rocker box clockwise until

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Intake valve face grinding (a) Set the valve refacing equipment to
30° for intake valves. Use a soft
CAUTION: DO NOT ATTEMPT TO BEND OR #80 grit wheel to grind only enough
STRAIGHTEN THE VALVE FACE OR STEM. of the valve face to remove small
pits.
NOTE: Intake valves require replacement at (b) Round off any burrs or sharp edges
overhaul. with a polishing stone while the
valve is still turning in the refacing
1) Intake valve faces that have minor pitting or equipment.
warping may be refaced by grinding. 2) After grinding and cleaning, the valve stem
may be polished to remove superficial
WARNING: USE THE CORRECT PERSONAL scratches.
PROTECTION. POLISHING AND GRINDING
WILL CAUSE LOOSE PARTICLES THAT CAN
GET IN YOUR EYES.

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Figure 72-00-12.3 • Valve Seat Dimensions

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Figure 72-00-12.4 • Valve to Seat Fit Acceptable Criteria

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REPAIR NO. 12
SPARK PLUG THREADED INSERT
Spark Plug Threaded Insert Replacement
Spark plug threaded inserts that were rejected (7) Screw the insert into the hole.
during inspection must be removed and (a) Be sure that the first coil of the
replaced as described in this section. Use an insert picks up the first thread of the
extraction tool to remove the rejected insert as hole. As the tool is turned, the
follows: insert will advance into the hole.
(b) When the face of the sleeve is
(1) Insert the tool in the spark plug hole so approximately 0.13 in. from the face
that the edges of the tool cut into the top of the boss, the inserting tool should
thread of the insert. be held tightly by the handle. The
(2) Rotate the tool counterclockwise to sleeve must be rotated
unscrew and remove the threaded insert counterclockwise which will free the
from the hole. left half turn of the insert.
(c) Slide the sleeve toward the top of
Inspect the condition of the tapped hole after the mandrel and check that the top
removal of the insert in accordance with the of the insert projects above the
Inspection and Check section of this manual. boss.
Assemble the insertion tool with new insert as (d) Rotate the mandrel until the insert
follows: disappears from sight. Stop the
turning action and remove the tool.
(1) Withdraw the mandrel portion of the tool (e) The top of the insert should be one
beyond the recessed section of the half turn from the face of the boss
sleeve. Place insert into the recess and the tang end should not
area. protrude into the combustion
(2) Allow the mandrel to advance to engage chamber.
its slotted end with the tang of the insert. (8) Set the insert as follows:
(3) Rotate the mandrel clockwise and press (a) Break off the tang of the insert at the
slightly. This engages the insert in the location of the notch.
threaded end of the sleeve. (b) Use an expander tool to secure the
(4) Continue to rotate the mandrel while insert in the plug hole. Set the limit
holding the sleeve. This secures the of expansion by fixing the stop nut
insert firmly on the insertion tool. on the expanding tool at the correct
(5) Wind the insert through the threaded position.
portion of the tool sleeve to within one- (c) Assemble a staking sleeve over the
half turn of the end of the coil. mandrel until the sleeve meets the
(6) Keep the insert tight on the tool to boss. Stake the insert by striking
prevent unwinding and facilitate the the top of the sleeve a light blow
installation of the insert. Wind the insert with a hammer. This will create a
so that the adjacent turns of the insert slight chamfered edge around the
are in contact with each other. This edge of the tapped hole.
eliminates the possibility of crossed (d) Remove the staking sleeve, release
threads. the adjusting screw, and remove the
expanding mandrel from the insert.

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REPAIR NO. 13
ROCKER ARM BUSHING REPLACEMENT
Rocker Arm Bushing Replacement
Rocker bushings that were rejected during Assemble a new rocker arm bushing using the
inspection must be removed and replaced as arbor press and extraction/insertion tool
described in this section. described above as follows:

Use an arbor press and an extraction/insertion (1) Support the rocker arm on the base of
tool (piloted shoulder press tool) to remove the the arbor press such that the center
rejected bushing as follows: bore of the rocker is directly supported.

(1) Support the rocker arm on the base of NOTE: Avoid supporting the rocker arm in
the arbor press such that the center such a way that bending loads are
bore of the rocker arm is directly placed on the rocker arms in order to
supported and the bushing can be freely prevent damage to the rocker arm.
pressed from the rocker arm.
(2) Rotate to align the bushing so that the
NOTE: Avoid supporting the rocker arm in lubrication hole is aligned with the oil
such a way that bending loads are hole on the pushrod side of the rocker
placed on the rocker arms in order to arm bore.
prevent damage to the rocker arms. (3) Insert the tool in the rocker arm bushing
so that the shoulder of the tool rests on
(2) Insert the tool in the rocker arm bushing the edge face of the bushing and is
so that the shoulder of the tool rests on clear of the ID of the rocker arm bore
the edge face of the bushing and is (4) Insert rocker arm bushing until the
clear of the ID of the rocker bore lubrication hole of the bushing is
(3) Press out the rocker arm bushing. centered on the oil hole on the pushrod
(4) Clean rocker arm bore and oil holes side of the rocker arm bore and the
thoroughly as described in the Cleaning bushing is flush with the sides of the
section of this manual and inspect the rocker arm.
condition of the rocker arm bore. Repair (5) Ream or hone the bushing ID to size per
scratches as required per the Cleaning the Table of Limits.
section of this manual.

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Revision C

REPAIR NO. 14
CONNECTING ROD BUSHING REPLACEMENT
Connecting Rod Bushing Replacement
Connecting Rod bushings (small end) that were Assemble a new connecting rod bushing using
rejected during inspection must be removed and the arbor press and extraction/insertion tool
replaced as described in this section. described above as follows:

Use an arbor press and an extraction/insertion (1) Support the connecting rod on the base
tool (piloted shoulder press tool) to remove the of the arbor press such that the
rejected bushing as follows: connecting rod bushing bore is directly
supported.
(1) Support the connecting rod on the base
of the arbor press such that the small NOTE: Avoid supporting the connecting rod in
end bushing bore of the connecting rod such a way that bending loads are
is directly supported and the bushing placed on the length of the connecting
can be freely pressed from the rod in order to prevent damage to the
connecting rod. connecting rod.

NOTE: Avoid supporting the connecting rod in (2) Insert the tool in the bushing so that the
such a way that bending loads are shoulder of the tool rests on the edge
placed on the length of the connecting face of the bushing and is clear of the ID
rod in order to prevent damage to the of the connecting rod bore
connecting rod. (3) Insert bushing until the bushing is
centered within the bore of the
(2) Insert the tool in the connecting rod connecting rod and bushing is flush with
small end bushing so that the shoulder the sides of the connecting rod.
of the tool rests on the edge face of the (4) Broach the bushing ID to size per
bushing and is clear of the ID of the SSD001 section 4.0 part 4.
connecting rod bore
(3) Press out connecting rod bushing.
(4) Clean connecting rod thoroughly as
described in the Cleaning section of this
manual and inspect the condition of the
connecting rod bushing bore. Repair
scratches as required per the Cleaning
section of this manual.

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Revision C

POST OVERHAUL ACCEPTANCE TESTING

General frame and secure with appropriate locking
This section defines the testing that each devices and lock pins.
Superior Vantage O-360 and IO-360 series
engine must undergo to determine its • Ensure magneto and fuel switches are “OFF”.
acceptability after assembly/overhaul. It is
preferred that acceptance testing be • If the engine is configured for constant speed
accomplished in an appropriate aircraft engine propellers, install temporary Hubbard plug in
test cell. However, testing after installation in the front of crankshaft, as required, when testing
aircraft is an acceptable alternative. The Fault with a fixed pitch prop or test club and remove
Isolation/Trouble Shooting section of the after test run is completed.
Superior Vantage Maintenance Manual, No.
SVMM01, should be consulted as required. • Install fuel delivery hose from test rig to engine
driven fuel pump inlet and primer line, as
NOTE: Refer to the Disassembly/Assembly required, along with engine breather hose.
sections of this manual for
replacement of defective components. • Connect oil cooler hoses and oil pressure hose
to engine using appropriate “quick connect”
Special Tools and Equipment ports.
Standard aviation shop tools and equipment are
required. • Install appropriate intake connection/duct to
carburetor or servo as required.
Engine Installation and Testing Procedures
NOTE: The order of installation for fuel system • Install exhaust system.
hoses, oil hoses, instrumentation wires and
connections, fittings, exhaust system
components and cooling baffles and shrouds • Install instrumentation:
may be changed as deemed appropriate by the
installation personnel. This will allow for the • Tachometer
flexibility of having more than one person attach • Fuel Flow
and/or remove the engine to and from the test • Manifold Pressure
bed as well as aid in the work flow. • Oil Temperature
• Intake Air Temperature
• Install slave oil cooler and oil pressure fittings • Cylinder Head Temperature (CHT, to all
to engine using anti-seize on fitting threads. cylinders recommended)
• Exhaust Gas Temperature (EGT, to all
• Attach appropriate engine mount to engine with cylinders recommended)
appropriate hardware and isolator mounts.
• Verify that magneto switch is in “OFF” position,
• Install Test Run oil filter. then install magneto P-leads.

• Install oil temperature probe. • Attach Operating Control Cables.

• Remove engine assembly from build stand. • Throttle cable

• Mixture cable
• If engine is to be installed on a Dynamometer • Propeller cable (if required)
Stand, ensure that a Hubbard Plug installed in
the front of the crankshaft and that the starter • Install ring gear to crankshaft propeller flange
ring is properly installed. and install test club or attach Dyno drive.
• Rotate ring gear to compression stroke of
• Attach engine and mount assembly to test bed number one cylinder.

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Revision C

NOTE: It may be necessary to rotate crankshaft • Secure hoses, lines, wires, etc. as required to
just beyond top dead center to allow magneto reduce chaffing and excessive movement during
impulse couplings to release. Upon release, test run.
rotate crankshaft in opposite direction, back to • Tie wraps may be used to aid in security.
correct timing degree mark.
• Align applicable timing mark on ring gear with • Fill engine with appropriate quantity of oil.
mark on starter housing.
• Reference Superior Vantage Installation
WARNING: DO NOT INSTALL THE IGNITION and Operations Manual SVIOM01for
HARNESS “B” NUTS ON THE SPARK PLUGS proper oil level.
UNTIL THE PROPELLER INSTALLATION IS
COMPLETED. FAILURE TO COMPLY COULD • Check/verify oil level on oil level gage.
RESULT IN BODILY INJURY WHEN THE
PROPELLER IS ROTATED DURING • Pressurize fuel system, check for leaks.
INSTALLATION.
• Install cooling hood to engine and secure
WARNING: USE THE CORRECT PERSONAL safety cable and lock pin.
PROTECTION EQUIPMENT TO AVOID
INJURY. ENSURE AREA IS FREE OF • Inspect engine and test bed for any oil and/or
MOVABLE OBJECTS THAT COULD IMPACT fuel leaks as well as for installation security of all
BY PROPELLER AIR BLAST. connections.

• Attach timing indicator leads of timing box NOTE: If the engine acceptance test is to be
(buzz box) to magneto p-lead connectors. accomplished with the engine installed
• Rotate/adjust magnetos until each indicator in the aircraft, install the engine in
light just comes on (or goes out depending on accordance with Superior Vantage
light configuration) indicating Installation and Operation Manual No.
that magneto points are just opening. SVIOM01 and the aircraft
• Snug magneto attach hardware and rotate Maintenance manual. All aircraft
crankshaft back, just a few degrees before cooling baffles and cowling must be in
correct timing degree, then slowly rotate crank in place to assure proper cooling. Face
the direction of rotation until the timing lights the aircraft into the wind to assure the
each, simultaneously, indicate magneto optimum cooling.
points are just opening. Repeat process above
for minor adjustments as needed to achieve Engine Test Run Instructions
correct timing.
General
• Torque magneto attachment hardware I/A/W • The following instructions reference RPM as
EO 242 “Table of Limits”, “Torque Limit Table”. the set-point for engine operation for use with a
fixed pitch propeller
• Document requested readings on a“Green
• Install spark plugs and ignition leads. Sheet” or Engine Run Sheet. See form at the
end of this section or prepare a similar form.
• Use of Test (Slave) plugs is acceptable; verify • If, at any time during the test run, fuel or oil
plug gap is within limits. (.016 to .021) leaks are noted, shut down engine; determine
the cause and correct.
• Connect ground cable from test stand to • During the engine test run, allow appropriate
engine. cooling periods as needed so as not to exceed
the following maximum operating temperatures:
• Connect starter cable to starter. • Oil temperature, 245°F.
• Cylinder head temperature, 475°F.

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Revision C

Leak Check Engine Performance Check

Start engine per engine starting instructions. • Increase engine RPM to 2000 ± 50 RPM and
Refer to SVIOM01 (Vantage Installation and run for ten (10) minutes.
Operation Manual) • Verify oil pressure to be 55 psi to 95 psi.
• Verify oil pressure (indicated within 30 seconds Adjust oil pressure relief valve as required.
of operation) is at least 20 psi, and does not
exceed 115 psi (cold). Note: Shut down engine or Reduce engine2.3.2
RPM If oil pressure pa
• If oil pressure parameters are not met, shut as required to make necessary adjustments.
engine down; determine the cause and correct
prior to restart. • Document instrumentation readings.
• Run engine for five (5) minutes at 1000 RPM ±
200 RPM and record instrumentation readings. Full Power Acceptance Check
• Shut down engine and check for fuel and oil • Increase engine to full RPM or Wide Open
leaks. Throttle, (“WOT”) for five (5) minutes and
• Remove oil level gage, wipe clean and re- document RPM and instrumentation readings.
install in housing. Remove gage and record oil
level. Note: Refer to the Superior Vantage Installation
and Operation Manual No. SVIOM01 for the
Engine Warm-up Horsepower and RPM limits for your model. The
• Re-start engine per starting instructions raw horsepower readings must be corrected to
SVIOM01. Standard Day conditions. Acceptance Tolerance
• Operate engine at 1000 RPM ± 200 RPM until is ± 3.0 percent for horsepower.
oil temperature reaches 75°F and record run
time and instrumentation readings. Cool Down
• Decrease engine RPM to 2300 ± 50 RPM for
Note: Under cold conditions it is permissible ten (10) minutes and document instrumentation
to increase RPM to 1400 after oil temperature readings.
reaches at least 65°F to continue warm-up to • Decrease engine RPM to 2000 ± 50 RPM for
75°F. ten (10) minutes and document instrumentation
readings.
• Increase RPM to 1700 ± 50 RPM. • Decrease engine RPM to 1600 ± 50 RPM for
five (5) minutes and document instrumentation
Magneto Performance Check readings.
• Select left magneto or turn right magneto • Decrease engine RPM to 1200 ± 50 RPM for
“OFF”. Note and record magneto RPM drop. five (5) minutes and document instrumentation
Return switch to “BOTH” position or turn right readings.
magneto “ON”. • Decrease engine RPM to 600 ± 200 RPM and
• Acceptance range for magneto RPM allow cylinder heads to cool to 300°F.
drop is 25 RPM to 150 RPM.
• Select right magneto or turn left magneto Idle mixture and cut-off check
“OFF”. Note and record magneto RPM drop. • Pull mixture to idle cut-off position and note
Return switch to “BOTH” position or turn left RPM change. Just before engine shuts down,
magneto “ON”. restore mixture to full rich. Shut down engine
• Acceptance range for magneto RPM drop is and adjust idle mixture, restart engine and
25 RPM-150 RPM with a maximum difference in repeat procedure as necessary to achieve a 50
the left and right RPM drops not to exceed 75 RPM rise ± 25 RPM.
RPM. • After idle mixture is set correctly, pull mixture
• Continue engine run at 1700 RPM ± 50 to idle cut-off and allow engine to shut down.
RPM for five (5) minutes and document Verify and record clean shut down and RPM
instrumentation readings. rise.

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Revision C

Note: Oil consumption not to exceed .75 quarts

Oil Consumption Check per hour.
• Remove oil level gage and wipe clean.
Re-install in housing and remove again to Engine reservation and Storage After Testing
determine oil quantity. Refer to the Preservation and Storage Section of
• Calculate oil consumption for one hour and this manual for storage instructions.
document.

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 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

APPENDIX A
ASSEMBLY IN-PROCESS QUALITY INSPECTIONS
Inspection 1 (d) Verify proper side clearance of
A. Inspect and verify correctness of all each rod in accordance with the
parts and procedures prior to further Table of Limits appendix C of
assembly of crankcase halves to the this manual.
crankshaft assembly. (e) Check the torque on each rod
B. This quality inspection shall include nut in accordance with the Table
visual inspection of parts and written of Limits appendix C of this
records (paperwork) in accordance with manual.
the assembly guidelines in this Overhaul (13) Verify that nose bolts are installed
Manual. with o-rings in the right case half.
C. This inspection shall be accomplished (14) Verify the presence of o-rings on
during the engine assembly process as rear through bolts in right case half.
noted in the Assembly section of this (15) Verify the crankshaft gear
manual. installation.
D. Perform the inspections as follows: (a) Ensure the gear is properly
(3) Verify the case serial numbers seated in the crankshaft recess
match each case half. in accordance with the Table of
(4) Verify correct crankshaft part Limits appendix C of this
number. manual. Verify security of the
(5) Verify correct camshaft part number. lock tab.
(6) Verify the correct main bearing part (16) Verify the nose seal installation.
number and ensure proper fit. (a) Verify that the seal is installed
(7) Verify that all pipe plugs and fittings with the flat side toward
are properly installed in the case crankshaft prop flange.
halves. (b) Verify that the seal spring is
(8) Check the tappet body fit in lifter correctly installed in the seal
bore and ensure that all tappet groove or lip.
bodies are installed. (17) Verify that the front main bearing on
(9) Rotate the camshaft in each case the crankshaft has the correct part
half to verify smooth fit. number and check its alignment
(10) Verify that all mating surfaces are marks.
clean and absent of burrs and/or
scoring. Inspection 2
(11) Verify thrust bearing and slinger A. Inspect and verify the correct installation
clearance of crankshaft. Verify the of cylinders and assembly hardware,
end clearance of camshaft. See the including proper torque and safety
Table of Limits appendix C of this techniques. Verify the internal timing of
manual. the crankshaft gear, camshaft gear, and
(12) Inspect fit of connecting rods to idler gear as well as proper clearances
crankshaft. and gear lash.
(a) Verify the correct rod installation B. This quality inspection shall include
with rod serial numbers in the visual and physical inspection of parts
same plane and oriented toward and assemblies in accordance with the
oil sump. assembly guidelines in this Overhaul
(b) Verify the correct rod nut Manual.
assembly with the lip out. C. This inspection shall be accomplished
(c) Rotate or spin each rod on the during the engine assembly process as
crankshaft to verify smooth noted in the Assembly section of this
rotation. manual.
D. Perform the inspections as follows:

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Appendix A
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

(1) Check the torque of cylinders and noted in the Assembly section of this
assembly hardware. manual.
(a) Check the torque on the cylinder D. Perform the inspections as follows:
base nuts in accordance with (1) Perform a valve train inspection as
the Table of Limits appendix C follows:
of this manual (a) Inspect the pushrod tube seals
(b) Check the torque on all for proper installation.
crankcase assembly hardware (b) Verify security and installation of
in accordance with the Table of the nut and lock tab securing
Limits appendix C of this the spring clip to each pushrod
manual. tube.
(2) Verify correct safety techniques. (c) Verify installation of the exhaust
(a) Verify the safety of the slotted valve rotator cap on the valve
nut and drilled stud at accessory stem of each exhaust valve.
location, under the camshaft (d) Verify the dry tappet clearance
gear. for each rocker arm in
(b) Verify the safety of the drilled accordance with the Table of
belly bolts/nuts at sump Limits Appendix C section 4.0 of
location. this manual.
(c) Verify the safety of the idler (e) Verify installation of the rocker
shaft hardware. shaft caps (thrust buttons) in
each rocker shaft.
NOTE: Ensure clearance between the idler (2) Perform inspection of the accessory
shaft stud and idler gear. housing as follows:
(a) Visually inspect the housing for
(3) Verify that the timing marks align damage and general condition.
correctly between the crankshaft (b) Verify proper installation of the
gear, camshaft gear, and idler gear plugs and fittings.
with #1 cylinder on TDC (top dead (c) Verify proper installation of the
center). tachometer shaft seal.
(4) Verify the gear lash of the idler (d) Verify safety of the oil pump
gears with the crankshaft gear and housing.
camshaft gear. Refer to the Table of (e) Ensure smooth rotation of the oil
Limits Appendix C section 5.0 of this pump drive shaft.
manual. (f) Verify correct installation of the
(5) Verify installation of the tachometer fuel pump plunger as required.
shaft, bushing and snap ring in the
camshaft. Inspection 4
A. Inspect and verify proper installation of
Inspection 3 the accessory housing, rocker covers,
A. Inspect and verify proper installation, inner cylinder baffles, sump, cylinder
safety, and clearances of the cylinder drain tubes, induction/intake system,
valve train and accessory housing accessory adapters, and accessories.
subassembly prior to rocker cover and B. This quality inspection shall include
accessory housing installation. visual and physical inspections of the
B. This quality inspection shall include complete engine assembly.
visual inspection of assembly and safety C. This inspection shall be accomplished
techniques. A physical check of after the engine assembly has been
clearances shall be performed as completed and prior to engine test.
described in this list. D. Perform the inspections as follows:
C. This inspection shall be accomplished (1) Perform complete visual and
during the engine assembly process as physical inspections of the engine
as follows:

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Appendix A
 Overhaul Manual
O-360 and IO-360 Series Engines
Revision C

(a) Inspect for loose or missing (h) Verify security of the intake
parts or components. elbows. Ensure that the flange
(b) Verify security of the accessory of intake elbow fits completely in
housing and accessory adapters the recess of the aluminum
to housing. flange at the cylinder port.
(c) Verify security of the (i) Verify installation and safety of
accessories including the oil pressure relief valve.
magnetos, carburetor or fuel (j) Verify installation and safety of
injector servo, starter, and the oil level gage housing and
alternator. the oil level gage.
(d) Verify security of the cylinder (k) Verify safety of the fuel pump
drain tubes. attachment hardware.
(e) Verify security of the rocker (l) Verify correct installation of the
covers. magneto harnesses.
(f) Verify security of the sump. (m) Check security and routing of
(g) Verify security and installation of the primer lines or fuel injection
the inner cylinder baffles. lines and fuel hoses as
applicable.

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Appendix A
 Overhaul Manual
O-360 and IO-360 Series Engines
Appendix B
Approved Assembly Materials

Table of Contents
1.0 Complementary Documents .......................................................................................................................................2
2.0 Scope ...........................................................................................................................................................................3
3.0 Lubricants ....................................................................................................................................................................3
4.0 Gasket and Joint Cement .............................................................................................................................................3
5.0 Thread Lock and Sealant ..............................................................................................................................................3
6.0 Anti-Seize Compound ..................................................................................................................................................3
7.0 Safety Wire ..................................................................................................................................................................3
8.0 Silk Thread ...................................................................................................................................................................3
9.0 Solvents........................................................................................................................................................................4
10.0 Lapping Compound ......................................................................................................................................................4
11.0 Preservative Oil.. ..........................................................................................................................................................4
12.0 Engine Test Lubricating Oil...........................................................................................................................................4
13.0 Engine Test Oil Filter ....................................................................................................................................................4

1.0 Complementary Documents

There are no complementary documents.

2.0 Scope
This document provides a listing of common manufacturer’s products approved as engine assembly materials. This is not
meant to limit use to only the listed products. Another manufacturer’s product that is equivalent to the listed product will
be acceptable.

3.0 Lubricants
3.1 Assembly grease – Lubriplate No. 105
3.2 Mineral Oil – SAE 50 Aviation Mineral Oil
3.3 Fuelube – #44
3.4 EZ TURN MIL-G-6032D
3.5 STP High Viscosity Oil Treatment - Pre-Lube mixture – Approximately 15% STP and 85% SAE 50 Aviation Mineral Oil
3.6 Dow Corning 4, Electrical insulating compound
3.7 CRC Sta-Lube, Extreme Pressure anti-seize engine assembly lubricant

4.0 Gasket/ Joint Cement and Adhesives

4.1 Titeseal No. 2 Gasket and Joint Compound
4.2 Loctite No. 2 Gasket Sealant
4.3 EZ TURN MIL-G-6032D
4.4 General Electric RTV 102 Silicon Sealant (Crankcase Parting Surface Sealant)
4.5 Dow Corning 737 RTV Sealant
4.6 Loctite 515 Gasket Eliminator (Crankcase Parting Surface Sealant)
4.7 Pliobond Contact Cement
4.8 Silastic 140 Adhesive (for fin stabilizers)

pg. 1 of 2
Revision C October 2014
Appendix B
Approved Assembly Materials
 Overhaul Manual
O-360 and IO-360 Series Engines
5.0 Thread Lock and Sealant
5.1 Loctite 262
5.2 Loctite 271
5.3 Permatex High Strength Threadlocker RED

6.0 Anti-Seize Compound

6.1 Copper Based Anti-seize, Fel-Pro or Loctite C5-A
6.2 Loctite Food Grade Anti-Seize

7.0 Safety Wire

7.1 .020 dia. Type 304 Stainless Steel Wire, MS20995 C20

7.2 .025 dia. Type 304 Stainless Steel Wire, MS20995 C25

7.3 .032 dia. Type 304 Stainless Steel Wire, MS20995 C32

7.4 .041 dia. Type 304 Stainless Steel Wire, MS20995 C41

8.0 Silk Thread

8.1 #50 (“OO”) Silk Thread (100% Silk)

9.0 Solvents
9.1 Fast dry solvent – Acetone (preferred) or Methyl Ethyl Ketone

10.0 Lapping Compound

10.1 Clover Brand 180 grit silicon carbide in grease

11.0 Preservative Oil

11.1 Mixture of twenty parts Exxon Rust Ban 392 to one part Chevron Snow White Grease

11.2 Cortec VpCI-326 or MIL-P-46002 Grade I

11.3 LPS 3 Heavy Duty Rust Inhibitor

12.0 Penetrant Oil

12.1 Mouse Milk

13.0 Engine Test Lubricating Oil

13.1 Aeroshell 100, or other aviation approved oil company, straight mineral oil
(select appropriate grade for ambient air temp)

13.2 Exxon Aviation Oil 20W-50, or other aviation approved oil company, mineral based non-dispersant oil.

14.0 Engine Test Oil Filter

14.1 WIX part no. 51515, NAPA part no. 21515, Champion part no. CH48108 or 48108-1

pg. 2 of 2
Revision C October 2014
Appendix B
Approved Assembly Materials
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

Superior Warranty .

APPENDIX C
TABLE OF LIMITS
SUPERIOR ENGINE ASSEMBLIES
Superior Performance.

Doc No.: SSD001

Revision: A Date: 03/04/08
Superior Manufacturing.
Superior Design.

Page 1

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

1.0 Reference Documents

There are no other applicable documents.

2.0 Purpose
Superior Warranty .

The purpose of this document is to provide criteria for the common assembly of
Vantage O/ IO-360 and XP-360 Engines.

3.0 Scope
This table of fits and clearances is provided for use in the assembly of Superior Engines and applies to all
personnel involved in the building of these engines.

4.0 Vantage O/IO-360 Dimensional Table of Limits (in inches)

DESCRIPTION OF LIMITS Min Max

Superior Performance.

1. Piston
Piston in Cylinder (Bottom of Skirt Clear)................................... 0.0065 0.0095
2. Piston Rings
Piston Ring in Groove Side Clearance (Top Comp.)…………… 0.0025 0.0055
nd
Piston Ring in Groove Side Clearance (2 Comp.)……………. 0 0.004
rd
Piston Ring in Groove Side Clearance (3 Oil)…………………. 0.002 0.004
End Gap (Top Comp)……………………………………………… 0.045 0.055
nd
End Gap (2 Comp)………........................................................ 0.045 0.055
End Gap (Oil Control)................................................................. 0.015 0.03
Superior Manufacturing.

NOTE: Measure end gaps 1.0” to 4.0” from bottom of barrel. Minimum top compression ring gap at top of stroke is
.008” (approx. 6.6” from bottom of barrel).

3. Piston Pin
Piston Pin and Plug in Cylinder (End Clear)…………………….. 0.025 0.057
Piston Pin in Piston (Diameter)…………………………………… 0.0003 0.0014
Piston Pin in Connecting Rod Bushing ………………………….. 0.0008 0.0021
4. Connecting Rod
Bearing to Crankpin.................................................................... 0.0008 0.0038
Connecting Rod to Crankshaft (Side Clear)...………………….. 0.004 0.01
Connecting Rod Bushing ID 1.1254 1.1262
Superior Design.

5. Crankshaft Main Bearings

Crankshaft in Front Bearing (End Clear)………......................... 0.009 0.016
Crankshaft in Front Bearing (Diameter)…………………………. 0.0015 0.0045
Crankshaft in Center and Rear Bearing (Diameter)……………. 0.0015 0.0045
Crankshaft Oil Slinger................................................................ 0.002 0.007

Page 2

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

4.0 Continued

DESCRIPTION OF LIMITS Min Max

6. Crankcase Main Bearing Retention Dowel Height
.070 .090
Superior Warranty .

7. Crankshaft Rod Journal Diameter............…………………….

2.124 2.125
8. Crankshaft Run-Out (Center Main)……………………………..
.005
-
T.I.R.
9. Crankshaft Main Bearing Journal Diameter …………………
2.375 2.376
10. Camshaft Journal
Superior Performance.

.001
Camshaft Center Bearing Journal Run-Out............................... -
T.I.R.
Journals in Crankcase ……………………………………………. 0.002 0.004
Rear Journal in Crankcase (End Clearance)…………………… 0.002 0.009
11. Valve Tappet in Crankcase ……………………………………
0.001 0.0033
12. Rocker Shaft
Rocker Shaft in Rocker Bushings……………………………............ 0.0007 0.0017
Rocker Shaft in Cylinder Head……………………………............... 0.0001 0.0013
13. Valves in Guides
Superior Manufacturing.

Exhaust Valve in Guide………………………………………….. 0.004 0.006

Intake Valve in Guide…………………………………………….. 0.001 0.0028
14. Oil Seal in Propeller Governor Adapter...……………………
.001T .003T
15. Valve Rocker (Side Clearance)…………………………………
0.005 0.013
16. Dry Tappet Clearance……...................................……………
0.028 0.08
17. Gears in Oil Pump Housing …………………………………...
Superior Design.

0.002 0.006
18. Oil Pump Gear Shaft in Accessory Case……….…………..
0.0015 0.003
19. Crankshaft Gear in Crankshaft Pilot…………………………
.0005T .0010L
20. Oil Seal in Accessory Tachometer Housing ………………….
.001T .003T

Page 3

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

4.0 Continued

DESCRIPTION OF LIMITS Min Max

21. Fuel Pump Plunger, in Accessory Case……………………
0.0015 0.003
Superior Warranty .

DESCRIPTION OF LIMITS Min Max

22. Tachometer Drive Shaft in Accessory Case...………………..
0.0015 0.0035
23. Alternator Belt Midspan Deflection with Load at 14lb
Midspan Deflection with Load at 14lb 0.31
Tension required to cause slippage for new belt 11 ft-lb 13 ft-lb

5.0 Vantage O/IO-360 Table of Backlash and End Clearance Limits (in inches)
Superior Performance.

DESCRIPTION OF LIMITS Min Max

Oil Pump Gear 0.008 0.015
Crankshaft Gear to Idler Gear…………………..………….............. 0.004 0.015
Magneto Drive Gears to Idler Gears........………………………….. 0.004 0.015
Camshaft Gear to Idler Gear......……………………………………. 0.004 0.015
Vacuum Pump Gear to Camshaft Gear...…………………………… 0.004 0.015
Vacuum Pump Gear (End Clear)……………..…………………….. 0.01 0.057
Idler Gears (End Clear).................................................................. 0.005 0.04
Superior Manufacturing.

Rear Propeller Governor Drive Gear to Crankshaft Idler Gear. .... 0.004 0.015
Rear Propeller Gov Gear (End Clearance).................................... 0.002 0.024
Front Propeller Governor Idler Gear to Camshaft 0.004 .015
Front Propeller Gov. Drive and Idler Bevel Gear 0.004 0.008
Front Propeller Governor Gear(End Clearance) 0.008 0.016

6.0 Vantage O/IO-360 Table of Torque Limits (in inch-pounds) and Install Height (inches)

STUD DRIVE TORQUE AND INSTALL HEIGHT (± .030) Min Torque Height
SL38-13 Cylinder Deck……………………………………………….. .80
SL38D-17 Crankcase Thru Stud, Rear……………………………... 100 1.27
Superior Design.

SL38-22 Crankcase Thru Stud, Front………………………………. 1.94

SL50-15 Cylinder Deck Studs..…………………..………….............. 250 .86
SL31-12 Exhaust port Studs………..........…………………………… 40 .78
SL31C -13 Propeller Gov Studs…………………………………….. 1.125
SL31C-12 Propeller Gov Adapter Pad Studs………………………. .75
SL31C-12 Magneto Pad Studs………………………………………. 25 .94
SL31C-16 Magneto Pad Studs………………………………………. 1.50
SL31C-19 Magneto Pad Studs......……………………………………. 1.78

Page 4

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

6.0 Continued

STUD DRIVE TORQUE AND INSTALl HEIGHT (± .030) Min Torque Height
SL38CD-17 Oil Pump Pad Studs……………………….. 25 1.44
SL25C-10 Oil Filter Adapter Studs .63
SL25C-12 Vacuum Pump Studs 15 .75
Superior Warranty .

SL25C-22 Vacuum Pump Studs 2.22

SPECIAL TORQUE REQUIREMENTS Torque Limits

Spark Plug……………………………………………………………............ 420
Slotted Nut 5/16” (Idler Shaft).................................................................. 140-160
Slotted Nut 5/16” (Oil Pump Housing) 180-200…………………………… 180-200
Nut 1/2-20 Cylinder to Crankcase…………………………………............. 600
Nut 3/8-24 Cylinder to Crankcase…………………………………............. 300
Superior Performance.

Nut 3/8-24 Crankcase Parting Flange …………………………............. 300

Slotted Nut ¼ “(Nut and Cap Screw) Crankcase Parting Flange……….. 55-60
3/8-24 Nut Connecting Rod Bolts......………………………………........... 480
Slotted Nut 3/8-24 (Drilled Stud Over Camshaft)...………........................ 300
5/16 Crankshaft Gear Bolt....................................................................... 204
¼-20 Push Rod Shroud Retaining Nut.................................................... 50-70
¼-20 Rocker Cover Screws..................................................................... 50
Piston Cooling Nozzles (1/16-27 NPT).................................................... 100
Oil Gage Tube (1-1/8-12)........................................................................ 300
Superior Manufacturing.

Drain Back Tube Nut............................................................................... 35

Drain Back Hose Clamp.......................................................................... 10
5/16 Hex Head Hose Clamps.................................................................. 45
Fuel Pump Vent Fitting……………………………………………………… 96
Fuel Pump and Prop Governor Hose Nuts.............................................. 35
Fuel Injector Hose Nuts........................................................................... 30
Fuel and Prop Governor Elbow Lock Nuts.............................................. 110
Spin-on Oil Filter...................................................................................... 192-216
Fuel Pump to Accessory Cover Socket Head Bolts (3/8-16)................... 225-250
Vernatherm Valve.................................................................................... 300
Superior Design.

Injector and Primer Nozzle...................................................................... 60

Primer and Injector Tubing Nuts.............................................................. 25
Slotted Nut, 3/8-24 Magneto Gear........................................................... 120-300
Slotted Nut 3.8-24 Alternator to Bracket 360

Page 5

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

6.0 Continued

STANDARD TORQUE UNLESS OTHERWISE LISTED Torque

Plug and Fitting (1/2-14 NPT)…...…………………………….................... 160
Plug and Fitting (1/16-27 NPT)…...………………….………..................... 40
Superior Warranty .

Plug and Fitting (1/8-27 NPT)…...…………………………….................... 40

Plug and Fitting (1/4-18 NPT)…...…………………………….................... 85
Plug and Fitting (3/8-18 NPT)…...…………………………….................... 110
Nut ¼ “(Nut and Cap Screws)……………………………………............... 96-108
Nut 5/16” (Nut & Cap Screws)................................................................. 200
Nut and Cap Screws (10-24, 10-32)........................................................ 49
Nut 3/8 (Nut & Cap Screw) 360
Superior Performance.

7.0 SV-360 Table of Spring Limits (in pounds)

Wire Compress
DESCRIPTION OF LIMITS Lbs Min Lbs Max
Diameter To:
Spring Valve, Inner, 0.135 1.17 59 67
Spring Valve, Outer, 0.177 1.3 111 122

8.0 SV-360 Table of Crush Type Gasket Tightening Angles (angular)

DESCRIPTION OF LIMITS Angle

Superior Manufacturing.

Oil Suction Screen Gasket............................................................................... 135°

Pressure Relief Valve Gasket.......................................................................... 135°
Oil Cooler Bypass Plug Gasket........................................................................ 135°
Note: Install Crush Gasket with seam toward aluminum case. Tighten thread until cap or valve body contacts gasket.
Turn additional angle shown above. Lock wire in place.

9.0 Exhaust valve Seat Standard and Oversize Dimensions

Exhaust Valve Seat Standard and Oversize “A” Diameter

Part Number (In) (In)
SL72058A STD 1.7387-1.7402
Superior Design.

SL72058A P05 +0.005 1.7437-1.7452

SL72058A P10 +0.010 1.7487-1.7502
SL72058A P20 +0.020 1.7587-1.7602
SL72058A P30 +0.030 1.7687-1.7702

Page 6

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com
 SVOHM01 Revision C October 2014
Doc No.: SSD001
Revision Date: 03/04/08

TABLE OF LIMITS – SUPERIOR ENGINE ASSEMBLIES

10.0 Intake valve Seat Standard and Oversize Dimensions

Intake Valve Seat Standard and Oversize “A” Diameter

Part Number (In) (In)
SL72057A STD 2.0807-2.0822
Superior Warranty .

SL72057A P05 +0.005 2.0857-2.0872

SL72057A P10 +0.010 2.0907-2.0922
SL72057A P20 +0.020 2.1007-2.1022
SL72057A P30 +0.030 2.1107-2.1122

11.0 Exhaust valve guide Standard and Oversize Dimensions

Exhaust Valve Guide Standard and Oversize “A” Diameter

Part Number (In) (In)
Superior Performance.

SL74230A STD 0.6638-0.6633

SL74230A P05 +0.005 0.6688-0.6683
SL74230A P10 +0.010 0.6738-0.6733
SL74230A P20 +0.020 0.6838-0.6833
SL74230A P30 -0.030 0.6938-0.6933
SL74230A P40 +0.040 0.7038-0.7033

12.0 Intake valve guide Standard and Oversize Dimensions

Superior Manufacturing.

Intake Valve Guide Standard and Oversize “A” Diameter

Part Number (In) (In)
SL61681A STD 0.5932-0.5940
SL61681A P05 +0.005 0.5982-0.5990
SL61681A P10 +0.010 0.6032-0.6040
SL61681A P20 +0.020 0.6132-0.6140
SL61681A P30 -0.030 0.6232-0.6240
SL61681A P40 +0.040 0.6332-0.6340
Superior Design.

Page 7

Superior Air Parts, Inc.

621 South Royal Lane, Suite 100 – Coppell, Texas 75019-3805 Phone: (972) 829-4600
www.superiorairparts.com