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o-360 & io-360 series engines overhaul manual

1. 1 GASKET 55 PLUG 5 OIL SUMP ASSEMBLY 60 PLUG 15 BOLT 65 PLUG 20 BOLT 70 PIPE INTAKE 25 WASHER PLAIN 75 SCREEN 30 WASHER LOCK 80 GASKET 35 NUT PLAIN 85 PLUG 45 STUD 50 STUD 50 STUD Figure 72 00 09 27 Oil Sump and Induction System a 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines 7 5 OIL GAGE TUBE 10 OIL GAGE 15 SEAL GAGE 20 SEAL TUBE Figure 72 00 09 28 Oil Level Gage 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines 1 GASKET FLANGE 5 TUBE INTAKE 10 FLANGE INTAKE TUBE 15 WASHER PLAIN 20 WASHER LOCK 25 SCREW CAP 30 HOSE INTAKE 35 CLAMP HOSE Figure 72 00 09 29 Induction System e 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 360 Series Engines CYLINDER INTAKE TUBE FLANGE GASKET VIEW LOOKING UP Figure 72 00 09 30 Intake Tube Assembly s 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR Installation of Cylinder Drain Tubes 1 Secure the cylinder drain tubes 90 to their corresponding cylinders Do this by installing the drain back hose
2. e 7 HELICAL 2 NOSE um INSERT SASS gt I d BUSHING VALVE 5 SEAT gt i A SKIRT CS STUD 77 Cx VALVE CYLINDER BARREL eg COOLING FINS a GUIDE Deg M d Ba S PLUG Le d HELICAL oa Ba E x INSERT i d CYLINDER HEAD COOLING FINS OIL VALVE DRAIN GUIDE HELICAL FITTING PLUG STUDS Figure 72 00 08 4 Cylinder Assembly ior Ai 72 00 08 March 2005 Superior Air Parts Inc 2224 SUPER IS Overhaul Manual Engine AIR PARTS INC O 360 and IO 360 Series Engines a ech Ee w 78 CONNECTING S ROD PISTON BEARINGS PISTON TOP Pd SURFACE 7 i COMPRESSION RINGS CONNECTING ROD BUSHING PISTON IN HOLE AND BOSSES PISTON PIN OIL RING F RING GROOVES AND LANDS Figure 72 00 08 5 Piston Assembly 9 72 00 08 March 2005 Superior Air Parts Inc inspection andiCheek Overhaul Manual Engine SUPERIZR O 360 and 360 Series Engines AIR PARTS INC THIS PART OF PISTON HAS LARGER DIAMETER THAN RING LANDS STRAIGHT EDGE MUST BE USED AS SHOWN FEELER GAGE STRAIGHT EDGE Figure 72 00 08 6 Piston Rings and Lands 16 72 00 08 March 2005 Superior Air Parts Inc inspection and Cheek WZ SUPERIZ Overhaul Manual antage Engine PARTS gg O 360 and 360 Series Engines Valve Rockers Inspect valve rocker for damage Refer to Figur
3. MAGNETO MAGNETO OIL FILTER Figure 02 00 00 4 O 360 Engine Top View 02 00 00 March 2005 Superior Air Parts Inc Desoriptionand Operation 2 SU PERI A R Overhaul Manual Vantage Engine R PARTS 1 O 360 and IO 360 Series Engines Oil Temp x Connection Tachometer Connection BER iss Vacuum Pump Pad Oil Filter also used for dual drivers Oil From Cooler Oil Pressure Gage Connection gt SS Oil Fill Tube and lt A P M va 5 Oil Level Gage p Se NUS S SI f 7 3 NS 247 7 lli A 02 7 f DA CH w Z aN SS CR o 9h 9 E X eM 3 Manifold SE im YN Pressure E Gage S S gt i9 whose Connection LITT LT BE gt M Ground Terminal il T 1 Ground Terminal Sms WI Je Ai Oil Line To Propeller Diaphragm Fuel Pump CS Fuel Pump Inlet Vent Line Connection kawa ss Oil Suction Screen Oil Drain Plug Figure 02 00 00 5 O 360 Engine Rear View 02 00 00 March 2005 Superior Air Parts Inc D soripti nand Ciperalidn WZ SUPERIZ Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines FUEL INJECTION MANIFOLD SPARK PLUG SPARK PLUG FUEL Hi INJECTOR CHT PROBE LOCATION TYPICAL EACH HEAD ALTERNATOR amp BELT STARTER NOT PROVIDED WITH ENGINE FUEL INJECTION SERVO Figure 02 00 00 6 IO 360 Engine Front View 02 00 00 March 20
4. 2 Lubricate the governor shaft gear 1 Figure 72 00 09 33 and the bore in the adapter 15 with pre lube oil Install the shaft gear in the adapter 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 CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 3 Place the thrust washer 5 on the shaft gear Secure the shaft gear in the adapter with snap ring 55 Refer to Figure 72 00 09 33 4 Ensure free spin of the gear in the adapter and check the end clearance Allowable end clearance is 0 002 to 0 024 in 5 Install the adapter assembly to the accessory housing with the gasket 10 washer 20 lock washer 25 and nut 30 per Figure 72 00 09 33 Torque the nuts 30 to 200 in lbs 6 Check the gear lash to the idler gear Clearances are 0 004 to 0 015 in 7 Lightly lubricate the threads of the 45 elbow 15 Figure 72 00 09 34 and its o ring 20 with pre lube oil and install in the propeller governor adapter 72 00 09 Engine Assembly N27 anlage Engine SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines 1 GASKET 5 PUMP FUEL 10 WASHER FLAT 15 SCREW 20 O RING 25 ELBOW 90 30
5. 11 Apply pre lube oil to the idler gear teeth and magneto drive gear teeth 35 and apply light coat of Dow Corning 4 or Fuelube to the magneto gasket 10 Install each magneto with the clamp 20 lock washers 25 and nut 30 Tighten moderately NOTE Magnetos must be able to move for final timing This will be accomplished later with the engine horizontal disconnected from nose stand and with the ring gear and starter installed March 2005 Superior Air Parts Inc 57 Overhaul Manual Engine O 360 and IO 360 Series Engines WARNING DO NOT ROTATE ENGINE OR CRANKSHAFT BEFORE REMOVAL OF TIMING LOCATOR PINS 12 Remove the timing locator pins from the magnetos 15 and install the harness Ensure correct harness locations Align the harness cover caps properly Secure with the screws removed from the cap removal Starter Installation 1 Verify the starter part number 2 Install the starter IAW the starter manufacturer s installation instructions Tighten the bolt and nuts to 200 in Ibs Alternator Installation if furnished 1 Verify the alternator part number is correct 2 Install pulley as required to alternator IAW manufacturer s installation instructions 3 Attach mounting bracket 55 Figure 72 00 09 43 to engine with bolts 60 and lock plate 50 and tighten until snug finger tight 4 Attach alternator to mounting bracket 55 using drilled shank bolts 25 3
6. 2 Remove clamps 35 intake hoses 30 3 and intake tubes 5 from oil sump assembly Remove oil screen plug 85 Figure 72 00 09 27 discard gasket 80 and remove oil suction screen 75 Inspect for debris Remove bolts 15 20 flat washers 25 30 lockwashers 25 and nuts 35 from sump assembly flange Discard gasket 11 and remove intake connection pipes 12 from sump assembly ROD AND CRANKCASE March 2005 Superior Air Parts Inc Cylinder drain tubes removal 1 Loosen hose clamps 85 Figure 72 00 09 17 on hose 80 at drain nipple 75 Slide away from drain nipple 75 Loosen gland nut at cylinder head fitting and remove tube assembly 90 from cylinder Intercylinder cooling baffle removal 1 Remove the intercylinder cooling baffles 1 Figure 72 00 09 26 using intercylinder battle tool Turn the baffle retaining hook 10 so that it disengages the retainer 5 Remove the baffle 1 and hook 10 from between the cylinders Cylinder removal 1 Remove the valve cover screws 130 NOTE Figure 72 00 09 15 and cover 125 and discard gasket 120 Rotate the crankshaft to place the piston of the No 1 cylinder at top center of the compression stroke With the piston in this position both valves will be closed and the piston extended away from the crankcase to avoid damage when the cylinder is removed Remove the valve rocker shaft caps 20 the valv
7. Runout at center bearing in excess of Reject 0 001 T I R Difference between camshaft bearing journals and Reject if crankcase bore 0 002 outside minimum to 0 004 in maximum Connecting Rods Inspection 14 March 2005 Superior Air Parts Inc Overhaul Manual O 360 and 360 Series Engines Visual inspection N27 i antage Engine Replace or Inspect bore in large ee end of connecting rod OUtSide the limits Inspect bushing bore Eu 2 in small end of Be Zr P connecting rod NO Check connecting rod parallelism Refer to Fits and Clearances outside Refer to Figure 72 00 the limits 08 13 Check connecting rod Replace if squareness Refer to 2 Fits and Clearances are outside Refer to Figure 72 00 the limits 08 15 72 00 08 Inspection and Check SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines BEARING SURFACES GEAR TEETH 5 CAMSHAFT ASSEMBLY 10 BUSHING 15 TACHOMETER SHAFT ASSEMBLY 20 PIN 25 RETAINING RING Figure 72 00 08 8 Camshaft Assembly 19 72 00 08 March 2005 Superior Air Parts Inc Inspection and Check LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK 18 72 00 08 March 2005 Superior Air Parts Inc inspection andiCheek SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines ENGINE ASSEMBLY Gen
8. 005 AT 6 0 STEP BARREL SIZE IS THE AVERAGE DIAMETER THROUGH VALVE CENTERS WITH DIAMETER 90 FROM VALVE CENTERS 40 2 BARREL SIZE OVER THIS LENGTH e5 125 006 35 37 CROSS ENTIRE LENGTH 60 2 50 2 Figure 72 00 13 1 Cylinder Interior Resurface Crosshatch 19 72 00 13 March 2005 Superior Air Parts Inc Repair Procedures A SUPER IZIR R P REPAIR NO 7 CYLINDER HEAD COOLING FINS Cylinder Head Cooling Fin Repair The Superior Vantage O 360 AND IO 360 series engines utilize cylinders constructed of through hardened steel and heads of cast aluminum Only the fins on the aluminum head may be repaired Cooling fins on the steel barrels may NOT be repaired by this process The cooling fins on these cylinders are finely balanced to provide appropriate cooling to the overall cylinder assembly CAUTION REFER TO THE INSPECTION AND CHECK SECTION OF THIS MANUAL TO DETERMINE DAMAGE LIMITS FOR COOLING FINS ANY CYLINDER PRIOR TO REPAIRS Perform repairs as follows 1 For cracks in the fin it is permissible to drill a 0 19 in diameter hole a stop drill at the end of the crack provided the crack is at least 0 25 in from the root of the fin 2 For fins cracked almost all the way across it is permissible to remove a portion of the fin as follows Refer to Figure 72 00 15 4 a The maximum material removed is no more than the total fin width b No
9. 2 grain size 54 grade K structure 5 porous vitrify bond treatment V92 diameter 3 v2 to 4 inches b Wheel speed e 3 2 inch wheel 5600 to 6000 surface feet per minute e 4inch wheel 5350 to 5730 surface feet per minute c Work speed 250 RPM March 2005 Superior Air Parts Inc 15 3 NOTE N27 i antage Engine Oversize allowance is determined by adding 0 004 in to the barrel diameter at the point of greatest wear This must not exceed 0 002 in per wall Grind the barrel to the oversize above this amount Grind the surface of the steel barrel to 25 35 microinches This can be obtained by grinding the barrel diameter to within 0 0005 to 0 001 in of the desired ID with rough in cuts Redress the wheel and make a finish pass Allow the wheel to run over the work up to five more times to ensure a proper surface finish The surface finish must be properly crosshatched along the entire length of the barrel The crosshatch pattern must be 35 37 from a line parallel with the cylinder base Refer to Figure 72 00 13 3 If oversizing must occur the cylinder must be fitted with P010 010 in oversize pistons and piston rings These must be used in opposing pairs to maintain the dynamic balance of the engine SUPERIZR Overhaul Manual Engine PARTS UN O 360 and 360 Series Engines BARREL SIZE 0035 0025 5 0 STEP BARREL SIZE 007
10. Overhaul Manual oT Engine O 360 and 360 Series Engines Se Q S CRANKCASE ACCESSORY END c f CAMSHAFT SAFETY WIRE HOLES IN IDLER GEAR SHAFT BASE FLANGE TYPICAL ao WIRE 2 COUNTER CLOCKWISE Figure 72 00 09 21 Idler Gear and Tachometer Shaft Assemblies cont d March 2005 Superior Air Parts Inc B1 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS INC O 360 and 360 Series Engines w AS AB AL CAMSHAFT GEAR gt KI UT LN FUELPUMP IDLER GEAR CRANKSHAFT GEAR RIGHT SIDE IDLER GEAR GASKET Figure 72 00 09 22 Accessory Drive Gear Arrangement SS 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR Accessory Housing Inspection and Subassembly 1 Inspect the accessory housing 1 Figure 72 00 09 23 for damage Check the studs threaded holes and mating surfaces for damage or debris Install new tachometer drive seal 30 Install the fitting 45 Figure 72 00 09 23 and or oil pressure fitting removed for cleaning Tighten per torque specifications Fits Clearances section of this manual 4 Install plug 55 and crush gasket 50 per Figure 72 00 09 35 and tighten per torque specifications Fits Clearances section of this manual 5 Inspect the oil pump housing 85 for damage Verify plug 100 installation 6 In
11. 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 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 pre lube oil to threads of 90 elbow 25 Figure 72 00 09 32 and o ring 20 Install into fuel pump 5 outlet port Position elbow 25 to point straight back and torque lock nut to 110 in Ibs 3 Apply pre lube oil to the threads of the 45 elbow 30 and o ring 20 Install into the fuel pump 50 inlet port Position the elbow 30 to point up and torque the lock nut to 110 in Ibs 4 Rotate the engine to provide least amount of fuel pump plunger extension b Apply grease to the fuel pump arm and plunger where they will make contact on the wear surfaces 6 Install the fuel pump 5 with the gasket 1 drilled sockethead screws 15 and flat washers 10 WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE 7 Torque the screws 15 to 250 in lbs Install safety wire 0 032 in March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 46 Installation of Propeller Governor Adapter Assembly 1 This instruction applies to engine models requiring a prop governor installation
12. Drain and refill tank with proper grade Clean points Check internal timing of magnetos Check wire with electric tester Replace defective wire Replace connectors on spark plug wire Table 72 00 03 8 Low Oil Pressure On Engine Gage Probable Cause Lack of oil Air lock or dirty relief valve Leak in line High oil temperature Defective pressure gage Stoppage in oil pump intake passage March 2005 Superior Air Parts Inc Correction Add to proper level Clean relief valve Inspect gasket between accessory housing and crankcase See Table 72 00 03 9 High Oil Temperature Replace defective gage Check line for obstruction Clean suction strainer 72 00 03 Testing and Fault Isolation SUPER IZIR A R P Overhaul Manual O 360 and IO 360 Series Engines N27 i antage Engine Table 72 00 03 9 High Oil Temperature Probable Cause Insufficient air cooling Insufficient oil supply Low grade of oil Clogged oil lines or strainers Excessive blow by Failing or failed bearing Defective temperature gage Correction Check air inlet and outlet for deformation or obstruction Fill to proper level with specified oil Replace with oil conforming to specifications Remove and clean oil strainers Check condition of engine rings Replace if worn or damaged Examine sump for metal particles If found engine overhaul may be required Replace gage Table 72 00 03 10 Excessive Oil Con
13. N27 antage Engine O 360 amp IO 360 SERIES ENGINES OVERHAUL MANUAL Si oa m m E a gt SUPERIZR ATR PART Sa N E 621 South Royal Lane Suite 100 Coppell TX 75019 800 277 5168 www superiorairparts com Manual P N SVOHM01 Revision A March 2005 THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUIPER IZR Overhaul Manual AIR PARTS INC O 360 and 360 Series Engines Manual Number 5 01 Revision History A 08 31 04 Initial Release All March 2005 Superior Air Parts Inc General Information LT N27 SUPERIZR Overhaul Manual antage Engine ATR PARTS ING O 360 and IO 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc General Information N27 SUPERIZR Overhaul Manual antage Engine AIR PARTS IN O 360 and 360 Series Engines SAFETY ADVISORY WARNING BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED KNOW THE HANDLING STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER 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 d
14. 10 places Secure with the bolt 20 washer 5 and lock washer 10 2 places Tighten per the torque specifications in the Fits and Clearances section of this manual Trim the protruding gasket ends flush with the sump mating surfaces See Figure 72 00 09 25 a Installation of the Rocker Cover Baffles 1 Install the rocker box covers with the gaskets 120 125 Figure 72 00 09 15 and screws 130 Torque the rocker cover screws 130 in accordance with torque specifications per the Fits and Clearances section of this manual Install the inner cylinder baffles with the hooks and retainers See Figure 72 00 09 26 2 ow Inspection of the Sump and Subassembly 1 Inspect the sump 5 Figure 72 00 09 27 for general condition handling damage stud damage mating surface condition and security of the roll swaged intake pipe extensions 70 WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE 2 Install the oil suction screen 75 with its gasket 80 and plug 85 Ensure the gasket seam faces the sump 5 Tighten the plug 85 until the plug body contacts the gasket 80 then turn an March 2005 Superior Air Parts Inc 34 Overhaul Manual O 360 and IO 360 Series Engines 2 a additional approx 135 degrees Install safety wire 0 032 in on the plug 85 Install the sump gasket over sump studs Install the sump with bolt 15 lock washers 30 wa
15. 621 South Royal Lane Suite 100 Coppell Texas 75019 March 2005 Superior Air Parts Inc Related Publications The following are related engine and accessory publications O amp IO 360 Installation and Operation Manual SVIOM01 O amp IO 360 Maintenance Manual SVMM01 O amp O 360 Illustrated Parts Catalog SVIPC01 Unison Master Service Manual F 1100 Unison Autolite Manual L 1710A Precision RSA 5 Service Manual 15 338 Precision MA 4 5 Manual MSAHBK 1 Champion Aerospace Service Manual AV 6R Kelly Aerospace Service Manual OE A2 Obtaining Service Information All Vantage Series Engine manuals and service information be downloaded at www superiorairparts com All Vantage Series Engine manuals and service information may be purchased by contacting Superior Air Parts 621 South Royal Lane Suite 100 Coppell Texas 75019 or call 972 829 4600 Accessory Information may be obtained at www championaerospace com www unisonindustries com www skytecair com www precisionairmotive com www aeroaccessories com www kellyaerospace com Abbreviations A list of abbreviations used in this manual is shown in Table 01 00 00 1 below 01 00 00 Introduction e 2 SUPERIZ Overhaul Manual Vantage Engine NAR PARTS UNE O 360 and 360 Series Engines Table 01 00 00 1 Abbreviations Abbreviation Definition AMS Aerospace Material Standard Assy Assembly BTC BTDC Before Top Center Before Top Dead Cente
16. Engine AIR PARTS ING O 360 and 360 Series Engines 9 478 001 SECTION EXHAUST VALVE GUIDE 20 593 0 750 NW 10 R 020 2 PLCS 0 065 0 060 INTAKE VALVE GUIDE Figure 72 00 13 4 Valve Guide Dimensions zi 72 00 13 March 2005 Superior Air Parts Inc Procedures SUPERIZR Overhaul Manual Engine AIR PARTS INC O 360 and 360 Series Engines VALVE SEAT 2 X A N 2 IN J EXHAUST VALVE INTAKE VALVE ACCEPTABLE UNSATISFACTORY SEATING 7 1 2 EXHAUST VALVE INTAKE VALVE NOT ACCEPTABLE F S 2 1 MAX EXHAUST VALVE INTAKE VALVE DESIRED 1 MAX ANGLE Figure 72 00 13 5 Valve to Seat Fit Acceptable Criteria 25 March 2005 Superior Air Parts Inc 72 00 13 Repair Procedures LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK 26 March 2005 Superior Air Parts Inc A SUPER IZIR R P Overhaul Manual O 360 and IO 360 Series Engines REPAIR NO 9 N27 i antage Engine SPARK PLUG THREADED INSERT Spark Plug Threaded Insert Replacement Spark plug threaded inserts that were rejected during inspection must be removed and replaced as described in this section Use an extraction tool to remove the rejected insert as follows 1 Insert t
17. IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 3 Apply a light coat of pre lube oil to the OD of each plunger 4 Insert plunger small tube end first into tappet body in crankcase Refer to Figure 72 00 09 15 5 Insert tappet cup or socket 30 into tappet body on top of plunger assembly 72 00 09 Engine Assembly N27 a anlage Engine SUPERIAR Put the cup side out flat side against plunger Refer to Figure 72 00 09 15 Installation of Pushrod Tubes Pushrods and Rocker Arms 1 Visually inspect the pushrod tubes 40 Figure 72 00 09 15 for handling damage dents or burrs Check 1 0 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 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 tha
18. Unison Magnetos Precision Carburetor Precision Fuel Injection Power Rating Piston Compression Ratio Cylinder Type 360 CR HP 8 511 180 For Future Use 2 02 00 00 Description and Operation Overhaul Manual N27 anlage Engine O 360 and 360 Series Engines SUPERIAR Engine Components General Description The O 360 and 360 series engines are air cooled four cylinder horizontally opposed direct drive engines See Table 02 00 00 1 for Manufacturer s General Specifications The complete engine includes the following components and assemblies Crankcase Assembly Crankshaft Assembly Camshaft Assembly Valve Train Assembly Cylinder Assemblies Connecting Rod Assemblies Oil Sump Assembly Intercylinder Baffles Starter Lubrication System Includes Cil Filter Accessory Drive Ignition System Includes Spark Plugs Fuel System Starter Support Assembly Oil Gage Induction System Accessories NOTE Complete engine does not include outer cylinder baffles propeller governor and airframe to engine control cables attaching hardware hose clamps vacuum pump exhaust system or fittings Fuel pump is included unless otherwise specified on carbureted engines Alternator may be included if specified Specifications The manufacturer s physical specifications are listed in Table 02 00 00 2 and are applicable to the 360 and 10 360 series engines Accessory Drive Specifications are provided in T
19. gasket to correspond with holes in the housing Refer to Figure 72 00 09 31 Install the vacuum pump adapter 25 and the gear assembly 1 over the studs in the accessory housing Align the holes and dowel pin Ensure that the drive gear teeth mesh with the idler gear teeth b Check the gear endplay and backlash Values must be within limits per Fits and Clearances section of this manual 6 Install the gasket 15 and cover plate 20 with the washer 30 lockwasher 85 and nuts 40 Torque the nuts 40 to 96 108 in Ibs d Installation of Accessories 1 Install the engine accessories per instructions given later in this section STOP PERFORM IN PROCESS QUALITY INSPECTION 4 REFER TO APPENDIX 72 00 09 Engine Assembly N27 anlage Engine SUPERIZR AIR PARTS INC Overhaul Manual O 360 and 360 Series Engines poc Engine 1 GEAR ASSY 5 WASHER THRUST 10 GASKET ACCESSORY DRIVE 15 GASKET VACUUM PUMP 20 COVER 25 ADAPTER 30 WASHER 35 WASHER LOCK 40 NUT PLAIN 50 PIN 55 OIL SEAL Figure 72 00 09 31 Vacuum Pump Drive 45 March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIAR Engine Accessory Assembly Installation NOTE Unless otherwise specified all torque loads listed for nuts bolts and screws are for use with pre lube oil Installation of Fuel Pump if furnished 1 Verify new fuel pump part number
20. 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 wvill provide a place to record findings and comments resulting from the inspections Materials and Tools Materials required for inspection are listed Table 72 00 08 1 Special tools and equipment required for inspection are listed Table 72 00 08 2 March 2005 Superior Air Parts Inc Table 72 00 08 1 Inspection Materials Item Source Commercially Magnetic base oil AVIS Commercially Preservative oil WR Dye penetrant and Commercially developer Available Commercially Available SC Commercially Mineral Spirits Available SAE 10 lubricating oil Commercially check fuel nozzle flow Available NOTE Equivalent substitutes may be used Table 72 00 08 2 Special Tools and Equipment Item Source Calipers and Commercially micrometers ID and OD Available Yr Commercially 10X Magnifying Glass Available T3 Commercially Machinist s Ruler Available z Commercially Small Flashlight Available Commercially SE Available Commercially Dial Indicator Available Commercially Spring Tension Tester Available Magnetic Particle Commercially Inspection Equipment Available NOTE Equivalent substitutes may be used 72 00 08 Inspection and Check A SUPER IZIR R P General Inspection Procedu
21. 00 04 Special Procedures N27 i antage Engine Overhaul Manual N27 anlage Engine O 360 and IO 360 Series Engines SUPERIAR ENGINE REMOVAL General e Consult the airframe manufacturer for This section contains engine removal engine to airframe connections procedures Equipment and Materials to accomplish removal procedures are listed in Table 72 00 05 1 NOTE NOTE Standard aviation shop tools are required Table 72 00 05 1 Equipment and Materials List Item Vendor Commercially Engine Stand Available 1 Commercially Engine Hoist Available Protective Covers for Commercially Open Lines or Ports Available Removal e Remove the engine from the airframe as follows NOTE Identify each item as the item is disconnected from the engine to aid in reinstallation e Turn all cockpit switches and fuel selector valves to OFF Remove aircraft cowling as required Disconnect the battery ground cable Disconnect the start cable Remove engine baffles as required Remove air intake ducting and heat ducting as required e Remove engine exhaust system as required e Disconnect and remove the B nuts from the spark plugs e Tag and disconnect the engine wiring bundles from all applicable components e Remove all clamps attaching engine wire bundles to engine components and route bundles clear of the engine e Drain the engine oil from the sump Replace drain plug and tighten e Remove propeller in ac
22. 20 and nut 25 that secure the oil filter adapter 10 to the accessory housing Discard gasket 5 Remove cooler bypass plug 55 and discard gasket 50 Vacuum pump or cover removal 1 Remove the vacuum pump cover attaching nuts 40 Figure 72 00 09 31 lockwashers 35 and flat washers 30 Remove pump or cover 20 as appropriate and discard gasket 15 Remove adapter assembly 25 Discard gasket 10 and remove vacuum gear 1 and thrust washer 5 from housing Remove oil seal 55 and discard Propeller governor removal as required 1 Remove the propeller governor oil line Remove any clamps Remove elbows 10 15 and any attaching hardware as required to allow hose removal discard o ring 20 Remove the cover nuts 30 as required Figure 72 00 09 33 lockwashers 25 and flat washers 20 Remove cover 65 and discard gasket 60 Remove retaining ring 55 and thrust washer 5 Remove adapter nuts 30 lockwashers 25 and flat washers 20 Remove propeller governor adapter 15 Discard gasket 10 Tag and save thrust washer 5 Remove gear shaft 1 from housing Accessory Housing Assembly Removal 1 Remove the accessory housing assembly by removing the bolts 15 Figure 72 00 09 23 lockwashers 10 and flat washers 5 Remove bolt 20 washer 10 and nut 25 two places Remove accessory housing 40 and gasket 35 Remove fuel pump plunger 1 Figure 7
23. 80 to the case nipple 75 and the drain tube using the clamps 85 Fasten the B nut end of the drain tube to 45 fitting in cylinder head Torque the 2 clamps 85 to 10 in lbs Torque the drain tubes 90 B nuts to 35 in lbs Refer to Figure 72 00 09 17 Ensure that the cylinder drain fitting is tight and pointed in the correct position for the drain tube 90 installation The tube should not touch the intake pipe cylinder or inner cylinder baffle Installation of Vacuum Pump Adapter 1 Install new oil seal 55 Figure 72 00 09 31 in the vacuum pump adapter 25 a Lightly lubricate the seal OD with Fuelube or equivalent Press into the adapter flat side up until it bottoms out 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 CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 44 2 Apply pre lube oil and thrust washer to the shaft gear 1 and install the gear in the housing Rotate the gear upon installation to ease it through the seal and to ensure it turns smoothly Install the gasket 10 over the studs in the accessory housing Align holes in
24. Assembly to Connecting Rod S 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR Cylinder Assembly Installation to Engine 1 Lubricate the rings and ring grooves on the piston with straight weight non detergent mineral aviation grade oil Stagger the ring gaps as follows Top ring gap is at approximately the 10 O clock position 2nd ring gap is at approximately 2 o clock and the oil control ring gap is at approximately 11 o clock 2 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 NOTE Oil control expander spring is installed in piston groove underneath the oil control ring and with its split line 180 from the ring gap 3 Lubricate the cylinder bores piston pins and piston pin bushing in connecting rod with straight weight non detergent mineral aviation grade oil 4 Lubricate the cylinder base o ring 5 Figure 72 00 09 17 with oil and install over the cylinder base 5 Lightly lubricate cylinder deck studs and through bolts with pre lube oil 6 Rotate the engine so that the 1 connecting rod is at the top of the stroke Install the 1 piston to the 1 connec
25. C32 Safety Wire 0 041 in Type 304 Stainless P N MS20995 C41 Mixed Locally Commercially Available Commercially Available Commercially Available Silk Thread 50 100 Silk STP High Viscosity Oil Treatment Titeseal No 2 Gasket and Joint Compound P N T2 01 Special Tools and Equipment Special tools and equipment required for assembly are listed in Table 72 00 09 2 below NOTE Equivalent substitutes may be used for listed items March 2005 Superior Air Parts Inc Commercially Available Commercially Available Commercially Available NOTE Standard reciprocating engine aviation shop tools and equipment are used unless otherwise specified NOTE Unless otherwise specified all gaskets are installed dry 72 00 09 Engine Assembly SUPERIAR Overhaul Manual O 360 and 360 Series Engines Table 72 00 09 2 Special Tools and Equipment Description Compressor Valve Spring amp Bar Piston Ring Expander Puller Set Oil Seal Puller Slide Hammer Medium Puller Valve Guide Socket Connecting Rod Nut Stand Engine Tool Crankcase Separating Tool Intercylinder Baffle Cylinder Base Wrenches 3 4 and 9 16 Piston Ring Grinder Piston Ring Compressor Nose Seal Installation Tool Snap Ring Pliers Engine Assembly WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE WARNING LUBRICANTS ARE TOXIC AND FLAMMABLE DO NOT BREATHE VAPORS BEFORE YOU USE READ THE MATERIAL SAFETY
26. CHE Commercially Corrosion preservative oil AUSSI Commercially Abrasive cloth crocus cloth Available NOTE Residue from the solvent washing must be captured and contained to prevent contamination of the surrounding environment WARNING USE THE CORRECT PERSONAL PROTECTION SOME CHEMICAL SOLUTIONS CAN CAUSE SKIN EYE AND LUNG DAMAGE FOLLOW THE MANUFACTURER S INSTRUCTIONS FOR EACH CLEANING SOLUTION CAUTION IF ANY WATER MIXED DEGREASING SOLUTIONS CONTAINING CAUSTIC COMPOUNDS OR SOAP ARE USED EXTREME CARE MUST BE EXERCISED THESE COMPOUNDS IN 72 00 07 Cleaning SUPERIAR ADDITION TO BEING POTENTIALLY DANGEROUS TO ALUMINUM AND MAGNESIUM MAY BECOME IMPREGNATED IN THE PORES OF THE METAL AND CAUSE OIL FOAMING WHEN THE ENGINE IS RETURNED TO SERVICE WHEN USING THESE WATER MIXED SOLUTIONS ALWAYS THOROUGHLY RINSE THE PART IN CLEAN BOILING WATER REGARDLESS OF METHOD OR SOLUTION USED ALWAYS COAT AND SPRAY ALL PARTS WITH LUBRICATING OIL IMMEDIATELY AFTER CLEANING IN ORDER PREVENT CORROSION CAUTION USE THE CORRECT PERSONAL PROTECTION HEATED PARTS WILL CAUSE BURNS Decarbonizing Decarbonizing is usually accomplished by immersion of the part in a decarbonizing solution usually heated Decarbonization solutions such as Gunk Penetrol Carbrax Super Chemco Gerlach No 70 or any suitable solution Refer to the above caution for water soluble decarbonizers Remove hard carbon deposits after degreasing b
27. Clockwise Propeller Governor not included 0 866 1 Clockwise Fuel Pump if furnished 0 500 1 Plunger Operated Table 02 00 00 3 Manufacturer s Physical Specifications Height Width Length Weight Bodl In In In Lb O 360 Axxx 24 6 33 4 32 8 288 O 360 Bxxx 24 6 33 4 32 8 291 O 360 Oxxx 24 6 33 4 32 8 291 O 360 Dxxx 24 6 33 4 32 8 294 O 360 Exxx 24 6 33 4 32 8 295 360 24 0 33 4 32 8 290 360 24 0 33 4 32 8 293 360 24 0 33 4 32 8 293 360 24 0 33 4 32 8 296 360 24 0 33 4 32 8 297 Table 02 00 00 4 Approved Engine Accessories Left Right Fuel Fuel Pump Spark Plug Alternator Model Magneto Magneto System if furnished Starter Harness if furnished O 360 Unison Unison Precision Aero Acc SkyTec Unison Kelly Aerospace 4371 4371 MA 4 5 AF15472 149 12LS M4001 ALY8520LS 10 360 Unison Unison Precision Aero Acc SkyTec Unison Kelly Aerospace 4371 4371 RSA 5 AF15473 149 12LS M4001 ALY8520LS 02 00 00 March 2005 Superior Air Parts Inc Baso otidnand Operation SUPERIZ Overhaul Manual rione Engine AUR PARTS INC O 360 and IO 360 Series Engines Table 02 00 00 5 Illustrated Views of the Engine Engine View Figure Number Location O 360 Engine Front View Figure 02 00 00 2 p 7 O 360 Engine Left Side View Figure 02 00 00 3 p 8 O 360 Engine Top View Figure 02 00 00 4 p 9 O 360 Engine Rear View Figure 02 00 00 5 p 10 IO 360 Engine Front View Figure 02 00 00 6 p 11
28. FREE FROM SPARKS WEAR PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 10 MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 9 Remove front main bearings Lubricate bearing surfaces liberally with pre lube oil and fit to crankshaft aligning the two parallel marks Refer to Figure 72 00 09 10 10 Install two 3 8 in bolts with their corresponding flat washers through the right case half and install 2 O rings 10 Figure 72 00 09 11 11 Install 2 O rings 75 on rear through studs of right case half 12 Lubricate crankshaft main bearing journals and cam bores with pre lube oil 13 Lay out crankcase assembly hardware per Figure 72 00 09 11 and 72 00 09 12 together with appropriate hand tools STOP PERFORM IN PROCESS QUALITY INSPECTION 1 REFER TO APPENDIX A 14 Assure that case mating surfaces are clean and dry WARNING 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 15 Apply an even thin coat of approved sealant to the backbone and breastbone surfaces of the left case half only and to the front nose seal bore both case halves as well as the nose seal OD 16 Wh
29. Manual O 360 and IO 360 Series Engines N27 i antage Engine DISASSEMBLY General This section contains disassembly procedures When necessary disassembly illustrations are also provided All item number references in the text are specific to this manual and the figures cited Disassembly Materials The materials required for disassembly are listed in Table 72 00 06 1 NOTE Equivalent substitutes may be used Table 72 00 06 1 Disassembly Materials Description Penetrating Oil Parts for Discard Parts to be discarded are listed in Table 72 00 06 2 Source Commercially Available 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 Stressed Bolts and Fasteners Intake and Exhaust Valves Valve Guides and Valve Keepers Crankshaft Gear Attaching Bolt Connecting Rod Nuts and Bolts All Lockwashers Circlips Retaining Rings Locktabs and Locknuts Counterweight Bushings in Crankshaft and Counterweights if applicable Counterweight Washers if applicable Vermatherm Oil Temperature Bypass Valve Special Tools and Equipment Special tools and equipment required for disassembly are listed in Table 72 00 06 3 March 2005 Superior Air Parts Inc NOTE Standard reciprocating engine aviation shop tools and equipment are used unless otherwise specified 72 00 06 En
30. NUT SLOTTED 3 8 24 35 WASHER FLAT 1 4 INCH 90 BOLT 1 2 20 X 1 1 8 40 WASHER LOCK 1 4 INCH 95 BOLT 1 4 INCH 45 NUT PLAIN 1 4 20 100 NUT SLOTTED 1 4 20 50 STRAP LIFTING Figure 72 00 09 11 Crankcase Attaching Hardware 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine O 360 and 360 Series Engines AIR PARTS IN C 95 M Figure 72 00 09 12 Crankcase Attaching Hardware cont d 18 on March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIZ Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines SILK THREAD SEALANT SHADED AREA L 2 Figure 72 00 09 13 Sealant Compound and Silk Thread Application D 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines CRANKSHAFT DRIVE GEAR TOOL CRANKCASE CRANKCASE LEFT HALF RIGHT HALF We kee PAN SCH eus 2L 9 CAMSHAFT SR GEAR END M V NS Th eZ gia Holt ER wy 2 Q n a LAE N RE 4 PROPELLER FLANGE END OF egere pu d L J z WN Figure 72 00 09 14 Crankcase Halves Assembly SS 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly Overhaul Manual N27 anlage Engine O 360 and IO 360 Series Engines SUPER I
31. Shaft in Rocker Bearings 0 0007 0 0017 Rocker Shaft in Cylinder Head 0 0001 0 0013 Valves in Guides Exhaust Valve in Guide 0 0040 0 0060 Intake Valve in Guide 0 0010 0 0028 Oil Seal in Propeller Governor Adapter 0 0010T 0 0030T Valve Rocker Side Clearance 0 0050 0 0130 Dry Tappet Clearance 0 0280 0 0800 Oil Pump Housing and Oil Pump Gear 0 0020 0 0060 Oil Pump Gear Shaft in Accessory Case 0 0015 0 00300 Crankshaft Gear in Crankshaft Pilot 0 0005T 0 0010L Oil Seal in Accessory Tachometer Housing 0 0010T 0 0030T Fuel Pump Pushrod in Accessory Case 0 0015 0 0030 Tachometer Drive Shaft in Accessory Case 0 0015 0 0035 72 00 11 March 2005 Superior Air Parts Inc Fiteand Clearances 2 SUPERIZR Overhaul Manual Vantage Engine AUR PARTS UNE O 360 and IO 360 Series Engines Table 72 00 11 2 Torque Limits Description of Limit Torque in Lb Spark Plug 420 Plug and Fitting 1 2 14 NPT 160 Plug and Fitting 1 16 27 NPT 40 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 Nut and Capsrew 96 108 Slotted Nut 4 Nut Capscrew 55 60 Nut 5 16 Nut and Capscrews 200 Slotted Nut 5 16 Idler Shaft 150 Nut 72 20 Cylinder to Crankcase 600 Nut 3 8 24 Cylinder to Crankcase 300 Nut 3 8 24 Crankcase to Crankcase 300 3 8 24 Nut Connecting Rod Bolts 480 Slotted Nut 3 8 24 Drilled Stud Over Camshaft 300 5 16 Crankshaft Gear Bolt 204 4 20 Pushrod Shro
32. a lubricant e On aircraft Perform a ground run up Perform a pre flight inspection and correct any discrepancies Fly the aircraft for approximately one hour or until 180 F oil temperature is reached Do not exceed 400 F cylinder head temperature e test cell Perform run up to warm engine to a minimum of 180 F oil temperature Do not exceed 400 cylinder head temperature Run at these conditions for a minimum of 15 minutes WARNING TO PREVENT POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH BEFORE MOVING THE PROPELLER DO THE FOLLOWING e DISCONNECT ALL SPARK PLUG LEADS e VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT THEY ARE IN THE OFF POSITION AND THE P LEADS ARE GROUNDED e THROTTLE POSITION CLOSED e MIXTURE CONTROL IDLE CUT OFF e SET BRAKES AND BLOCK AIRCRAFT WHEELS ENSURE THAT AIRCRAFT TIE DOWNS ARE INSTALLED AND VERIFY THAT THE CABIN DOOR LATCH IS OPEN e DO NOT STAND WITHIN THE ARC OF THE PROPELLER BLADES WHILE TURNING THE PROPELLER e After operation verify all spark plug leads are removed and remove the top spark plugs Protect the ignition lead ends with AN 4060 protectors or equivalent Using a common garden sprayer or equivalent March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines spray approximately 2 3 ounces of atomized preservative oil MIL P 46002 Grade or Cortec VpCl 326 at room temperature through the upper spark
33. are made from an aluminum alloy The piston pin is a full floating type with a plug located in each end of the pin The piston is a 3 ring type with 2 compression rings and 1 oil control ring Cooling System Superior Vantage Engines are designed to be air cooled Baffles 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 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 02 00 00 Description and Operation SUPERIZ A Lubrication System The full
34. burrs or sharp edges remain March 2005 Superior Air Parts Inc 17 Overhaul Manual O 360 and IO 360 Series Engines N27 i antage Engine c The minimum filet at the root of the removed portion of the fin is 0 25 in radius Minimum corner at top of fin adjacent to the removed portion is 0 50 in radius 3 For damaged cracked or broken fins it is permissible to perform the following repairs a A damaged area may be blended The blended area for any one fin shall not exceed 0 38 in square area or 0 38 in depth b There may be no more than two blended areas on one fin c No more than four blended areas on the pushrod side of the cylinder head No more than six blended fins on the side opposite the pushrod side of the cylinder head It is recommended that a fluorescent penetrant inspection be performed upon completion of any of these repairs a Pay special attention to the area on exhaust port side of the cylinder b Pay special attention to the area around the lower spark plug counterbore SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines C MAX FIN REMOVAL TO THIS LINE ONLY NEVER ENTER BASE METAL Figure 72 00 13 2 Cooling Fin Removal Maximum 18 72 00 13 March 2005 Superior Air Parts Inc Repair Procedures SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines REPAIR NO 8 VALVE VALVE SEAT
35. can be freely pressed from the connecting rod NOTE Avoid supporting the connecting rod in such a way that bending loads are placed on the length of the connecting rod in order to prevent damage to the connecting rod S Insert the tool in the connecting rod small end bushing so that the shoulder of the tool rests on the edge face of the bushing and is clear of the ID of the connecting rod bore Press out connecting rod bushing 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 AR March 2005 Superior Air Parts Inc 31 Assemble a new connecting rod bushing using the arbor press and extraction insertion tool described above as follows 1 Support the connecting rod on the base of the arbor press such that the connecting rod bushing bore is directly supported NOTE Avoid supporting the connecting rod in such a way that bending loads are placed on the length of the connecting rod in order to prevent damage to the connecting rod 5 Insert the tool in the bushing so that the shoulder of the tool rests on the edge face of the bushing and is clear of the ID of the connecting rod bore 3 Insert bushing until the bushing is centered within the bore of the connecting rod and bushing is flush with the sides of the connecting rod Broach
36. does not occur shut down engine and determine cause e engine just long enough to confirm all components are properly adjusted and secured There must be no fuel and or oil leaks e Install cowling e Operate engine at 1000 1200 RPM until oil has reached minimum operating temperature 120 F e Check magneto drop at normal RPM e f engine is equipped with a controllable pitch propeller cycle only to a 100 RPM drop e Shut down engine and check for fuel and or oil leaks and repair any discrepancies e At no time should cylinder head temperature be allowed to exceed recommended maximum cruise limit of 430 F Break In Flight Operation e Perform normal pre flight and run up in accordance with the Installation and Operation Manual SVIOMO1 remember cycle controllable pitch prop to only a 100 RPM drop Keep ground runs to a minimum e Conduct normal take off at full power full rich mixture to a safe altitude NOTE In certain geographic locations and weather conditions eg high density altitudes Full Rich operation may not be practical In this event substitute the requirement of Full Rich as discussed in this chapter with the richest practical setting 72 00 04 Special Procedures N27 anlage Engine SUIPER IZ A R PARTS NC NOTE Verify the crankcase breather and vent lines correctly installed positioned Excessive oil discharge through the breather can often
37. flange correct thickness of paint will appear green with a yellow tint and allow the metal to show N27 anlage Engine SUPERIZ A R PARTS IN C Overhaul Manual O 360 and 360 Series Engines N27 i antage Engine through Paint that is too thick will appear zinc chromate yellow CAUTION THICKNESS OF PRIMER MUST BE NO MORE THAN 0 0005 IN USE EITHER A TINSLEY THICKNESS GAGE OR A MICROMETER TO MEASURE THE THICKNESS OF THE FLANGE BEFORE AND AFTER PAINTING IF THE PRIMER IS TOO THICK IT MUST BE REMOVED AND THE BARREL REPAINTED March 2005 Superior Air Parts Inc 12 5 Mask off the flange area around nut seating surface Paint the cylinder with an enamel resin or equivalent that has been properly thinned with toluene or equivalent Use a cloth wet with thinner to clean paint from surfaces where overspray paint may have adhered Allow the cylinder to air dry for 15 minutes then bake in an oven until completely dry SUPERIZ Overhaul Manual KZ Engine AUR PARTS INC O 360 IO 360 Series Engines REPAIR NO 5 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 microns procedure
38. plug hole of each cylinder with the piston at bottom dead center position Rotate crankshaft as opposite cylinders sprayed Stop crankshaft with none of the pistons at top dead center e Remove carburetor or fuel injection servo drain all fuel from system and lines and cap lines Insert desiccant bag in intake port Attach red Remove Before Flight streamer to each bag of desiccant and seal the openings e Preserve carburetor or fuel injection servo IAW manufacturer s storage instructions Follow the appropriate section below Tor temporary or indefinite preservation and storage Temporary Storage After following the above steps and while the engine is still warm prepare the engine for short term 90 days or less storage or shipment in the following manner e Drain preservative oil Re spray each cylinder To thoroughly cover all surfaces of the cylinder interior move the nozzle or spray gun from the top to the bottom of the cylinder e 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 e Seal all engine openings exposed to the atmosphere using suitable plugs and covers e On aircraft tag each propeller or if propeller is not installed on the propeller flange with the following notation on the tag Do Not Turn Propeller Engine Preserved Preservation Date NOTE f the engine is not returned to fl
39. pressure wet sump lubrication system is supplied by a gear type pump It is contained within the accessory housing Priming System A manual primer system is provided on all engines using a carburetor Fuel injected engines do not require a manual priming system relying instead on the fuel injectors for priming Ignition System Dual ignition is furnished by two Unison magnetos with two spark plugs per cylinder Electrical System Engines may be furnished with an alternator if provided for in the model specification If an alternator is furnished installation brackets hardware and belt are provided Alternators are available in either 12 or 24 volt systems and a range of amperages March 2005 Superior Air Parts Inc Overhaul Manual R PARTS INC O 360 and IO 360 Series Engines 17 N27 i antage Engine 02 00 00 Airworthiness Limitations LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK 18 02 00 00 March 2005 Superior Air Parts Inc Ainvonhi ess Limitations A SUPERIZR R P Overhaul Manual O 360 and IO 360 Series Engines AIRWORTHINESS LIMITATIONS The Airworthiness Limitations Section is FAA approved and specifies maintenance required under sections 43 16 and 91 403 of the Federal Aviation Regulations unless alternate program has been FAA approved This section is part of the type design of
40. the rocker arms in order to prevent damage to the rocker arm Rotate to align the bushing so that the lubrication hole is aligned with the oil hole on the pushrod side of the rocker arm bore Insert the tool in the rocker arm bushing so that the shoulder of the tool rests on the edge face of the bushing and is clear of the ID of the rocker arm bore Insert rocker arm bushing until the lubrication hole of the bushing is centered on the oil hole on the pushrod side of the rocker arm bore and the bushing is flush with the sides of the rocker arm Ream or hone the bushing ID to size per the Fits and Clearances section of this manual N27 i antage Engine LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK 30 March 2005 Superior Air Parts Inc A SUPER IZIR R P Overhaul Manual O 360 and IO 360 Series Engines REPAIR 11 CONNECTING ROD BUSHING REPLACEMENT Connecting Rod Bushing Replacement Connecting Rod bushings small end that were rejected during inspection must be removed and replaced as described in this section Use an arbor press and an extraction insertion tool piloted shoulder press tool to remove the rejected bushing as follows 1 Support the connecting rod on the base of the arbor press such that the small end bushing bore of the connecting rod is directly supported and the bushing
41. with Repair section 4 March 2005 Superior Air Parts Inc 72 2 SUPERIAR Overhaul Manual rione Engine O 360 and IO 360 Series Engines INSPECTION AND CHECK General The inspection of engine parts consists of three 3 categories visual structural dimensional Visual and structural inspections deal primarily with structural defects The dimensional checks are concerned with the size shape and fit of a given part Upon successful completion of inspection coat all steel parts with preservative oil Visual inspections should precede all other inspections cleaning operation should be permitted until a complete initial visual inspection is made of the part in question Residue from the engine s operation can provide additional information as to hidden defects or other dangerous conditions Refer to the Cleaning section of this manual Structural inspections will include checking flatness out of roundness and passageway clearance They may also include magnetic particle and dye penetrant procedures as well as eddy current ultra sonic other non destructive testing methods For dimensional inspections refer to the tables set forth in the Fits and Clearances section of this manual For repairs required prior to a final inspection or dimensional check of a part refer to the Repairs section of this manual The use of a recording form is recommended during the inspection procedures The form
42. 0 with shim washers 35 and hardware as required for alternator pulley belt alignment to starter ring gear assembly b Attach strut support 80 to alternator bracket in forward location using bolt 25 6 Install adjusting link 65 to crankcase and alternator with drilled head bolts 75 10 Use single washer 70 at the crankcase attach point and two 2 washers 5 at slotted alternator attach point for strength NOTE Leave all attach hardware snug or finger tight as required to allow for alignment and belt tension adjustment e Install alternator belt not shown to starter ring gear assembly and install starter ring gear assembly to crankshaft flange Reference SVMM01 Maintenance Manual slave bolt may be used to temporarily hold starter 72 00 09 Engine Assembly Overhaul Manual N27 anlage Engine O 360 and IO 360 Series Engines SUPER IZIR A R P ring gear assembly in place if propeller and spinner are to be installed later Install new belt to alternator pulley and adjust alternator and or brackets to achieve proper alignment Adjust belt tension to allow a midspan deflection of 0 31 with a 14lb load NOTE alternate method of checking belt tension is to measure the torque required to slip the belt at the small alternator pulley A new belt is properly tensioned when 12 ft lb 1 is required to cause it to slip 10 Torque and safety the 3 8 24 slot
43. 05 Superior Air Parts Inc Desoriptionand Operation SUPERI A R Overhaul Manual Engine O 360 360 Series Engines CYLINDER ASSEMBLY FUEL INJECTION MANIFOLD ACCESSORY ASSEMBLY HOUSING STARTER SUPPORT ASSEMBLY OIL FILTER WIRING HARNESS MAGNETO Dr FUEL PUMP iB FUEL LINE FUEL INJECTION SERVO STARTER SPARK PLUG OIL SUMP Figure 02 00 00 7 10 360 Engine Left Side View 02 00 00 March 2005 Superior Air Parts Inc D soripti nmand Operation N27 SUPERIZR Overhaul Manual antage Engine AUR PARTS INC O 360 and 360 Series Engines FUEL INJECTION MANIFOLD FUEL INJECTIOR ME CT l o r KOR Ch Wien N gt I RSC III ni HE Figure 02 00 00 8 IO 360 Engine Top View 02 00 00 March 2005 Superior Air Parts Inc Operation LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines Fuel Manifold Oil Temp Connection Tachometer Connection Breather Fitting Vacuum Pump Pad Oil Filter also used for dual drives l From Cooler Oil Pressure Gage Connection Oil Fill Tube and 2 s Oil Level Gage Q Manifold 2 6 Pressure Connection Ground Terminal Oil To Cooler OA Oil Line To Propeller Diaphragm Fuel Pump Fuel Pump Inlet Vent Line Connection
44. 10 Remove manifold 15 retaining bolts 25 and washer 20 Disconnect and remove fuel hoses 30 35 Figure 72 00 09 38 Remove nuts 25 lockwashers 20 and flat washers 15 from studs Remove injector servo assembly 10 and remove gasket and spacer 5 Magneto and harness removal 1 Unscrew ignition wiring harness leads 5 10 Figure 02 00 00 10 from the top and bottom spark plugs 50 Remove harness attaching caps 5 two places from the magneto Remove spark plugs 50 from cylinder 2 Remove magneto 15 Figure 72 00 09 40 attaching nut 30 washer 25 and clamp 20 Remove the magneto 15 and discard gasket 10 Remove the adapter 5 and gasket 1 Remove cotter pin 40 nut and washer Remove magneto gear 35 and install nut back on threads to prevent damage to drive shaft threads Oil level gage housing Removal 1 Unscrew the oil gage 10 Figure 72 00 09 28 and remove the oil gage housing 5 Discard seals 15 20 Fuel pump removal as required 1 Remove fuel pump screws 15 Figure 72 00 09 32 and washers 10 Remove fuel pump 5 and gasket 1 Remove elbows 25 30 and discard o rings 20 Oil filter and Adapter removal 1 Unscrew the oil filter 40 Figure 72 00 09 35 Remove the vernatherm temperature control valve 35 Remove screws 30 washers 15 March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines
45. 2 Safety Wire 0 041 Type 304 Stainless Steel P N MS20995 C41 Silastic 140 Sealant Silk thread size 00 100 Silk STP High Viscosity Oil Treatment TitesealTM No 2 Gasket and Joint Compound P N T2 01 Phthalate resin type enamel AMS3125C or equivalent MIL E 7729 Randolph Black 303 Toluene or equivalent AMS3180 or equivalent Federal Spec TT T 548 Zinc Chromate Primer March 2005 Superior Air Parts Inc Source Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Locally Prepared Mixture Locally Prepared Mixture General Electric Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Ohio Industrial Lubricants 01 00 00 Introduction LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK i 01 00 00 March 2005 Superior Air Parts Inc Introduction A SUPER IZIR R P Overhaul Manual O 360 and IO 360 Series Engines DESCRIPTION AND OPERATION General Description Superior Vantage Engines four cy
46. 2 00 09 24 a Remove nuts 90 and washers 85 to remove oil pump housing assembly 80 Remove pump drive shaft 115 and impeller gears 105 110 72 00 06 Engine Disassembly N27 i antage Engine SUPERIAR Idler gears and shaft removal Overhaul Manual O 360 360 Series Engines N27 i antage Engine 1 Remove idler gears 15 20 Figure 72 00 09 20 Remove idler shaft mount screws 5 and nut 10 Remove idler shafts 1 from crankcase Starter _alternator _attaching hardware removal 1 Remove starter mount bolt 15 Figure 72 00 09 42 nuts 20 lockwashers 10 and flat washers 5 Remove starter 1 from crankcase a Remove alternator mount bolt 10 Figure 72 00 09 43 and washer 5 to loosen drive belt Remove cotter pin 45 slotted nut 40 support bolt 25 and shims 35 Remove cotter pin 45 slotted nut 40 shims 35 and support bolt 30 Remove bolts 20 90 and flat washers 15 85 from strut bracket 80 Remove strut support 80 and remove alternator Remove alternator bracket 55 by removing bolts 60 and lock plate 50 Remove bolt 75 flat washer 70 and adjusting link 65 Visually inspect hardware and bag for reuse if not damaged OU induction disassembly 1 Remove screws 25 Figure 72 00 09 29 lockwashers 20 and flat washers 15 from intake pipe flange 10 Discard gaskets 1
47. 360 Engine Left Side View Figure 02 00 00 7 p 12 IO 360 Engine Top View Figure 02 00 00 8 p 13 360 Engine Rear View Figure 02 00 00 9 p 14 Ignition Wiring Diagram Figure 02 00 00 10 p 15 Oil System Schematic Figure 02 00 00 1 1 p 16 02 00 00 March 2005 Superior Air Parts Inc Description and Operation NA SUIPER IZ Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines SPARK PLUG qo 1 i P asss CHT PROBE LOCATION TYPICAL EACH HEAD PRIMING SYSTEM ALTERNATOR amp BELT NOT PROVIDED WITH ENGINE STARTER THROTTLE LEVER FUEL LINE CARBURETOR Figure 02 00 00 2 O 360 Engine Front View 02 00 00 March 2005 Superior Air Parts Inc Desoriptionand Operation 2 SUPERI A R Overhaul Manual Vantage Engine ATR PARTS 1 O 360 and 360 Series Engines CYLINDER ASSEMBLY ACCESSORY CRANKCASE HOUSING ASSEMBLY STARTER SUPPORT ASSEMBLY FILTER HARNESS ay dd a N MAGNETO PRIMING SYSTEM SPARK PLUG STARTER MIXTURE LEVER INDUCTION OIL SUMP SYSTEM ASSEMBLY CARBURETOR Figure 02 00 00 3 O 360 Engine Side View 02 00 00 March 2005 Superior Air Parts Inc Desoriptionand Operation 2 Sal IER 2 Overhaul Manual niege Engine AIR PARTS 1 O 360 and IO 360 Series Engines INTER CYLINDER BAFFLE SPARK PLUG m Lem IECH i T ir s A H T4 ni il RUT
48. 60 and 360 Series Engines 1 HOUSING ASSEMBLY ACCESSORY 50 SHIELD OIL BREATHER 5 WASHER FLAT 80 HOUSING ASSEMBLY OIL PUMP 10 WASHER LOCK 85 WASHER FLAT 15 BOLT 90 NUT SLOTTED 20 BOLT 95 HOUSING 25 NUT HEX 105 GEAR IMPELLER 30 SEAL 110 GEAR IMPELLER 35 GASKET 115 SHAFT OIL PUMP DRIVE 45 SET SCREW PLUG Figure 72 00 09 23 Accessory Housing B9 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines FUEL PUMP DRIVE SHAFT ACCESSORY HOUSING CASTLE NUTS Figure 72 00 09 24 Oil Pump Assembly 96 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual k Engine AIR PARTS INC O 360 and 360 Series Engines ACCESSORY EXCESS GASKET HOUSING MATERIAL EXCESS GASKET MATERIAL NOTE EXCESS GASKET MATERIAL BETWEEN ACCESSORY HOUSING AND CRANKCASE CRANKCASE MUST BE TRIMMED FLUSH TO THOSE ASSEMBLY SURFACES PRIOR TO INSTALLATION OF OIL SUMP HOUSING Figure 72 00 09 25 Accessory Housing Gasket Trimming SS 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZ A R PARTS N C Installation of Intake Pipes Overhaul Manual O 360 and 360 Series Engines 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 recesse
49. ACE SHIELD TO PROTECT YOUR EYES THIS WILL HELP PREVENT INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT IF YOU GET AN EYE INJURY SEEK MEDICAL ATTENTION CAUTION DO NOT USE WIRE BRISTLE BRUSHES OR METAL SCRAPERS ON ANY BEARING MACHINED OR CONTACT SURFACES CAUTION DO NOT USE GRIT BLASTING ON THE PISTON RING GROOVES USE WOODEN SCRAPER Scratch and Corrosion Removal Remove corroded or pitted surfaces on the fillets at the edges of crankshaft main and crankpin journal surfaces and thrust bearing races by polishing with crocus cloth or other mild abrasive material Refer to the Fits and Clearances section of this manual for limits Shallow or small scratches minor abrasions or pitting on gears or screwed fittings may be dressed out with a fine abrasive crocus cloth small file or polishing stone Refer to the Fits and Clearances section of this manual for limits Accessory Mounts Clean mounting pads and studs by wiping with a clean cloth moistened with solvent Use care to remove sludge and debris from around the bases of the studs 72 00 07 Cleaning N27 anlage Engine SUPERIAR NOTE Use care to not force debris into drilled areas passages ports or threaded receptacles 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 WI
50. AND VALVE GUIDE General Valves and valve guides must be replaced at overhaul The surfaces of the valves and their seats normally be resurfaced and reconditioned as a repair Valves must be removed from the cylinder and cleaned of all sludge and carbon build up prior to repairs Refer to the Cleaning section of this manual Refer to the Inspection and Check section of this manual for appropriate inspection procedures and limits on damage and wear Valve seat grinding 1 The ID of the valve guide is used as a pilot for all valve seat reconditioning operations WARNING USE THE CORRECT PERSONAL PROTECTION POLISHING AND GRINDING WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES 2 Grind valve seats with suitable grinding equipment to a 30 angle on intake valve seats and a 45 angle on exhaust valve seats Grind valve seats to 16 RA max ref concentric to guide bore within 0 002 in a On intake valve seats use a 15 grinding wheel to grind the top surfaces of the valve seat to produce the outer face diameter Bring the face of the intake valve seats to the specified width Dimension by narrowing the throat with a 75 wheel Refer to Figure 72 00 13 5 b On exhaust valve seats use a 15 grinding wheel to grind the top surface of the valve seats to produce the outer face diameter The width of the exhaust valve seats should conform to dimension D Refer to Figure 72 00 13 5 c I
51. About This Manual The purpose of this Overhaul Manual is to provide the necessary instructions for major repair and replacement of Superior Vantage O 360 and IO 360 series engines Maintenance information may be found in the Maintenance Manual SVMM01 The information in this publication is based on data available at the time of publication and is updated supplemented and automatically amended by Service Bulletins and Publication Revisions that are issued by Superior Air Parts Inc This manual is divided into separate sections relating to the general and specific overhaul instructions required for the engine These general and specific instructions are generally organized and numbered per the recommendations of the General Aviation Manufacturers Association GAMA In this way information may be located in a conventional manner to aid in both accuracy and timeliness Page numbering is organized within each section The section number e g 72 00 01 is displayed in the right hand section of the footer on each page The page number is displayed in the center of the footer on each page Superior Air Parts has made clear and accurate information available for those who maintain own and repair the Vantage 360 and 360 Series Engines Superior Air Parts values your input regarding revisions and additional information for our manuals Please forward your comments and input to Superior Air Parts Attn Engineering Department
52. C Y Figure 72 00 08 3 Crankcase Bearing and Flange Surfaces S 72 00 08 March 2005 Superior Air Parts Inc inspection and Chisdk SUPERIZR A R P Cylinder Head Initially inspect cylinder head Refer to Figure 72 00 08 4 e Obvious excessive damage to pelea cylinder head Visually inspect cylinder head 1 Inspect cylinder head valve seats e Loose scored or pitted valve Reject seats 2 Inspect cylinder for loose or damaged studs e Loose or damaged studs Reject NOTE Loose or damaged studs must be replaced with oversized studs using 0 003 0 007 or 0 012 inch 3 Inspect cylinder head spark plug helical coil inserts e Loose or damaged Reject inserts NOTE Loose or damaged helical coil inserts must be replaced with oversized insert See Repair No 1 4 Inspect cylinder rocker box covers intake and exhaust ports e Nicked scored Blend hand or dented polish per mounting pads Repair No 2 5 Inspect cylinder head cooling fins for cracks e Fin adjacent to the exhaust SEN SE port flange i e Physically damaged See Repair broken or bent No 10 fins March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines N27 i antage Engine Cylinder Head Dimensional Inspections Inspect the rocker shaft bushings e Check the ID of the rocker shaft bushings a minimum of two 2 positions 90 Pu degrees apart Several s an Clearances check locati
53. DATA SHEET MSDS FROM THE MANUFACTURER OR SUPPLIER USE IN A WELL VENTILATED AREA FREE FROM SPARKS WEAR PROTECTIVE GEAR CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER NOTE Unless otherwise specified all torque loads listed for nuts bolts and screws are for use with pre lube oil March 2005 Superior Air Parts Inc Source Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Crankcase Inspection and Preparation for Assembly 1 Place crankcase halves on workbench Check for handling damage Inspect for slight nicks and burrs surface finish split lines bearing and cam bores mating surfaces and tappet bores 2 Inspect studs for thread damage bent condition 3 Inspect tang slots for deformation Install center and aft main bearings in case halves 4 Check front main bearing retention dowel installation for correct height of 0 070 0 090 in Refer to Figure 72 00 09 1 WARNING 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 O
54. DO NOT BREATHE VAPORS CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 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 IF ONE SURFACE IS POLISHED TO UNDERSIZE ALL CORRESPONDING SURFACES MUST BE POLISHED TO THE SAME SIZE 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 DO NOT DAMAGE THE NITRIDED SURFACES OF THE CRANKSHAFT USE CORRECT PERSONAL PROTECTION SOME CHEMICAL SOLUTIONS CAN CAUSE EYE SKIN AND LUNG DAMAGE FOLLOW THE MANUFACTURER S INSTRUCTIONS FOR EACH STRIPPING SOLUTION USE THE CORRECT PERSONAL PROTECTION USE OF A HAMMER CAN CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES DO NOT ROTATE ENGINE OR CRANKSHAFT BEFORE REMOVAL OF TIMING LOCATOR PINS TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH BEFORE MOVING THE PROPELLER DO THE FOLLOWING e VERIFY ALL SPARK PLUG LEADS ARE DISCONNECTED e VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT THEY ARE IN THE OFF POSITION AND P LEADS ARE GROUNDED e THROTTLE POSITION CLOSED e MIXTURE CONTROL IDLE CUT OFF e SET BRAKES AND BLOCK AIRCRAFT WHEELS ENSURE THAT AIRCRAFT TIE DOWNS ARE INS
55. E THE CORRECT PERSONAL PROTECTION EQUIPMENT AVOID INJURY ENSURE AREA IS FREE OF MOVABLE OBJECTS THAT COULD IMPACT BY PROPELLER AIR BLAST Engine Storage After Testing Refer to the Assembly Section of this manual for storage instructions N27 i antage Engine LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines APPENDIX A N27 i antage Engine ASSEMBLY IN PROCESS QUALITY INSPECTIONS Inspection 1 A Inspect and verify correctness of all parts and procedures prior to further assembly of crankcase halves to the crankshaft assembly This quality inspection shall include visual inspection of parts and written records paperwork in accordance with the assembly guidelines in this Overhaul Manual This inspection shall be accomplished during the engine assembly process as noted in the Assembly section of this manual Perform the inspections as follows 3 Verify the case serial numbers match each case half 4 Verify correct crankshaft part number 5 Verify correct camshaft part number 6 Verify the correct main bearing part number and ensure proper fit 7 Verify that all pipe plugs and fittings are properly installed in the case halves 8 Check the tappet body fit in lifter bore and ensure that all
56. EA FREE FROM SPARKS WEAR PROTECTIVE GEAR CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 25 Lightly lubricate shank and threads of the Y in Dia through bolts 1 Figure 72 00 09 12 with pre lube oil Install using a soft faced dead blow hammer as far as possible Finish installation with sufficiently sized ball peen hammer or equivalent using a nut or threaded cap to protect the threads and thru bolt end Thru bolts are properly installed when an equal number of threads protrude from each case half 72 00 09 Engine Assembly N27 i antage Engine SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines 10 15 25 30 35 40 45 BEARING ROD ASSY BOLT ROD NUT ROD BUSHING PISTON PIN AND PLUG ASSY RING OIL CONTROL RING COMPRESSION Figure 72 00 09 6 Connecting Rod and Piston Assembly March 2005 Superior Air Parts Inc e 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines FRONT MAIN BEARING SURFACE 0 SLINGER N N ROD ASSEMBLY SERIAL NUMBERS MUST MATCH AND FACE TOWARD THE OIL SUMP OPPOSITE THE CAMSHAFT lt J BUSHING PROP FLANGE Figure 72 00 09 7 Connecting Rod Installation i 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPER
57. ELBOW 45 Figure 72 00 09 32 Fuel Pump 47 on March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines N27 anlage Engine 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 8 Apply TiteSeal thread sealant or equivalent to the threads of 90 elbow fitting 10 and install in the right crankcase half forward of No 1 cylinder Refer to Figure 72 00 09 34 Position fittings per Figure 72 00 09 34 and install the propeller governor oil hose 1 Torque the oil hose 1 nuts to 35 in Ibs Installation of Propeller Governor Cover Plate 1 This instruction applies to all engine models not requiring a prop governor 2 For the engine models where no propeller governor is used install cover 65 Figure 72 00 09 33 gasket 60 washer 30 and lockwasher 25 Torque the 5 16 in nuts 30 to 200 in Ibs Installation of Oil Filter Adapter if furnished 1 Install the Vernatherm valve 45 with the aluminum gasket and torque to 300 in lbs Install safety wire 0 032 in from the Vernatherm to the adapter 2 Install the oil filter adapter 10 Figure 72 00 09 35 to the accessory housing with the gasket 5 washer
58. ENGINE WITHOUT PRELIMINARY EXAMINATION CAN CAUSE FURTHER DAMAGE TO A DISABLED COMPONENT AND POSSIBLE INJURY TO PERSONNEL MAKE SURE THOROUGH INSPECTION AND TROUBLESHOOTING PROCEDURES ARE ACCOMPLISHED THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL AND OR DAMAGE TO THE EQUIPMENT Prior to Break In Start Up e Engine oil sump should be filled with 100 straight weight mineral oil Use MIL L 6082 specific grade depending on ambient temperature Refer to chapter 72 00 13 for fluid requirements e Engine must be pre oiled and oil pressure obtained prior to start up e pre oil an engine do the following 1 Attach pressure oiling equipment to one end of the main gallery and force oil through the galley at 35 psi until oil flows from the opposite galley with the plug removed from the front end of the opposite galley 2 Engine baffles and seals must be in good condition and properly installed 3 Verify accuracy of instruments required for engine operation March 2005 Superior Air Parts Inc CAUTION BREAK IN OF AN ENGINE FRIGID CONDITIONS CAN LEAD TO CYLINDER GLAZING AND FAILED BREAK IN DUE TO LOW OIL TEMPERATURE IT IS RECOMMENDED THAT OIL TEMPERATURE BE MAINTAINED BETWEEN 180 AND 190 F Break In Ground Run Flight propeller may be used if test club is not available e Head aircraft into the wind e Start engine and observe oil pressure Oil pressure should be indicated within 30 seconds If this
59. EPAIR NO 10 ROCKER ARM BUSHING REPLACEMENT Rocker Arm Bushing Replacement Rocker bushings that were rejected during inspection must be removed and replaced as described in this section Use an arbor press and an extraction insertion tool piloted shoulder press tool to remove the rejected bushing as follows 1 Support the rocker arm on the base of the arbor press such that the center bore of the rocker arm is directly supported and the bushing can be freely pressed from the rocker arm NOTE Avoid supporting the rocker arm in such a way that bending loads are placed on the rocker arms in order to prevent damage to the rocker arms 2 Insert the tool in the rocker arm bushing so that the shoulder of the tool rests on the edge face of the bushing and is clear of the ID of the rocker bore Press out the rocker arm bushing Clean rocker arm bore and oil holes thoroughly as described in the Cleaning section of this manual and inspect the condition of the rocker arm bore Repair scratches as required per the Cleaning section of this manual AR March 2005 Superior Air Parts Inc 29 Assemble a new rocker arm bushing using the arbor press extraction insertion tool described above as follows 1 Support the rocker arm on the base of the arbor press such that the center bore of the rocker is directly supported NOTE Avoid supporting the rocker arm in such a way that bending loads are placed on
60. Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines fA 2 K n qe Wa il EA Wun 1 HOSE 10 ELBOW 90 15 ELBOW 45 20 O RING 25 CLAMP 30 WASHER FLAT 35 WASHER LOCK 40 BOLT Figure 72 00 09 34 Propeller Governor Oil Line 50 March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIZR Overhaul Manual cm Oe 360 360 Series Engines 30 VALVE CONTROL ASSY VERNATHERM OIL FILTER SPIN ON FITTING CRANKCASE BREATHER GASKET COPPER 55 oT Engine 45 ae 4 42 S 50 42 Eb Ces A d STUD 1 4 20 X 1 1 4 GASKET ADAPTER ADAPTER OIL FILTER WASHER FLAT 1 4 INCH WASHER LOCK 1 4 INCH NUT PLAIN 1 4 INCH SCREW 1 4 20 X 31 32 PLUG OIL COOLER BYPASS Figure 72 00 09 35 Oil Filter Assembly March 2005 Superior Air Parts Inc 51 po 2 ALES ef A cL 475 Gol N qr R e 72 00 09 Engine Assembly SUPERIAR Installation of Carburetor and Primer System NOTE 1 2 This section applies to carbureted engine models only Verify the correct part number of the carburetor Install the carburetor b Figure 72 00 09 37 gasket 1 washers 10 lockwashers 15 and nuts 20 per Figure 72 00 09 37 Torque the nuts 20 to 200 in Ibs Apply anti seize to the threads of
61. Engine Runs Rough Low Oil Pressure On Engine Gage High Oil Temperature Excessive Oil Consumption Troubleshooting WARNING OPERATION OF A DEFECTIVE ENGINE WITHOUT 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 HOT OIL MAY CAUSE BURNS TO EYES AND SKIN PUT ON SPLASH GOGGLES INSULATED GLOVES AND OTHER PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER March 2005 Superior Air Parts Inc Table 72 00 03 3 72 00 03 4 72 00 03 5 72 00 03 6 72 00 03 7 72 00 03 8 72 00 03 9 72 00 03 10 WARNING FUEL IS TOXIC AND FLAMMABLE DO NOT BREATHE VAPORS USE IN A WELL VENTILATED AREA FREE FROM SPARKS FLAME OR HOT SURFACES PUT ON SPLASH GOGGLES SOLVENT RESISTANT GLOVES AND OTHER PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER NOTE The Fault Isolation sequence is in order of approximate ease of checking not necessarily in order of probability 72 00 03 Testing Fault Isolation SUPERIAR Overhaul Manual Bag Engine O 360 and IO 360 Series Engines Table 72 00 03 3 Engine Will
62. GHT 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 V March 2005 Superior Air Parts Inc General Information Overhaul Manual N27 anlage Engine O 360 and 360 Series Engines SUPERIAR WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING March 2005 Superior Air Parts Inc PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE USE THE CORRECT PERSONAL PROTECTION EQUIPMENT TO AVOID INJURY ENSURE AREA IS FREE OF MOVABLE OBJECTS THAT COULD IMPACT BY PROPELLER AIR BLAST 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 SOLVENT IS TOXIC USE IN WELL VENTILATED AREA PREVENT EYE AND SKIN CONTACT AND
63. IZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines 5 CAMSHAFT ASSEMBLY 10 BUSHING 15 TACHOMETER SHAFT ASSEMBLY 20 PIN 25 RETAINING RING Figure 72 00 09 8 Camshaft Assembly 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines CRANKCASE LEFT HALF FORWARD MARKS MAIN BEARINGS __ en b cc og Bee Deng am Q M ENGINE FORWARD END S INDICATION C Figure 72 00 09 9 Main Bearing Reference Marks 19 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines CRANKSHAFT MATCH MARKS 2 o ENGINE FORWARD END INDICATORS SLINGER e SEAL PROP FLANGE Figure 72 00 09 10 Main Bearing Installation 16 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines 1 STUD 1 2 20 X 10 11 16 55 BOLT 1 4 20 X 2 5 BOLT 3 8 24 X 3 37 64 60 WASHER FLAT 1 4 INCH 10 SEAL OIL RING 65 WASHER LOCK 1 4 INCH 15 WASHER FLAT 3 8 INCH 70 NUT PLAIN 1 4 20 20 WASHER LOCK 3 8 INCH 75 SEAL OIL 25 NUT PLAIN 3 8 24 80 WASHER PLAIN 3 8 INCH 30 BOLT 1 4 20 X 1 1 2 85
64. Inc N27 i antage Engine Page Number Own General Information March 2005 Superior Air Parts Inc SUPER IS Overhaul Manual AIR PARTS INC O 360 and 360 Series Engines LIST OF FIGURES Figure S 5 o amp d 2 02 00 00 1 Engine Model Number Designation 02 00 00 02 00 00 2 360 Front View 02 00 00 3 O 360 Engine Left Side View 02 00 00 4 O 360 Engine Top View 02 00 00 5 O 360 Engine Rear View 02 00 00 6 360 Engine Front View 02 00 00 7 360 Engine Left Side View 02 00 00 8 360 Engine Top View 02 00 00 9 360 Engine Rear View 02 00 00 10 Ignition Wiring Diagram 02 00 00 11 Oil System Schematic 72 00 08 1 Reserved 08 72 00 08 2 Accessory Housing 72 00 08 3 Crankcase Bearing and Flange Surfaces 72 00 08 4 Cylinder Assembly 72 00 08 5 Piston Assembly 72 00 08 6 Piston Rings and Lands 72 00 08 7 Valve Train 72 00 08 8 Camshaft Assembly 72 00 09 1 Crankcase Bearing Retention Dowel 09 72 00 09 2 Crankshaft Bearing and Oil Pressure Relief Valve 72 00 09 3 Crankshaft Assembly 72 00 09 4 Crankshaft Thrust and Slinger Clearance 72 00 09 5 Crankcase Assembly 72 00 09 6 Connecting Rod and Piston Assembly 72 00 09 7 Connecting Rod Installation 72 00 09 8 Camshaft Assembly 72 00 09 9 Main Bearing Reference Marks 72 00 09 10 Main Bearing Installation 72 00 09 11 Crankcase Attaching Hardware 72 00 09 12 Crankcase Attaching Hardware cont d 72 00 09 13 Sealant Comp
65. Install external pipe plugs using Titeseal thread sealant Torque plug 40 Figure 72 00 09 5 to 40 in Ibs 11 Install piston cooling nozzle if furnished using Locktite 95 Figure 72 00 09 5 torque nozzle to 100 in lbs c NOTE Plug s MS27769 1 may be used in place of piston nozzle s as required by the engine model Torque plug s to 40 in Ibs March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines Crankshaft Inspection and Preparation for Assembly 1 Visually inspect crankshaft for handling damage Check bearing slinger and thrust face surfaces 2 Measure and record main journal dimensions with micrometer Dimensions must be within limits per Fits and Clearances section of this manual 3 Measure and record rod journal dimensions with micrometer Dimensions must be within limits per Fits and Clearances section of this manual Crankshaft Front Oil seal Installation 1 Remove spring from new front oil seal 15 Figure 72 00 09 2 Apply pre lube mixture to the crankshaft propeller flange LD of oil seal Install oil seal with flat side out to prop flange Use tool to carefully stretch seal over flange Re install the spring in seal 15 groove Clean oil from the prop flange Apply oil to crankshaft and front oil seal 15 at their fit locations 5 f required apply pre lube and install the propeller flange bushings 50 55 60 Figur
66. LD 50 NIPPLE 5 WASHER LOCK 55 TUBING INJECTOR 10 BOLT 60 TUBING INJECTOR 15 DIVIDER FLOW 65 BRACKET 20 WASHER LOCK 70 CLAMP 25 SCREW 75 CLAMP 30 PLUG 80 SCREW 35 ELBOW TUBE 85 NUT LOCK 40 FITTING 90 NOZZLE ASSEMBLY 45 FITTING 45 Figure 72 00 09 39 Fuel Injection Manifold Installation x 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR NOTE While rotating the magneto shaft backwards with alignment pin in hole if the shaft stops turning due to internal interference against the alignment pin prior to pin seating pull pin out just far enough to allow the shaft to continue to rotate Re insert the pin and continue rotation until the pin seats as previously described This procedure locates the magneto at the No 1 cylinder firing position 8 Repeat for the 2nd magneto s alignment 9 Bring the engine to the compression stroke on the No 1 cylinder 10 Rotate engine to approx 25 before top dead center using a timing indicator installed in a spark plug hole of the No 1 cylinder or equivalent method 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
67. MAGE FOLLOW THE MANUFACTURER S INSTRUCTIONS FOR EACH CLEANING SOLUTION N27 anlage Engine LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines REPAIR NO 4 PAINTED PARTS Painted Parts Repair Some parts may have had paint removed from either normal operation or during the cleaning and inspection procedures The new crankcase and other aluminum cast components have been alodined after machining and prior to any hardware installation per MIL C 5541 Class 1A Parts requiring the use of paint for protection should be painted in accordance with the following recommendations using material from the list of approved materials See Table 72 00 15 6 All paint used in these procedures should be sprayed on If it is necessary to brush the paint on extreme care must be exercised to prevent excessive accumulation of paint in small corners or void areas of the crankcase NOTE All machined bosses should be masked before painting Do not paint areas under hold down nuts or bolt heads where torque is required Table 72 00 15 6 Consumable Materials for Paint Procedures Material Resin type enamel AMS 3125C or equivalent MIL E 7729 such as Randolph Black 303 Toluene or equivalent AMS3180 or equivalent Federal Spec TT T 548
68. Materials 72 00 09 2 Special Tools and Equipment 72 00 10 1 Equipment and Materials List xiii March 2005 Superior Air Parts Inc Chapter 02 72 N27 i antage Engine Section 00 00 Sub Section e e 03 05 06 07 08 09 10 Page ar BRO ON oO Go OO N N N ch O n General Information SUPER IS Overhaul Manual AIR PARTS INC O 360 and IO 360 Series Engines LIST OF TABLES cont d Table 72 00 11 1 Dimensional Limits 72 00 11 2 Torque Limits 72 00 11 3 Backlash and End Clearance Limits 72 00 11 4 Valve Spring Dimensional Limits 72 00 11 5 Crush Type Gasket Tightening Angles 72 00 12 1 Storage Materials 72 00 13 1 List of Repairs 72 00 13 2 List of Materials 72 00 13 3 List of Equipment 72 00 13 4 List of Repair Codes 72 00 13 5 Reserved 72 00 13 6 Consumable Materials for Paint Procedures 72 00 13 7 Exhaust Valve Seat Standard and Oversize Dimensions 72 00 13 8 Intake Valve Seat Standard and Oversize Dimensions 72 00 13 9 Exhaust Valve Guide Standard and Oversize Dimensions 72 00 13 10 Intake Valve Guide Standard and Oversize Dimensions xiv March 2005 Superior Air Parts Inc N27 i antage Engine 5 s 5 3 S lt 1 o o 72 00 11 14 13 P P P Go A Page N N 20 20 21 21 General Information SUPER IZIR A R P Overhaul Manual O 360 and IO 360 Series Engines N27 i antage Engine INTRODUCTION
69. N GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES IF YOU GET AN EYE INJURY GET MEDICAL ATTENTION b Inspect oil galleys in each crankcase half to ensure they are clean and that 72 00 09 Engine Assembly N27 a anlage Engine SUPERIAR they properly intersect Compressed air may be used 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 INA WELL VENTILATED AREA FREE FROM SPARKS WEAR PROTECTIVE GEAR CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 6 Apply a light coat of pre lube oil to main bearings 5 Figure 72 00 09 2 Install crankshaft 25 Figure 72 00 09 3 in right crankcase half 7 Using a feeler gage check thrust and slinger clearances Clearances must be within limits per Fits and Clearances section of this manual Rotate crankshaft 360 degrees to ensure adequate cheek to case clearance and record Refer to Figure 72 00 09 4 8 Repeat steps 6 and 7 in the left crankcase half and record clearances Lightly lubricate camshaft bore journals and temporarily install the camshaft and rotate in each crankcase half Using feeler gage measure and record end clearance in each half Clearances must be within limits per Fits and Clearances section of this manual 10 Check threaded areas of crankcase halves
70. NTION IN CASE OF SKIN CONTACT days The best method for reducing the likely WASH WITH SOAP AND WATER hood of corrosion is to fly the aircraft at least once every week for a minimum of one hour WARNING ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES PUT ON PERSONNEL PROTECTIVE GEAR Table 72 00 12 1 Storage Materials NOMENCLATURE VENDOR Preservative Oil MIL C 6529 Type ll or equivalent Commercially Available 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 Preservative Oil Mil C 16173 Grade 2 or equivalent Commercially Available Dehydrator plugs AN4062 1 or MS27215 2 Commercially Available Covers as required Commercially Available Moisture Resistant Caps Commercially Available Moisture Resistant Tape Commercially Available 72 00 12 March 2005 Superior Air Parts Inc D erer SUPERIAR The following instructions are general and apply to both temporary and indefinite storage e f engine contains engine oil remove oil sump drain plug and drain oil Replace drain plug torque and safety Remove oil filter Install new oil filter torque and safety e Service engine to proper sump capacity with MIL C 6529 Type Il preservative oil or equivalent or a mixture of 1 part Cortec VpCl 326 to 10 parts regular single grade engine oil This oil is not to be used as
71. Not Start Probable Cause No Fuel Excessive Priming Defective ignition wire Dead battery Malfunction of magneto breaker Lack of sufficient fuel flow Water in fuel injector or carburetor Internal failure Correction Fill with fuel Leave ignition Off and mixture control in Idle Cut Off open throttle and clear cylinders by cranking a few seconds Turn ignition switch On and proceed to start Check with electric tester and replace any defective wires Replace battery Clean points Check internal timing of magnetos Disconnect fuel line and check fuel flow Drain fuel injector or carburetor and fuel lines Check oil screens for metal particles If found complete overhaul of the engine may be required Table 72 00 03 4 Rough Idling Probable Cause Incorrect idle mixture Leak in the induction system Incorrect idle adjustment Uneven cylinder compression Faulty ignition system Correction Adjust mixture Tighten all connections in the induction system Replace any damaged parts Adjust throttle stop to obtain correct idle Check condition of piston rings and valve seats Check entire ignition system Table 72 00 03 5 Engine Not Able To Develop Full Power Probable Cause Leak in the injection system Throttle lever out of adjustment Improper fuel flow Restriction in air scoop Improper fuel Faulty ignition Internal Timing March 2005 Superior Air Parts Inc Correction Tighten all c
72. Oil Suction Screen Oil Drain Plug Vent Line Connection Figure 02 00 00 9 360 Engine Rear View 13 March 2005 Superior Air Parts Inc e 02 00 00 Description and Operation 2 SUPERI A R Overhaul Manual Vantage Engine ATR PARTS 1 O 360 and 360 Series Engines Firing Order Clockwise Rotation 1 3 2 4 Ignition Wiring Diagram E I 2 in Sech gt IER d Figure 02 00 00 10 Ignition Wiring Diagram ta 02 00 00 March 2005 Superior Air Parts Inc Desoriptionand Operation WW SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines To Prop Governor lf installed vematherm Qil Pump Valve Oil Filter T L To From Bypass Valve D es Oil Cooler Oil Cooler Pump Pressure ae Vacuum Pum i Suction Screan P Drive Reliet Valve Splash Oil T eps 4 Piston Drain Sump Cooling Nozzle If installed Idler Gears No 3 Main f Bearing Let Crankcase Right Crankcase Oil Galley Oil Galley Splash Gyl 29 4 To Pistons Crankpins Cams Etc Cyl 2 amp 3 Piston Cooling Nozzle If installed Lifters Lifters Left Side Right Side N
73. Parts Inc Overhaul Manual O 360 and IO 360 Series Engines General Non Destructive Testing All parts must be thoroughly clean and dry prior to the start of the test and again upon completion of the test procedures Refer to Cleaning section of this manual It is important to carefully consider the results of the test to provide accurate interpretation All Ferro magnetic steel parts should be inspected using a magnetic particle inspection method such as MIL STD 1949 performed by appropriately qualified personnel This inspection is especially effective when used on highly stressed parts such as keyways gear teeth splines roots of threads small holes and fillets NOTE Perform the magnetic particle inspection strictly in accordance with the manufacturer s guidelines Failure to do so can result in erroneous readings and the reuse of critical components with hidden damage that may cause engine failure NOTE Care must be taken to prevent overheating or burning of the part as a result of the applied electricity during this test Tests using the dye penetrant method must be thoroughly cleaned of all penetrant and developer residue upon completion of the test Any oils or other fluids used for other non destructive procedures must be thoroughly cleaned from the part upon completion of the test NOTE Upon completion of any cleaning procedure be sure to coat all steel parts with preservative oil Do not handle cleaned part
74. TALLED AND VERIFY THAT THE CABIN DOOR LATCH IS OPEN e DO NOT STAND WITHIN THE ARC OF THE PROPELLER BLADES WHILE TURNING THE PROPELLER vi General Information SUPERIZ RA STS Chapter 01 02 04 72 Section 00 00 00 00 N Sub Section 00 00 00 03 04 Overhaul Manual O 360 and 360 Series Engines TABLE OF CONTENTS General Information Revision History Safety Advisory Table of Contents List of Figures List of Tables Introduction About This Manual Related Publications Obtaining Service Information Abbreviations Consumable Materials List Description and Operation General Description Continued Airworthiness Model Designations Engine Components General Description Specifications Features and Operating Mechanisms Airworthiness Limitations Mandatory Replacement Time Mandatory Inspection Intervals Other Mandatory Intervals or Procedures Distribution of Changes to Airworthiness Testing and Fault Isolation General Troubleshooting Special Procedures General Break In Procedures Special Tools and Equipment Break In Procedures Prior to Break In Start Up Break In Ground Run Break In Flight Operation Post Break In Procedures vii March 2005 Superior Air Parts Inc N27 i antage Engine Page Number wow pure N on General Information WZ SUPERIZ Overhaul Manual antage Engine A
75. TH SOAP AND WATER Fuel Injector and Primer Nozzles Remove the nozzle Submerge in a cleaning solvent such as Stoddard Solvent or MEK or equivalent Allow soaking for several hours Remove from solvent and dry with dry and clean compressed air Ultra sound cleaning methods may also be used WARNING 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 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 CAUTION DO NOT USE A SHARP TOOL TO CLEAN OR DISASSEMBLE FUEL OR AIR BLEED NOZZLES NOTE Under normal conditions the shield and screen are NOT removed from the nozzle assembly If removal is necessary both must be thoroughly cleaned prior to reassembly The shield must have a tight fit on the body March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines Screens and Filters A Fuelsystem filters 1 Fuel screens may be soaked and rinsed in clean solvent and dried with compressed air B Oil system filters 1 screens may be soaked and rinsed in clean solvent and dried with compres
76. UG EXPANSION Figure 72 00 09 3 Crankshaft Assembly March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Z Engine ATR PARTS INC O 360 and 360 Series Engines REAR SURFACE EUR Pup FORWARD MAIN BEARING SLINGER Fan al Figure 72 00 09 4 Crankshaft Thrust and Slinger Clearance 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Z Engine PARTS UN O 360 and 360 Series Engines 40 PLUG 60 STUD 75 INSERT 85 DOWEL 95 PLUG OR PISTON COOLING NOZZLE AS REQUIRED Figure 72 00 09 5 Crankcase Assembly 8 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR Connecting Rod Assembly Inspection 1 Visually inspect the rod assembly 5 Figure 72 00 09 6 for handling damage defects and corrosion 2 Inspect the bore finish This must be smooth and free of burrs 3 Verify correct rod part number 4 Verify the serial number match for each rod and cap assembly 5 Verify and record each rod assembly weight NOTE Difference in rod assembly weights must not exceed 2 grams in opposing pairs 6 Check each piston pin 35 in each rod 5 for fit The pins must slide freely through the rod Subassembly of Connecting Rods Crankshaft 1 Visually inspect the rod bolts and nuts 10 15 Figure 72 00 09 6 Li
77. UR PARTS INC O 360 and IO 360 Series Engines TABLE OF CONTENTS S Ss Page Number ol 5 o 05 Engine Removal General 1 Removal 1 Preservation 1 06 Engine Disassembly General Disassembly Materials Parts for Discard Special Tools and Equipment General Disassembly Procedures Disassembly N N 07 Cleaning General Tools and Materials Cleaning Instructions Degreasing Decarbonizing Scratch and Corrosion Removal Accessory Mounts Fuel Injector and Primer Nozzles Screens and Filters Accessories Preservation and Corrosion Prevention OO N N N viii March 2005 Superior Air Parts Inc General Information SUPERIZ RA STS Chapter Section Sub Section e e N C Overhaul Manual O 360 and 360 Series Engines TABLE OF CONTENTS cont d Inspection and Check General Materials and Tools General Inspection Procedures General Non Destructive Testing Accessory Housing Crankcase Assembly Cylinder Head Cylinder Head Dimensional Inspections Oylinder Barrel Inspections Cylinder Barrel Dimensional Inspections Cylinder Assembly Inspection Piston Inspections Piston Dimensional Inspections Valve Rockers Pushrod Inspection Valve Springs Inspection Crankshaft Crankshaft Counterbore Face Inspection Camshaft Inspection Connecting Rods Inspection 09 Engine Assembly General Fits Clearances and Torque
78. Values Materials Required for Assembly Special Tools and Equipment Engine Assembly Engine Accessory Assembly Installation Storage After Assembly 10 Engine Installation General Preparing Engine for Service Installation of Engine March 2005 Superior Air Parts Inc N27 i antage Engine Page Number O OO O N NN sech F a a a 14 General Information SUPERIZ RA STS N C Overhaul Manual O 360 and 360 Series Engines TABLE OF CONTENTS cont d E EK S 9 o 8 72 00 11 Fits and Clearances General Service Limits 12 Preservation and Storage General Temporary Storage Indefinite Storage Returning an Engine to Service After Storage 13 Repair General Repair Procedures Repair 1 Threaded Area Repair and Stud Replacement Repair 2 Nick and Scratch Repair Repair 3 Crankshaft or Crankpin Repair Repair 4 Painted Parts Repair 5 Crankshaft Oil Seal Surface Repair 6 Cylinder Interior Surface Repair 7 Cylinder Head Cooling Fins Repair 8 Valve Valve Seat and Valve Guide Repair 9 Spark Plug Threaded Insert Repair 10 Rocker Bushing Replacement Repair 11 Connecting Rod Bushing Replacement 14 Testing General Special Tools and Equipment Engine Installation and Testing Procedures Engine Storage After Testing Appendix A Assembly In Process Quality Inspections March 2005 Superior Air Parts
79. Verify security of the rocker covers f Verify security of the sump g Verify security and installation of the inner cylinder baffles March 2005 Superior Air Parts Inc N27 i antage Engine h Verify security of the intake elbows Ensure that the flange of intake elbow fits completely in the recess of the aluminum flange at the cylinder port i Verify installation and safety of the oil pressure relief valve Verify installation and safety of the oil level gage housing and the oil level gage k Verify safety of the fuel pump attachment hardware I Verify correct installation of the magneto harnesses m Check security and routing of the primer lines or fuel injection lines fuel hoses as applicable LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc
80. WASHER 45 COTTER PINS 90 BOLT Figure 72 00 09 43 Alternator Installation 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK oa 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR Overhaul Manual rione Engine O 360 IO 360 Series Engines ENGINE INSTALLATION General This section consists of installation procedures Aircraft engine oil Equipment and Materials to accomplish installation procedures are listed in Table 72 00 10 1 Model specific illustrations and data may be found in the Model Specification Data attached to the Installation and Operation Manual SVIOMO1 for the appropriate engine model Table 72 00 10 1 Equipment and Materials List Item Vendor Commercially Engine Hoist Available Commercially Available Accessory drive pad Commercially gaskets as required Available NOTE Standard aviation shop tools are required Preparing Engine for Service If the engine has been preserved perform the following steps 1 Remove the shipping plugs installed in the upper spark plug holes and inspect the cylinder bores for rust or contamination 2 Remove the shipping plugs installed in the lower spark plug holes and turn the crankshaft through at least twice in order to remove the cylinder preservation
81. WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER Installation of Crank Gear to Crankshaft 1 Inspect the crank gear 5 Figure 72 00 09 3 bolt 15 and lockplate 10 for defects Lightly lubricate with pre lube crank bolt threads and install the gear 5 to crankshaft with bolt 15 and new lockplate 10 Ensure that the gear 5 fits evenly in crank recess aligns with dowel and sits flat when torqued Tapping the gear with a soft aluminum or brass drift will help ensure the seal is properly seated Torque crankshaft gear bolt 15 to 204 Attempt to insert pointed 0 001 in feeler gage or piece of shim stock between the gear and the crankshaft at each of the three scallops There is no allowable clearance between crankshaft and gear Bend lockplate 10 tab up to secure bolt head 2 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 72 00 09 Engine Assembly N27 anlage Engine SUPERIAR Assembly of Case and Crankshaft Assembly 1 With crankcase halves lying on bench with interior sides up ensure that center and rear main b
82. ZIR A R P Cylinder Assembly Inspection 1 Verify cylinder part number and serial 8 Verify piston ring 40 45 part numbers 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 17 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 85 90 105 110 Figure 72 00 09 15 installations Visually check threaded holes for thread integrity and helical coil insert if required Ensure the absence of foreign matter 4 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 b Wipe cylinder bores clean with lint free rag saturated with fast dry solvent 6 Inspect piston 30 Figure 72 00 09 6 part number and weight 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 March 2005 Superior Air Parts Inc 21 Fits and Clearances section of this manual 10 Insert piston rings one at a time in their respe
83. Zinc chromate primer A Aluminum and steel parts 1 Clean and degrease all parts prior to paint procedures WARNING SOLVENT IS TOXIC USE IN WELL VENTILATED AREA PREVENT EYE AND SKIN CONTACT AND DO BREATHE VAPORS IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 2 Apply one coat zinc chromate primer thinned with approximately 2 parts toluene and allow to air dry NOTE Parts from which the paint has not been removed may be repainted without the primer coat 3 Apply one coat of enamel and bake at 250 F for 1 2 hour If allowed to air dry an inferior finish will result March 2005 Superior Air Parts Inc 11 Source Commercially Available Commercially Available Commercially Available WARNING USE THE CORRECT PERSONAL PROTECTION HEATED PARTS WILL CAUSE BURNS B Oylinder Barrels 1 Thoroughly clean all old paint from the cylinder vapor degreaser is well suited for this purpose Superior Air Parts does not recommend painting of cylinder heads for optimum cooling Only alodine is required for cylinder head surface protection Mask off the cylinder head plug flange bolt holes and cover cylinder bore 2 NOTE Masking materials may include tape corks plugs foil metal covers etc 4 Spray a very light coat of zinc chromate primer 0 0005 in maximum thickness on the cylinder
84. able 02 00 00 2 and is also applicable for both 360 and 360 models Table 02 00 00 3 lists Physical Specifications for the engines and Accessories are provided in Table 02 00 00 4 The Model Specification Data MSD provides more specific information by engine type and is available from Superior Air Parts Inc Illustrated views of the O 360 and 10 360 engines identifying key components and sub assemblies are provided in Figures 02 00 00 1 thru 02 00 00 9 of this section and are listed Table 02 00 00 5 for convenience Figure 02 00 00 10 illustrates the engine wiring diagram and Figure 02 00 00 11 illustrates the oil system schematic Table 02 00 00 1 Manufacturer s General Specifications Model O 360 and IO 360 Rated Power Hp 180 Rated Speed RPM RPM 2700 Bore inches In 5 125 Stroke inches In 4 375 Displacement cubic inches In 361 0 Compression Ratio 8 511 Firing Order 1 3 2 4 Spark timing 25 Propeller drive ratio 1 1 Propeller drive rotation Clockwise viewed from rear 02 00 00 March 2005 Superior Air Parts Inc D soripti nmand Operation N27 SUPERIZR Overhaul Manual antage Engine AUR PARTS UNE O 360 and 360 Series Engines Table 02 00 00 2 Accessory Drive Specifications Drive Direction of ER Ratio Rotation Starter 16 556 1 Counter Clockwise Alternator not included 3 250 1 Clockwise Tachometer 0 500 1 Clockwise Magneto 1 000 1 Clockwise Vacuum Pump not included 1 300 1 Counter
85. agnetic particle inspection should be performed whenever the crankshaft is removed from the engine Visually inspect the shaft e Scoring galling pitting corrosion cracks Reject Visually inspect the bearing surfaces e Scoring scratching etching Reject Dimensionally inspect the bearing surfaces e Refer to Fits and Reject if Clearances of this Pevond manual acceptable limits Visually inspect the ID of the forward end of the shaft e Deterioration of the cadmium plating See Repair No 7 Measure the run out of the crankshaft center main bearings and flange by supporting the crankshaft on a flat surface in vee blocks on the front and rear main bearing Reject if run e Measure run out of out exceeds the crankshaft limits of the center main bearing Fits and Clearances Reject if run e Measure run out of out exceeds crankshaft prop limits of the flange Fits and Clearances 13 March 2005 Superior Air Parts Inc Overhaul Manual O 360 360 Series Engines N27 i antage Engine Crankshaft Counterbore Face Inspection Inspection of the counterbored gear mounting flange surface e Fretting galling scoring pitting e Check threads in gear retaining hole for nicks or burrs Check for hole depth by measuring with a gear retaining bolt threaded all the way in Compare the exposed length of the bolt with the thickness of the gear and lockplate e Inspect dowel for damage out of rou
86. ally Available Commercially Available Disassembly WARNING FUEL IS TOXIC AND FLAMMABLE DO NOT BREATHE VAPORS AVOID EYE AND SKIN CONTACT USE PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE Removal of Carburetor and Priming System 1 Remove engine fuel lines 30 Figure 72 00 09 37 and all attaching hardware a Remove engine fuel priming system attaching hardware clamps 25 30 45 Figure 72 00 09 36 screws 35 and nuts 40 Disconnect tube 1 5 10 15 coupling nuts at cylinder head and attaching tee tubes 20 2 Remove the carburetor on O 360 series engines as follows a Remove nuts 1 Figure 72 00 09 37 lockwashers 2 and flat washers 3 from studs four places b Remove carburetor 7 from studs and discard gasket 4 c Remove elbow 5 and discard o ring 6 72 00 06 Engine Disassembly N27 a anlage Engine SUPERIAR Fuel injection system removal 1 Remove engine fuel injection manifold tubing clamps 70 75 Figure 72 00 09 39 nuts 85 and screws 80 2 Disconnect injector tubing 55 60 eight places at fittings 40 elbow 25 and injector nozzle assembly 90 Remove nozzle assemblies 90 four places 3 Remove fuel manifold bracket 1 retaining nuts washers 5 and bolts
87. alve Inner 0 135 1 17 59 67 Spring Valve Outer 0 177 1 30 111 122 Table 72 00 11 5 Crush Type Gasket Tightening Angles Description of Limit Angle approx Oil Suction Screen Gasket 135 Pressure Relief Valve Gasket 90 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 72 00 11 March 2005 Superior Air Parts Inc Fiteand Clearances 2 SUPERIZR Overhaul Manual Vantage Engine AUR PARTS UNE O 360 and IO 360 Series Engines PRESERVATION AND STORAGE General There is no practical procedure that will ensure NOTE Corrosion may reduce engine service corrosion prevention installed aircraft life Primary wear concerns engines Geographical locations season and cylinders piston rings camshaft and usage all influence the degree of corrosion The lifters owner operator is responsible for recognizing the conditions that are conducive to corrosion WARNING HOT OIL MAY CAUSE BURNS TO and for taking appropriate precautions EYES AND SKIN PUT ON SPLASH GOGGLES AND INSULATED GLOVES AND Corrosion can occur in engines that are flown OTHER PROTECTIVE GEAR IN CASE OF only occasionally regardless of geographical EYE CONTACT FLUSH WITH WATER FOR location In coastal areas and areas of high 15 MINUTES SEEK MEDICAL humidity corrosion can occur in as little as a few ATTE
88. angerous 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 LI
89. ary to align timing marks on this gear S Check gear backlash of both idler gears with feeler gauge or dial indicator Backlash limits must be within limits March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 28 specified in Fits and Clearances section of this manual 8 Install tachometer shaft assembly 15 Figure 72 00 09 8 with retaining ring 25 in camshaft 5 at gear end STOP PERFORM IN PROCESS QUALITY INSPECTION 2 REFER TO APPENDIX Cleaning Inspection and Installation Hydraulic Plunger and Cup Assembly 1 Visually inspect and clean hydraulic plunger assemblies 25 Figure 72 00 09 15 with fast dry solvent 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 2 Depress hydraulic plunger piston with thumb to ensure proper spring action a If unit does not compress use blunt end of a 3 32 in diameter rod to dislodge check ball allowing trapped air oil or solvent to escape b Remove rod and try depressing piston again 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
90. as 1000 hours A TBO extension program is in process Model Designations The model number designation is defined in a way that the digits of the model number can easily identify the basic configuration of the engine as described in Figure 02 00 00 1 360 1 2 Fuel System Cylinder Type Crankshaft amp Propeller Type Power Rating Accessory Package Crankcase amp Engine Mount Type Figure 02 00 00 1 Engine Model Number Designation March 2005 Superior Air Parts Inc 02 00 00 Description and Operation N27 i antage Engine SUPERIZ AIR PARTS N C Fuel System Type Overhaul Manual rione Engine O 360 and 360 Series Engines IO Denotes Port Fuel Injection System and opposed cylinder arrangement O Denotes a carbureted system and opposed cylinder arrangement Cylinder Type 360 Parallel valve cylinder 361 cubic inches Model Suffix 1st Digit moou 2nd Digit ech 3rd Digit 4th Digit March 2005 Superior Air Parts Inc Denotes detail engine configuration Crankshaft amp Propeller Type Fixed Pitch Thin wall front main Constant Speed Thin wall front main Fixed Pitch Heavy wall front main Constant Speed Heavy wall front main Fixed Pitch Solid front main Crankcase amp Engine Mount Type 1 Dynafocal Mount 2 Dynafocal Mount Conical Mount Accessory Package Ignition System Fuel System Carbureted O 360 Fuel Injected IO 360
91. ase keys CAUTION DO NOT DRIVE THE VALVES THROUGH THE GUIDES a Remove upper valve spring seats 95 100 inner and outer springs 85 90 and lower valve spring seats 75 80 from rocker box Keep parts for each valve 65 70 separate Hold valves by the stems to keep them from dropping out of the cylinder and remove cylinder from the holding block Reach inside and remove valves If valves are difficult to remove push valves back in and clean carbon from stems CAUTION BE CAREFUL NOT TO SCRATCH OR SCORE PISTONS WHEN REMOVING THE RINGS b Using the piston ring expander tool remove the rings 40 45 Figure 72 00 09 6 from all pistons Remove March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines the rings in order starting with the top ring and work down 5 Remove and disassemble the hydraulic lifter assembly CAUTION MAINTAIN THE PARTS OF EACH TAPPET ASSEMBLY TOGETHER DURING ALL OVERHAUL OPERATIONS ALL COMPONENT PARTS BE REASSEMBLED WITH THEIR ORIGINAL MATING PARTS AND EACH ASSEMBLY REINSERTED IN ITS ORIGINAL LOCATION a Using hydraulic tappet tool remove the pushrod socket 30 Figure 72 00 09 15 by placing heavy grease on ball end of the T By inserting the ball end in the tappet and withdrawing the socket will adhere to the grease b Using the hollow end of the tool push it over the plunger and withdraw the plunger If the tool is n
92. be directly related to an improperly installed or restricted breather line Maintain shallow climb Use caution to not overheat the cylinders Should overheating occur reduce power and adjust mixture appropriately Monitor RPM oil pressure oil temperature and cylinder temperature During the first hour of operation maintain level flight at 7596 power Vary the power setting every 15 minutes during the second hour between 65 75 Avoid long descents at cruise RPM and low manifold pressure could cause ring flutter Continue flying at 65 75 power and full rich mixture on subsequent flights while March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines monitoring RPM Pressure Oil Temperature Cylinder Head Temperature and oil consumption Continue until oil consumption stabilizes and cylinder head temperatures drop and stabilize These are indications that the piston rings have seated and the cylinders are broken in At no time should cylinder head temperature be allowed to exceed recommended maximum cruise limit 430 F After landing check again for any fuel and or oil leaks or other discrepancies and repair as required Post Break In Procedures After break in drain all mineral oil Examine this oil for foreign matter or metal particle content Fill with ashless dispersant of the appropriate grade for the expected normal operating conditions and ambient temperature 72
93. cordance with the airframe manufacturer s instructions August 2004 Superior Air Parts Inc 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 e Attach a hoist to the engine lifting eye bracket and relieve the weight from the engine mounts Only the lifting eye bracket installed on the backbone of the crankcase should be used to hoist the engine e Remove the engine mounts and engine as follows 1 Loosen and remove the engine mounts bolts in accordance with manufacturer s instructions 2 Hoist the engine vertically out of the nacelle and clear of the aircraft NOTE Hoist the engine slowly and make sure that all wires lines and hoses have been disconnected 3 Install the engine onto a transportation stand dolly or an engine shipping container base e Install protective covers plugs on remaining open fuel oil hydraulic lines and electrical leads and exhaust ports Preservation e If the engine is to be stored for longer than 30 days refer to the Preservation and Storage section of this manual for procedures and materials 72 00 05 Engine Removal LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK a 72 00 05 March 2005 Superior Air Parts Inc Engine Removal SUPER IZIR A R P Overhaul
94. crankshaft ends are retained by two bolts with self locking nuts per cap Caps are tongue and groove type for improved alignment and rigidity Camshaft Valve Operating Mechanism The camshaft is located above and parallel to the crankshaft The camshaft actuates hydraulic lifters that operate the valves through pushrods and valve rockers Crankcase The crankcase is made from aerospace grade stabilized structural aluminum alloy The assembly consists of two reinforced aluminum alloy castings fastened together by means of studs bolts and nuts The main bearing bores are machined for use with precision type main bearing inserts Accessory Housing The accessory housing is made from an aluminum casting and is fastened to the rear of the crankcase and the top rear of the sump Oil Sump The sump incorporates an oil drain plug oil suction screen mounting pad for carburetor or fuel injector the intake riser and intake pipe connections March 2005 Superior Air Parts Inc 16 Cylinders Millennium Cylinders are used exclusively These air cooled cylinders are manufactured by screwing and shrinking the two major parts head and barrel together The cast heads are made from a special aluminum alloy All barrels are made from forgings produced to aerospace specifications They are internally choked and honed to allow optimal operating conditions for the rings and pistons at operating temperatures Pistons The pistons
95. ctive grooves 11 Using a ring expander install rings to piston with the lower ring first then middle and top NOTE Numbers on the ring face indicate top of the piston or up 12 Check side clearance of each ring Piston compression ring 45 in top groove is 0 0025 to 0 0055 in Piston compression ring 45 in 2nd groove is 0 000 to 0 0040 in Piston oil control ring 40 in 3rd groove is 0 0020 to 0 0040 in NOTE Side clearance is checked with ring in its respective groove and flush with outside edge of piston 72 00 09 Engine Assembly SUPERIZR AIR PARTS IN C 10 15 20 25 20 35 45 Overhaul Manual 360 10 360 Series Engines PUSH ROCKER ARMS BUSHING ROCKER ARM SHAFT CAP ROCKER SHAFT PLUNGER ASSY PUSH ROD SOCKET SEAL TUBE BOTTOM SHROUD TUBE SEAL TUBE 120 125 130 135 140 145 150 GASKET VALVE COVER VALVE COVER SCREW GASKET EXHAUST WASHER FLAT WASHER LOCK NUT PLAIN Figure 72 00 09 15 Cylinder Valve Train and Spring Assembly March 2005 Superior Air Parts Inc 22 72 00 09 Engine Assembly SUPERIZ Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines CONNECTING ROD ARROW SHOWS PISTON PIN BEING PUSHED INTO PISTON PISTON PIN PLUG PISTON PIN OIL CONTROL RING NO 1 PISTON N COMPRESSION RINGS RIGHT SIDE OF CRANKCASE Figure 72 00 09 16 Piston
96. d 0 38 in nut 85 to 300 in lbs Install safety wire 0 041 in at accessory location by cam gear 14 Torque the three drilled shank 0 25 in belly bolts 95 and slotted nuts 100 to 55 60 in lbs Install safety wire 0 032 in T 72 00 09 Engine Assembly N27 anlage Engine SUPERIZR AIR PARTS IN C Overhaul Manual oT Engine O 360 and 360 Series Engines 10 NUT PLAIN 1 2 X 20 20 25 40 45 50 SEAL CYLINDER BASE CYLINDER ASSEMBLY NUT PLAIN 3 8 X 24 SPACER GASKET COVER SCREW 75 NIPPLE DRAIN 80 HOSE 85 CLAMPS 90 TUBE ASSEMBLY Figure 72 00 09 17 Cylinder Assembly and Head Oil Drain Line March 2005 Superior Air Parts Inc Ss 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Engine O 360 and 360 Series Engines AIR PARTS IN C e h P Ar I f RIGHT SIDE OF CRANKCASE CONNECTING ROD RING COMPRESSION TOOL 20 Aa NO 1 PISTON Figure 72 00 09 18 Piston Assembly with Ring Compressor Tool 26 nN March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly 2 SUPERIZ Overhaul Manual Engine ATR PARTS INC O 360 and IO 360 Series Engines Figure 72 00 09 19 Cylinder Base Nuts Sequence of Tightening Left Side Shown 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIAR Installation of Idler Shafts a
97. d 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 Refer to Figure 72 00 09 29 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 b 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 96 to 108 in Ibs 7 Position the clamps 35 over the hose coupler 20 to secure each side of the connection Tighten to 10 in Ibs 38 March 2005 Superior Air Parts Inc N27 i antage Engine 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines 1 BAFFLE ASSEMBLY 5 RETAINER 10 HOOK RETAINER Figure 72 00 09 26 Inner Cylinder Cooling Baffle x 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines
98. e 72 00 09 3 Pull through with puller tool Refer to Figure 72 00 09 3 for bushing positions 6 Install and secure the crankshaft to a vertical support stand PON 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 72 00 09 Engine Assembly N27 anlage Engine SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines Figure 72 00 09 1 Crankcase Bearing Retention Dowel 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Dirige Engine AIR PARTS ING O 360 and 360 Series Engines 5 MAIN BEARINGS 10 FRONT MAIN BEARINGS 15 SEAL OIL FRONT 20 LIFTER BODY 25 VALVE ASSY OIL RELIEF 30 GASKET COPPER 35 SPRING 40 BALL Figure 72 00 09 2 Crankshaft Bearing and Oil Pressure Relief Valve 5 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 360 Series Engines 10 15 20 25 50 55 60 65 GEAR CRANKSHAFT LOCKPLATE SCREW DOWEL STEPPED CRANKSHAFT ASSY BUSHING LONG BUSHING INDEXED BUSHING SHORT PL
99. e 72 00 08 7 e Check for damaged badly worn pitted or scored tips and rod sockets e Check rocker bushing Replace ID at two 2 locations bushing per 90 apart Refer to Fits Repair and Clearances No 13 Reject Pushrod Inspection Inspect pushrods for wear fit and alignment Refer to Figure 72 00 08 8 e Inspect for excessive Reject if in wear or damage excess e Rod must be straight Reject if in within 0 010 inch excess March 2005 Superior Air Parts Inc 11 Valve Springs Inspection Check valve springs using a spring tester Refer to Figure 72 00 08 7 e Reference spring load and deflection limits in Replace if Fits and Clearances weak section of this manual 72 00 08 Inspection and Check SUPERIZR Overhaul Manual Z Engine PARTS UN O 360 and 360 Series Engines PLUNGER EN SOCKET Ta PUSH ROD TN Ma N Sg b RS TUBE EXHAUST iy vave 5 E GA NDT AN Due P EN INTAKE E BUSHINGS VALVE Kk ROCKER ARM BUSHING BOSS ROCKER ROCKER VALVE EXHAUST VALVE SHAFT SHAFT CAP ROCKERS 227 LOWER SEAT e EXHAUST VALVE UPPER SEAT INTAKE VALVE 27 LOWER SEAT d OUTER VALVE SPRINGS INNER VALVE T k m4 CAP KEYS SPRINGS INTAKE VALVE UPPER SEAT Figure 72 00 08 7 Valve Train 12 March 2005 Superior Air Parts Inc 72 00 08 Inspection and Check SUPER IZIR R P Crankshaft NOTE m
100. e left case half and bearing properly seated the helper places a tool inserted through the 4 connecting rod piston pin hole The case is rotated to wedge the tool against the case half Firm pressure is maintained on crankcase Refer to Figure 72 00 09 14 NOTE Itis imperative that the helper maintains constant pressure on the left case half throughout the assembly process until case halves are snugged together Enough case assembly hardware must be installed to not allow the front main bearing to shift from the locating dowels March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 11 20 Check thread and nose seal 15 Figure 72 00 09 2 for proper placement 21 Install camshaft in left case half and have helper hold in place 22 Mate the right case half to the left case half by carefully aligning rear through studs and front 3 8 in nose bolts NOTE Care should be taken not to push out the 3 8 in nose bolts 5 Figure 72 00 09 11 causing the o rings 10 to fall out NOTE 23 Ensure that nose seal is properly in place 24 Install backbone bolts 30 breastbone bolts 90 95 and nose bolts 5 with appropriate hardware Snug all uniformly Check for free case to crank rotation 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 AR
101. e rocker shaft caps thrust buttons in each rocker shaft 2 Perform inspection of the accessory housing as follows a Visually inspect the housing for damage and general condition b Verify proper installation of the plugs and fittings c Verify proper installation of the tachometer shaft seal d Verify safety of the oil pump housing e Ensure smooth rotation of the oil pump drive shaft f Verify correct installation of the fuel pump plunger as required Inspection 4 A Inspect and verify proper installation of the accessory housing rocker covers inner cylinder baffles sump cylinder drain tubes induction intake system accessory adapters and accessories This quality inspection shall include visual and physical inspections of the complete engine assembly This inspection shall be accomplished after the engine assembly has been completed and prior to engine test Perform the inspections as follows 1 Perform complete visual and physical inspections of the engine as follows N27 i antage Engine SUPERIZ Overhaul Manual R PARTS INC O 360 360 Series Engines A a Inspect for loose or missing parts or components b Verify security of the accessory housing and accessory adapters to housing c Verify security of the accessories including magnetos carburetor or fuel injector servo starter and alternator d Verify security of the cylinder drain tubes e
102. e rocker shaft 15 valve rocker arms 5 and the exhaust valve stem cap 115 from cylinder assembly Remove the pushrod 1 by grasping the rod end and pulling it through the rod tube 40 Remove nut 60 spring 55 and lockplate 50 Pull rod tube through cylinder head and discard tube seals 35 45 a Remove cylinder assembly by removing nuts from cylinder base Remove oylinder by pulling straight away from crankcase As the cylinder is being pulled away hold the piston to prevent damaged Discard cylinder base seal CAUTION THE CONNECTING ROD MUST BE SUPPORTED TO PREVENT DAMAGE TO THE SUPPORT EACH 72 00 06 Engine Disassembly SUPERIAR CONNECTING ROD WITH HOLD DOWN PLATES TOOL OR RUBBER BANDS OR DISCARDED CYLINDER BASE SEALS LOOPED AROUND THE CYLINDER BASE STUD 3 Remove the piston pin 35 Figure 72 00 09 6 using a piston pin drive tool Drive pin 35 from piston to remove piston 30 from the connecting rod 5 NOTE Removal of the remaining cylinders and pistons may be done in any sequence but less turning of the crankshaft is involved if the cylinders are removed in firing order 1 3 2 4 4 Compress valve springs 90 95 Figure 72 00 09 15 with spring compressor tool while supporting cylinder far enough to remove the valve cylinder keys 105 110 NOTE Ifthe valve keys are stuck in the spring seat a light blow with a leather mallet on top of the compressor tool will rele
103. earings 5 Figure 72 00 09 2 are installed and lubricated with pre lube 2 Lubricate tappet bore holes and tappet bodies 20 shank and install bodies in case 3 Apply cam pre lube liberally to tappet 20 faces and camshaft lobes 5 Figure 72 00 09 8 moly graphite grease is recommended 4 Place camshaft 5 on bench beside case halves 5 Clean mating surfaces of both case halves including nose seal area with fast dry solvent 6 Clean nose seal OD with fast dry solvent 7 Place front main 10 Figure 72 00 09 2 bearing temporarily in place in the left crankcase half making sure the bearing is properly seated on the 2 locator dowels NOTE front main bearing 10 unlike the center and rear main bearings splits on the horizontal centerline of the engine Use a felt marker to trace on the front bearings halves at the intersection between the crankcase parting flanges and the bearing Make a vertical reference mark on both the bearing half and each case half at a convenient point along the line of intersection This locates the bearing both radially and axially Make two parallel marks across both bearing shells at their intersection for alignment reference Refer to Figure 72 00 09 9 CO 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
104. en using RTV 102 the coating must not be too thick A thin translucent coating is sufficient Wipe off any excess on the inside and outside edges Refer to Figure 72 00 09 13 Because this sealant will dry quickly when applied this thinly it is important to proceed quickly until case halves are together and snug A helper is required during this assembly process 72 00 09 Engine Assembly N27 anlage Engine SUPERIAR 17 Lay a single line of silk thread on the RTV sealant at the centerline of the sealing surface and loop the inside of each bolt hole The tail of the thread should extend beyond the mating surface approximately 0 25 in to the accessory gasket surface at the rear the nose seal surface at the front and the sump gasket surface at the bottom Refer to Figure 72 00 09 13 18 A helper places the left case half up to the crank assembly with the connecting rods protruding through their appropriate cylinder holes and allows the assembler to align the front main bearing inserts with the dowels in the crankcase The helper uses light pressure against case half as the assembler adjusts front main bearing until it snaps in place NOTE Using a tool to gently lift up on bearing while holding case half tight to crankshaft will aid in determining if bearing is properly seated When properly seated the bearing and case will move slightly up and down together as the front of the bearing is pried up and down 19 With th
105. eral This section has the procedures and illustrations necessary to assemble the Vantage O 360 and IO 360 series engine Fits Clearances and Torque Values Fits clearances and torque values to be established during repair or assembly are listed in the applicable paragraph so that the unit can be assembled without reference to another section of the manual NOTE Limits followed by a letter T indicate tight i e interference fit An example is the valve guide in the cylinder head Where no T exists the fit is a clearance dimension Materials Required for Assembly Materials required for assembly are listed in Table 72 00 09 1 below NOTE Equivalent substitutes may be used for listed items Table 72 00 09 1 Assembly Materials Material Acetone or Methyl Ethyl Ketone MEK Assembly Grease Lubriplate No 105 Cleaning Solvent Copper Based Anti seize Fel Pro C5 A Fuelube Loctite 241 P N 27183 Loctite No 2 Gasket Sealant P N 30514 Oil Aviation Grade Mineral Non detergent Permatex P N 27100 Source Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available N27 anlage Engine Pre Lube Mixture approx 15 STP and 85 Aviation Mineral Oil RTV 102 Silicon Sealant Safety Wire 0 032 in Type 304 Stainless P N MS20995
106. ersize A Diameter In 2 0807 2 0822 2 0857 2 0872 2 0907 2 0922 2 1007 2 1022 2 1107 2 1122 2 Install valve guides as follows a Prior to installation of a new valve guide measure the guide hole to determine if an oversize guide must Refer to Tables 72 00 13 9 and 72 00 13 10 and Figure 72 00 13 6 Use a hole plug gage and measure each valve guide hole Determine if a standard size or oversize guide must be used Refer to Tables 72 00 13 9 and 72 00 b Fasten the cylinder in place on a guide replacement tool Set the tool Part Number In SL72057A STD SL72057A P05 0 005 SL72057A P10 0 010 SL72057A P20 0 020 SL72057A P30 0 030 Valve guide replacement 1 Remove valve guides as follows a Use a valve guide puller to the head of a 94 16 bolt Place the tool retainer over the valve guide inside be used the rocker box Insert the 34 16 bolt into the retainer and valve guide From inside the cylinder insert the 3 8 24 bolt into the end of the larger bolt Tighten the 3 8 bolt until it is against the valve guide Turn the nut in the rocker box clockwise until 13 10 the valve guide is out of the cylinder head 20 March 2005 Superior Air Parts Inc SUPERIAR to the appropriate angle for the guide being installed If an oversize guide must be installed use an appropriate size reamer in a drill press Ream the valve guide hole to the specified size Measure the hole again and confirm p
107. etween the crankshaft gear camshaft gear and idler gear with 1 cylinder on TDC top dead center Verify the gear lash of the idler gears with the crankshaft gear and camshaft gear Refer to Fits and Clearances Gear Backlash Table 72 00 12 3 Verify installation of the tachometer shaft bushing and snap ring in the camshaft Inspection 3 A Inspect and verify proper installation safety and clearances of the cylinder valve train and accessory housing subassembly prior to rocker cover and accessory housing installation This quality inspection shall include visual inspection of assembly and safety techniques A physical check of clearances shall be performed as described in this list This inspection shall be accomplished during the engine assembly process as March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines noted in the Assembly section of this manual Perform the inspections as follows 1 Perform a valve train inspection as follows a Inspect the pushrod tube seals for proper installation b Verify security and installation of the nut and lock tab securing the spring clip to each pushrod tube c Verify installation of the exhaust valve rotator cap on the valve stem of each exhaust valve d Verify the dry tappet clearance for each rocker arm in accordance with the Fits and Clearances section of this manual e Verify installation of th
108. eve is approximately 0 13 in from the face of the boss the inserting tool should be held tightly by the handle The sleeve must be rotated counterclockwise which will free the left half turn of the insert c Slide the sleeve toward the top of the mandrel and check that the top of the insert projects above the boss d Rotate the mandrel until the insert disappears from sight Stop the turning action and remove the tool e The top of the insert should be one half turn from the face of the boss and the tang end should not protrude into the combustion chamber 8 Set the insert as follows a Break off the tang of the insert at the location of the notch b Use an expander tool to secure the insert in the plug hole Set the limit of expansion by fixing the stop nut on the expanding tool at the correct position c Assemble a staking sleeve over the mandrel until the sleeve meets the boss Stake the insert by striking the top of the sleeve a light blow with a hammer This will create a slight chamfered edge around the edge of the tapped hole d Remove the staking sleeve release the adjusting screw and remove the expanding mandrel from the insert LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK 28 March 2005 Superior Air Parts Inc A SUPER IZIR R P Overhaul Manual O 360 and IO 360 Series Engines R
109. ew stud 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 March 2005 Superior Air Parts Inc 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 d Coat threads of new stud with lubricant or Loctite and drive stud to correct depth with suitable stud driver Torque IAW Fits and Clearances section of this manual Preservation Coat threads of repaired threaded areas or studs with lubricant or preservative oil LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUPERIZ Overhaul Manual KZ Engine AIR PARTS INC O 360 and IO 360 Series Engines 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
110. f the flange area to reduce distortion Polishes and re plates pilot diameter of crankshaft forward end Hones glazed interior surfaces of hardened cylinders Repairs nicks chips cracks Reseats polishes re faces valves and adjoining parts Replaces the spark plug threaded insert Replaces the bushing in intake and exhaust rockers Replaces the bushing in small end of the connecting rod Table 72 00 13 2 List of Materials Material Dress wheel polishing Thread lubricant Locktite Abrasive crocus cloth Zinc chromate primer AMS 3110 or equivalent per MIL P 8585 Sodium dichromate Enamel paint AMS 3125C or equivalent per MIL E 7729 Source Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Toluene AMS 3180 or equivalent per TT T 548 Alodine Mil C 5541 Class 1A or equivalent March 2005 Superior Air Parts Inc Commercially Available Commercially Available WW SUPERIZ Overhaul Manual antage Engine AUR PARTS INC O 360 and IO 360 Series Engines Table 72 00 13 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 Commercia
111. f the seat wear has progressed to the extent that the entire face of the 159 narrowing wheel must be brought into contact with the seat in order to achieve the specified March 2005 Superior Air Parts Inc 19 diameter the seat must be replaced Valve seat replacement 3 Valve seats that are damaged worn or loose must be replaced Use the following procedure or an equivalent NOTE The valve guide must be replaced at the same time as a valve seat is replaced This ensures concentric grinding of the valve seat See discussions later in this Repair for guide replacement procedures NOTE For the purpose of removing valve seats a tool may be fabricated from threaded bar stock hardware and sponge material NOTE The valve seats are an interference fit installation The cylinder must be heated and the valve seat cooled The resulting difference in size will allow the seat to be removed from the cylinder head WARNING USE THE CORRECT PERSONAL PROTECTION HEATED PARTS WILL CAUSE BURNS 4 Heat the cylinder to 575 F and secure to a fixture b Soak the removal tool sponge in cold refrigerated water Insert the tool through the valve seat The seat should shrink slightly and stick to the sponge Pull the tool back out with the seat Use care to not tilt the seat during this process NOTE This procedure must be performed as quickly as possible Measure the ID of the valve seat recess to determine which overs
112. fects or other dangerous conditions Tools and Materials For tools required during cleaning refer to Table 72 00 07 1 For consumable materials required during cleaning refer to Table 72 00 07 2 Table 72 00 07 1 Equipment Required for Cleaning Item Vendor Brush soft and stiff Commercially bristles Available Commercially Immersing tank Available Commercially Scraper wood Available l Commercially Grit blaster Available NOTE Equivalent substitutes may be used Cleaning Instructions Two 2 processes are used in cleaning engine parts degreasing to remove dirt and sludge soft carbon and the removal of hard carbon by decarbonizing brushing or scraping and grit blasting March 2005 Superior Air Parts Inc CAUTION DO NOT USE SAND OR METALLIC ABRASIVES WITH THE GRIT BLASTING EQUIPMENT Degreasing Degreasing is accomplished by immersing or spraying the part in solution of white furnace oil 38 40 specific gravity or another suitable solvent such as Varsol or Perm A Chlor Table 72 00 07 2 Materials Required for Cleaning Vendor Cleaning solvent or degreaser such as white furnace oil Varsol or Perm A Chlor Decarbonizing solutions such as Gunk Penetrol Carbrax Super Chemco or Gerlach 70 Commercially Available Commercially Available Isopropyl Alcohol Commercially Available Aerosol electrical contact Commercially cleaner Available 9 Commercially Lubricating Cil SAE 20
113. ghtly lubricate bolt shanks and threads with pre lube oil 2 Verify bearing part number and size for crankshaft and model application 3 Install the connecting rod bearing shell 1 in each rod and cap 5 4 Apply pre lube oil to the bearing shell 1 b Apply pre lube oil to the rod bearing journals of crankshaft Insert 2 rod bolts through each rod cap Begin with the lowest serial number rod cap and install it to the crankshaft with its matching rod 5 at the 1 most forward rod location a Install with serial numbers in same plane and down towards oil sump Refer to Figure 72 00 09 7 b Install the nuts with flat side to connecting rod Refer to Figure 72 00 09 7 Tighten moderately to check fit prior to torque Tighten each rod nut to bolt 10 15 Figure 72 00 09 6 evenly to 480 in lb torque 8 Rotate each connecting rod 5 after torque to check for smooth and free rotation 6 a March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 9 Measure and record connecting rod to crankshaft side clearance Clearance must be within limits per Fits and Clearances section of this manual WARNING LUBRICANTS ARE TOXIC AND FLAMMABLE DO NOT BREATHE VAPORS BEFORE YOU USE READ THE MATERIAL SAFETY DATA SHEET MSDS FROM THE MANUFACTURER OR SUPPLIER USE IN A WELL VENTILATED AREA FREE FROM SPARKS WEAR PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH
114. gine Disassembly SUPERIAR Overhaul Manual O 360 and 360 Series Engines Table 72 00 06 3 Special Tools and Equipment Nomenclature Compressor Piston Ring Expander Piston Ring Puller Slide Hammer Medium Compressor Valve Spring Bar Intercylinder Baffle Tool Puller Valve Guide Puller Set Oil Seal Stand Vertical Nose Support Tool Hydraulic Tappet Removal General Disassembly Procedures e Place engine in horizontal position on a transfer cart WARNING ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES PUT ON PERSONNEL PROTECTIVE GEAR e Remove the oil drain plug and drain the oil from the engine if not previously drained e Remove the starter ring gear support e Perform visual inspection during disassembly immediately after disassembly All individual parts should be laid out in an orderly manner as they are removed e All loose studs cracked baffles and loose or damaged fittings should be tagged to prevent being overlooked during regular inspection e all components and parts as they are removed Bag loose assemblies or attaching hardware e Prior to starting the component or parts disassembly phase engine may be placed on a vertical nose support stand March 2005 Superior Air Parts Inc Source Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commercially Available Commerci
115. he dehydrator plugs have changed color in one half or more of the cylinders all desiccant material on the engine must be replaced The cylinder bores of all engines prepared for indefinite storage must be re sprayed with corrosion preventive oil mixture every 90 days Returning an Engine to Service After Storage Remove all seals and all desiccant bags Remove cylinder dehydrators and plugs from upper and lower spark plug holes WARNING TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH BEFORE MOVING THE PROPELLER DO THE FOLLOWING March 2005 Superior Air Parts Inc Overhaul Manual O 360 360 Series Engines e DO NOT STAND WITHIN THE ARC THE PROPELLER BLADES WHILE TURNING THE PROPELLER e VERIFY ALL SPARK PLUG LEADS ARE DISCONNECTED e VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT THEY ARE IN THE OFF POSITION AND P LEADS ARE GROUNDED e THROTTLE POSITION CLOSED e MIXTURE CONTROL IDLE CUT OFF SET BRAKES AND BLOCK AIRCRAFT WHEELS ENSURE THAT AIRCRAFT e TIE DOWNS ARE INSTALLED AND VERIFY THAT THE CABIN DOOR LATCH IS OPEN Rotate propeller by hand for several revolutions to remove preservative oil Remove oil sump drain plug and drain the corrosion preventive oil mixture Replace drain plug torque and safety Remove oil filter Install new oil filter torque and safety Service the engine with oil in accordance with the maintenance instructions Ser
116. he tool in the spark plug hole so that the edges of the tool cut into the top thread of the insert 2 Rotate the tool counterclockwise to unscrew and remove the threaded insert from the hole Inspect the condition of the tapped hole after removal of the insert in accordance with the Inspection and Check section of this manual Assemble the insertion tool with new insert as follows 1 Withdraw the mandrel portion of the tool beyond the recessed section of the sleeve Place insert into the recess area 2 Allow the mandrel to advance to engage its slotted end with the tang of the insert 3 Rotate the mandrel clockwise and press slightly This engages the insert in the threaded end of the sleeve 4 Continue to rotate the mandrel while holding the sleeve This secures the insert firmly on the insertion tool 5 Wind the insert through the threaded portion of the tool sleeve to within one half turn of the end of the coil 6 Keep the insert tight on the tool to prevent unwinding and facilitate the installation of the insert Wind the insert so that the adjacent turns of the insert are in contact with each other This eliminates the possibility of crossed threads March 2005 Superior Air Parts Inc 27 7 Screw the insert into the hole a Be sure that the first coil of the insert picks up the first thread of the hole As the tool is turned the insert will advance into the hole b When the face of the sle
117. inspect piston general condition Refer to Figures 72 00 08 5 and 72 00 08 6 e Inspect the top of the piston for excessive pitting Reject cavities or surface distortion e Inspect the piston lands piston pin holes and bosses Reject for excessive wear or damage e Inspect the piston ring in grooves clearances in excess of limits Refer to Fits and Clearances March 2005 Superior Air Parts Inc Piston Dimensional Inspections Inspect pistons for correct dimensions Refer to Figure 72 00 08 5 e Side clearance Refer to Fits between piston and and ring Clearances NOTE These pistons are ground with a slight taper from the skirt to the head The exception is the lands between the top compression and oil control rings which are ground parallel The clearance on wedge type compression rings must be measured with ring flush to outside edge of piston as shown in Figure 72 00 08 6 in order to obtain a true check of the side clearance Refer to Fits and Clearances e Inside diameter of piston pin hole NOTE No pitting or corrosion is permitted in this area Clearance between piston skirt and Refer to Fits cylinder and piston and diameter at top and Clearances bottom 72 00 08 Inspection and Check SUPERIZR Overhaul Manual Wantage Engine cm O 360 and 360 Series Engines EXHAUST VALVE cvuNpER CYLINDER SEAT Geer BARREL NS MOUNTING Ni SS FLANGE 5 us NUTS
118. instructions Installation of Engine e Install engine per airframe manufacturer s instructions Use only the lifting eye bracket installed on the backbone of the crankcase to hoist the engine e Consult airframe manufacturer s instructions for engine to airframe connections Remove all protective covers plugs caps and identification tags as each item is connected or installed CAUTION FAILURE TO PURGE THE AIRCRAFT FUEL TANKS AND LINES CAN CAUSE ERRATIC FUEL SYSTEM OPERATION AND DAMAGE TO ITS COMPONENTS The aircraft fuel tanks and lines must be purged to remove all contamination prior to installation in the main fuel inlet line to the fuel pump or engine e Install the approved propeller in accordance with the manufacturer s instructions WARNING DO NOT INSTALL THE IGNITION HARNESS B NUTS ON THE SPARK PLUGS 72 00 10 Engine Installation LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS UNE O 360 360 Series Engines UNTIL THE PROPELLER INSTALLATION IS COMPLETED FAILURE TO COMPLY COULD RESULT IN BODILY INJURY WHEN THE PROPELLER IS ROTATED DURING INSTALLATION a 72 00 10 March 2005 Superior Air Parts Inc Engine Installation SUPERIAR Overhaul Manual Bag Engine O 360 and IO 360 Series Engines FITS AND CLEARANCES General These limits provide dimensions clearances and interference fits necessary to repair and overhaul Superior Vantage O 360 and 1O 360 series engines Ser
119. ion to the first shoulder locking the shaft 72 00 09 Engine Assembly N27 i antage Engine SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines BOTTOM VIEW _ 3 TUBE PRIMING 5 TUBE PRIMING 10 TUBE PRIMING lt j 15 TUBE PRIMING 40 i 20 TEE TUBE 30 25 25 CLAMP amp 30 CLAMP 35 SCREW 40 NUT LOCK d 45 CLAMP TUBE Figure 72 00 09 36 Fuel Priming System 98 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine PARTS UN O 360 and 360 Series Engines 1 GASKET 5 CARBURETOR 10 WASHER PLAIN 15 WASHER LOCK 20 NUT PLAIN 25 FITTING 30 HOSE ASSEMBLY FUEL Figure 72 00 09 37 Carburetor Installation 54 on March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Engine PARTS UN O 360 and 360 Series Engines 1 GASKET 5 SPACER 10 THROTTLE BODY FUEL INJECTION SERVO 15 WASHER FLAT 20 WASHER LOCK 25 NUT PLAIN 30 HOSE ASSY 35 HOSE ASSY Figure 72 00 09 38 Fuel Injection Servo Installation 55 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines TOP VIEW 9 80 TEN 70 e 85 1 MANIFO
120. ior Vantage Engine Service Bulletins may be obtained by writing to Superior Air Parts 621 South Royal Lane Suite 100 Coppell Texas 75019 or call 972 829 4600 or on the web at www superiorairparts com 04 00 00 Airworthiness Limitations N27 i antage Engine LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK a 04 00 00 March 2005 Superior Air Parts Inc Ainwonhiness Limitations SUPER IS Overhaul Manual N27 a anlage Engine O 360 and IO 360 Series Engines TESTING AND FAULT ISOLATION General This section provides the Fault Isolation procedures Review all probable causes given The engine electrical diagram and engine oil system schematic are provided as an additional aid in determining probable cause Testing is limited to continuity checks of the ignition wiring harness e Special tools and equipment are listed in Table 72 00 03 1 e Fault Isolation procedures are listed in Table 72 00 03 2 e engine ignition diagram is provided Figure 02 00 00 10 e The engine oil system is provided in Figure 02 00 00 1 1 Table 72 00 03 1 Special Tools and Equipment Item Electrical Tester Vendor Commercially Available Table 72 00 03 2 Abnormal Operating Procedures Symptom Engine will not start Rough Idling Engine Not Able to Develop Full Power Rough Engine Operation Low Power and
121. ize seat must be installed Refer to Tables 72 00 13 7 and 72 00 13 8 N27 i antage Engine SUPERIAR WARNING USE THE CORRECT PERSONAL PROTECTION POLISHING AND GRINDING WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES 7 Use an appropriately sized cutter installed with its pilot and drive on a drill press Cut the recess in the cylinder head to proper oversize Remove no more metal than required to clean the major diameter of the seat recess NOTE The cutter pilot shall engage the ID of the valve guide hole in the cylinder head Overhaul Manual O 360 and IO 360 Series Engines 8 Place the new valve seat onto a replacement drift WARNING USE THE CORRECT PERSONAL PROTECTION HEATED PARTS WILL CAUSE BURNS 9 Heat the cylinder to 575 F and secure to a fixture Place the new seat on a replacement drift Drive the new seat into the recess by tapping the drift with a hammer 10 Grind the face of the new seat as described above in this Section Table 72 00 13 7 Exhaust Valve Seat Standard and Oversize Dimensions N27 anlage Engine Exhaust Valve Seat Standard and Oversize A Diameter Part Number In In SL72058A STD 1 7387 1 7402 SL72058A 05 40 005 1 7437 1 7452 SL72058A P10 40 010 1 7487 1 7502 SL72058A P20 40 020 1 7587 1 7602 SL72058A P30 0 030 1 7687 1 7702 Table 72 00 13 8 Intake Valve Seat Standard and Oversize Dimensions Intake Valve Seat Standard and Ov
122. ket Install the bolt 10 with lock washer 5 Apply anti seize to the fuel injectors 90 Install in the cylinders Torque the injectors to 60 in lbs Install the fuel lines 55 between the fuel injectors 90 and the flow divider 15 Tighten to 25 in lbs Install clamps Install the fuel hose 30 Figure 72 00 09 38 between the fuel pump and fuel servo Install the fuel hose 35 Figure 72 00 09 38 between the fuel servo and flow divider Torque the hose 30 35 B nuts to 45 in lbs Magneto and Harness Installation 1 Verify the correct magneto part numbers 2 Assemble the magnetos as follows SC gt a Install the drive gear 35 Figure 72 00 09 40 to the magneto 15 by removing the gear retaining nut washer and cotter pin 40 from the magneto Install the drive gear 35 with the washer and nut Torque the nut to 120 320 in lbs Secure with cotter pin 40 Repeat for the 2nd magneto s assembly Install the magneto gasket 1 and spacer 5 as appropriate to the accessory housing at each magneto location Remove the harness cover cap from each magneto as required Retain screws for harness installation Determine direction of rotation Refer to magneto data plate Insert the alignment pin in appropriate hole R or L magneto as determined by the direction of rotation and slowly rotate the magneto drive shaft backwards until the alignment pin drops into posit
123. l rione Engine NAR PARTS UNE O 360 and 360 Series Engines 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 NOTE Refer to Figure 72 00 13 7 equipment 2 After grinding and cleaning the valve stem 1 Intake valve faces that have minor pitting or may be polished to remove superficial warping may be refaced by grinding scratches WARNING USE THE CORRECT PERSONAL PROTECTION POLISHING AND GRINDING WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES 22 March 2005 Superior Air Parts Inc SUPERIZR Overhaul Manual Dirige Engine ATR PARTS INC O 360 and 360 Series Engines N Fi INTAKE N ORIGINAL OUTLINE OF SEAT EXHAUST A INTAKE INTAKE C EXHAUST EXHAUST 2 145 2 155 076 117 1 740 1 750 058 077 VALVE SEAT DIMENSIONS FOR RECONDITIONING REPLACE SEAT IF WHEEL PRODUCES GRINDING STEP HERE VALVE SEAT PILOT VALVE GUIDE REJECTION CRITERIA FOR VALVE SEAT Figure 72 00 13 3 Valve Seat Dimensions m 72 00 13 March 2005 Superior Air Parts Inc Procedures SUPERIZR Overhaul Manual
124. linder horizontally opposed air cooled direct drive powerplants incorporating a wet sump bottom mounted induction bottom exhaust with either carbureted or port injected fuel systems Provisions exist for both front and rear mounted accessories All engine components will be referenced as they are installed in the airframe Therefore the front of the engine is the propeller end and the rear of the engine is the accessory mounting drive area The oil sump is on the bottom of the engine and the cylinder shroud tubes are on the top The terms left and right are defined as being viewed from the rear of the engine looking toward the front Oylinder numbering is from the front to the rear with odd numbered cylinders on the right side of the engine The direction of crankshaft rotation is clockwise as viewed from the rear of the engine looking forward unless otherwise specified Accessory drive rotation direction is defined as viewed from the rear of the engine looking forward Continued Airworthiness Vantage Engines discussed in this document must be installed and operated in accordance with the limitations conditions and operating procedures described in the Installation and Operation Manual SVIOMO1 They must also be maintained in accordance with this manual and the applicable Overhaul Manual SVOHMO1 and other Instructions for Continued Airworthiness The engine s time between overhaul TBO period is initially defined
125. lly Available Bushing puller kit Commercially Available Tap amp die set Commercially Available Extraction tool for threaded inserts Commercially Available Insertion tool for threaded inserts Commercially Available Table 72 00 13 4 List of Repair Codes Material Source Main crankpin journals 0 003 inch undersize M03M Main bearing journals 0 003 inch undersize M03P Crankpin bearing journals 0 003 inch undersize 3 March 2005 Superior Air Parts Inc LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines REPAIR NO 1 N27 anlage Engine THREADED AREA REPAIR AND STUD REPLACEMENT Repair and Replacement 1 Repair defective threaded areas on studs with a suitable die or tap Small nicks can be removed satisfactorily with files or small edged stones 2 Replace defective studs with a collet grip tool or other appropriate tool a If stud is broken and tool cannot be used drill a hole into the stud to use a pilot bushing A stud extractor may then be utilized to remove the stud b After defective stud is removed check hole threads for damage Repair or reject as required Also check thread size to determine replacement stud thread size c Use compressed air to clean out shavings prior to installation of n
126. mum service limits are exceeded standard shafts be polished to 0 003 in undersize and fitted with 0 003 in undersize bearing inserts CAUTION DO NOT ALLOW LATHE SPEED TO EXCEED 150 RPM DURING ANY POLISHING OPERATION Polish crankshaft or crankpin journals as needed to reestablish proper fits and clearances Refer to Fits Clearances section of this manual for size limits WARNING DO NOT DAMAGE THE NITRIDED SURFACES OF THE CRANKSHAFT March 2005 Superior Air Parts Inc WARNING IF ONE SURFACE IS POLISHED TO UNDERSIZE ALL CORRESPONDING SURFACES MUST BE POLISHED TO THE SAME SIZE WARNING USE THE CORRECT PERSONAL PROTECTION POLISHING WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES NOTE Main bearing surfaces may be polished without affecting crankpin surfaces and likewise the crankpin bearing surfaces may be polished without affecting the main bearing surfaces Inspection After Resurface Procedure 1 Upon completion of the polishing procedure thoroughly clean the part Buff the surface to a high finish 2 After polishing operation clean the part and perform a complete magnetic particle inspection of the shaft or pin If any cracks or checks are found the part must be rejected 3 Coat the clean surfaces of approved parts with preservative oil and store until ready for reassembly WARNING USE CORRECT PERSONAL PROTECTION SOME CHEMICAL SOLUTIONS CAN CAUSE SKIN EYE AND LUNG DA
127. nd Gears Internal Gear Timing 1 Install 2 each idler shafts 1 Figure 72 00 09 20 with 3 bolts 5 and one nut 10 Torque the bolts 5 and nut 10 in accordance with the torque specifications the Fits Clearances section of this manual Safety the nuts and bolts with 0 032 in safety wire to idler shaft flange holes Refer to Figure 72 00 09 21 WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE 2 Inspect idler gears and for handling damage burrs and general condition WARNING LUBRICANTS ARE TOXIC AND FLAMMABLE DO NOT BREATHE VAPORS BEFORE YOU USE READ THE MATERIAL SAFETY DATA SHEET MSDS FROM THE MANUFACTURER OR SUPPLIER USE IN A WELL VENTILATED AREA FREE FROM SPARKS WEAR PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 3 Apply pre lube oil to idler shafts 1 and gear bushing 25 Highlight with a marker the timing marks on the camshaft crank gear and fuel pump drive idler gear 15 5 Place the left hand idler gear fuel pump drive idler gear over the left idler shaft aligning its timing marks with the corresponding timing marks on cam and crank Rotate cam and crank as needed to align with marks on the idler gear See Figure 72 00 09 22 Install the right hand idler gear 20 on the right side idler shaft 4 It is not necess
128. nder End Clear 0 0250 0 057 Piston Pin in Piston Diameter 0 0003 0 0014 Piston Pin in Connecting Rod Bushing 0 0008 0 0021 Connecting Rod Bearing to Crankpin 0 0008 0 0038 Connecting Rod to Crankshaft Side Clear 0 0040 0 0100 Connecting Rod Weight Difference Opposing Pairs 1 oz Connecting Rod Crankpin Bore to Piston Pin Bore Twist 001 in per in Connecting Rod Crankpin Bore to Piston Pin Bore Convergence 001 in per in March 2005 Superior Air Parts Inc 72 00 11 Fits and Clearances N27 SUPERIZR Overhaul Manual antage Engine AIR PARTS IN O 360 and 360 Series Engines Continued on Next Page Table 72 00 11 1 Dimensional Limits continued Description of Limit Minimum in Maximum in Crankshaft Main Bearings Crankshaft in Front Bearing End Clear 0 0090 0 0160 Crankshaft in Front Bearing Diameter 0 0015 0 0045 Crankshaft in Front Bearing Diameter 0 0015 0 0045 Crankshaft Oil Slinger 0 0020 0 0070 Crankshaft Rod Journal Diameter 2 1240 2 1250 Crankshaft Run Out to Center Main 0 0050 T I R Crankshaft Main Bearing Journal Diameter 2 3750 2 3760 Crankshaft Flange O D Run out 0 0050 T I R Crankshaft Flange Pilot Diameter to Front and Rear Mains 0 0020 T I R Camshaft Journal Camshaft Center Bearing Journal Run Out 0 0010 T I R Journals in Crankcase 0 0020 0 0040 Rear Journal in Crankcase End Clearance 0 0020 0 0090 Valve Tappet in Crankcase 0 0010 0 0033 Rocker Shaft Rocker
129. ndness Refer to Repair No 4 e Inspect pilot diameter of the counterbore for size and damage The diameter should not exceed 2 1262 inches at any place Refer to Repair No 4 Reject See Repair No 8 Replace Repair CAUTION IF THE DOWEL MUST BE REMOVED BE CAREFUL NOT TO DAMAGE THE CRANKSHAFT HOLE DRILL A 1 8 INCH DIAMETER HOLE THROUGH THE CENTER OF THE DOWEL FILL THE HOLE WITH OIL AND INSERT A PIECE OF 1 8 INCH DIAMETER DRILL ROD IN THE HOLE STRIKE THE END OF THE DRILL ROD WITH A SHARP BLOW THE RESULTING HYDRAULIC PRESSURE SHOULD FORCE THE DOWEL OUT NOTE f the crankshaft requires repairs other than those specified above measure the crankshaft counterbore face If the crankshaft measures more than the minimum dimension shown the surface may be reworked to the dimensions shown do not plate the surface The surface must be true within 0 001 inch T I R The surface finish must be held to 45 to 90 microns 72 00 08 Inspection and Check SUPERIZ PARTS A R N C Camshaft Inspection Visual inspection Entire shaft for fretting galling scoring pitting cracks pitting or other damage Cam lobes for indications of distress surface irregularity or feathering along the edges Reject Reject If the hydraulic lifter bodies have been rejected for spalling inspect the corresponding cam lobe s Dimensional inspection NOTE Refer to Fits and Clearances section of this manual
130. o 2 Main Bearing Camshaft Camshaft Journal No 2 Journal No 3 Rocker Rocker Arm Thrust Estin Splash Oil Splash Oil 5 9 To Rocker Camshaft Face To Rocker Arms Valves Journal No 1 Arms Valves Etc Etc No 1 Main Bearing Splash Oil To Pistons Sams Ele Cyl 1 Piston ransp Cooling Nozzle If installed Figure 02 00 00 11 Oil System Schematic 13 02 00 00 March 2005 Superior Air Parts Inc Description and Operation Overhaul Manual N27 anlage Engine O 360 and 360 Series Engines SUPERIAR Features and Operating Mechanisms Crankshaft The crankshaft is made from high quality aerospace grade steel All bearing journal surfaces are nitrided There are 3 kinds of crankshafts thin wall thick wall and solid front mains which can be identified by looking at the center of the front of the crankshaft or prop oil cavity The thin wall and thick wall crankshafts are each available as fixed pitch or constant speed Fixed pitch versions have a plug installed in the inner diameter of the front main or prop oil cavity which prevents escape of oil out the front since there isn t a prop governor or constant speed prop for the oil pressure to act upon Connecting Rods The connecting rods are made from aerospace grade high quality steel They have replaceable bearing inserts in the crankshaft ends and bronze bushings in the piston ends The bearing caps on the
131. ocker shaft 15 in bushing for correct fit c Lubricate the rocker arm socket and oil feed hole to ensure clear passage 11 Rotate the engine until cylinder 1 is at top dead center TDC 12 Apply a light film of pre lube oil to the rocker shafts Install rocker arms and shafts in the 1 cylinder head 13 Check dry tappet clearance Clearance must be within limits per Fits and Clearances section of this manual a Repeat for all remaining cylinders b Install the rocker shaft caps thrust buttons 20 in each end of the rocker shaft 15 immediately before installing rocker cover NOTE Change the pushrod length as required to achieve proper clearance NOTE light coat of grease applied to the thrust buttons will aid in retaining them in position until the rocker covers 45 Figure 72 00 09 17 are installed 72 00 09 Engine Assembly N27 anlage Engine SUPERIZR Overhaul Manual Engine AIR PARTS ING O 360 and 360 Series Engines 1 SHAFT IDLER 5 SCREW 10 NUT SLOTTED 15 GEAR IDLER 20 GEAR IDLER 25 BUSHING 30 PLUNGER FUEL PUMP Figure 72 00 09 20 Idler Gear and Tachometer Shaft Assemblies 30 NN March 2005 Superior Air Parts Inc 72 00 09 Engine Assembly SUPERIZR AIR PARTS IN C NOTE WIRE MUST PULL TO TIGHTEN AND GO AROUND NUT NOT OVER THE TOP FOR STUD CLEARANCE CLEARANCE BETWEEN TOP OF STUD AND IDLER GEAR IS MINIMAL AND CRITICAL
132. oil from the cylinders 3 Drain preservation oil from engine Engines that have been subjected to a cold environment for long periods of time should be placed into at least a 70 F atmosphere for 24 hours or more before attempting to drain the preservative oil If this cannot be done heat the engine with heating lamps before attempting to drain the engine Remove exhaust port protective plugs Service the lubrication system with mineral non detergent oil Remove the shipping plate from the propeller governor pad as required for March 2005 Superior Air Parts Inc governor installation Lubricate the governor shaft splines with engine oil install a new gasket and then install the propeller governor control e Align the spline of the governor drive gear and be sure that the governor is fully seated to the adapter prior to installing the attaching hardware This eliminates the possibility of misalignment e Attach with plain washers and new lock washer Torque the nuts to 200 e Optional accessories such as vacuum pumps hydraulic pumps etc may be installed on the accessory drive pads located on the rear of the accessory housing Remove the accessory drive covers and install new gaskets Install accessories accordance with the manufacturer s instructions e Install any airframe manufacturers required cooling baffles hoses fittings brackets and ground straps in accordance with airframe manufacturer s
133. on 72 00 13 1 Cylinder Interior Resurface Crosshatch 15 72 00 13 2 Cooling Fin Removal Maximum 72 00 13 3 Valve Seat Dimensions 72 00 13 4 Valve Guide Dimensions 72 00 13 5 Valve to Seat Fit Acceptable Criteria xii N27 i antage Engine 22 23 25 26 27 30 31 32 35 36 37 39 40 41 42 43 45 47 49 50 51 53 54 55 56 59 60 61 16 18 23 24 25 General Information SUPER IS Overhaul Manual AIR PARTS INC O 360 and 360 Series Engines LIST OF TABLES Table 01 00 00 1 Abbreviations 01 00 00 2 Consumable Materials 02 00 00 1 Manufacturer s General Specifications 02 00 00 2 Accessory Drive Specifications 02 00 00 3 Manufacturer s Physical Specifications 02 00 00 4 Engine Accessories 02 00 00 5 Illustrated Views of the Engine 72 00 03 1 Special Tools and Equipment 72 00 03 2 Abnormal Operating Procedures 72 00 03 3 Engine Will Not Start 72 00 03 4 Rough Idling 72 00 03 5 Engine Not Able To Develop Full Power 72 00 03 6 Rough Engine Operation 72 00 03 7 Low Power amp Engine Runs Rough 72 00 03 8 Low Oil Pressure On Engine Gage 72 00 03 9 High Oil Temperature 72 00 03 10 Excessive Oil Consumption 72 00 05 1 Equipment and Materials List 72 00 06 1 Disassembly Materials 72 00 06 2 Discard Parts 72 00 06 3 Special Tools and Equipment 72 00 07 1 Equipment Required for Cleaning 72 00 07 2 Materials Required for Cleaning 72 00 08 1 Inspection Materials 72 00 08 2 Special Tools and Equipment 72 00 09 1 Assembly
134. on until the timing lights simultaneously indicate the magneto points are just opening 7 Repeat the process above for minor adjustments as needed to achieve the correct timing 8 Torque the magneto nut 30 to 200 in Ibs 9 Remove the timing indicator leads of the magneto synchronizer from the magneto P lead connections and ground lead 10 Install the spark plugs into the top and bottom spark plug ports of each cylinder Torque to 420 Reference 5 01 Maintenance Manual 11 Attach the harness leads Refer to wiring diagram Figure 02 00 00 10 Secure to each spark plug 12 Install the clamps provided with the harness kit to prevent wire chafing NOTE Assembly steps 10 11 and 12 above may be replaced by assembly of dehydrator plugs if the engine will be stored prior to engine test In this event spark plug leads should be neatly coiled and stowed with the clamps for later assembly Storage After Assembly If not immediately proceeding to engine testing section preserve the engine for storage per instructions in the Preservation and Storage section of this manual 72 00 09 Engine Assembly SUPERIZR Overhaul Manual Engine PARTS UN O 360 and 360 Series Engines GASKET ADAPTER ADAPTER 10 GASKET MAGNETO 15 MAGNETO 20 CLAMP 25 WASHER 30 NUT 35 DRIVEGEAR 40 COTTER PIN 45 HARNESS COVER CAP 50 HARNESS LEADS UD Figure 72 00 09 40 Magne
135. onnections and replace damaged parts Adjust throttle lever Check strainer gage and flow at the fuel inlet Examine air scoop and remove restrictions Drain and refill tank with proper fuel Tighten all connections Check system with tester Check ignition timing Check rocker arm motion as engine is rotated on nose stand 2 72 00 03 Testing Fault Isolation SUPERIAR Overhaul Manual O 360 IO 360 Series Engines N27 anlage Engine Table 72 00 03 6 Rough Engine Operation Probable Cause Broken engine mount Mounting bushings worn Unstable compression Correction Replace or repair mount Install new mounting bushings Check compression Table 72 00 03 7 Low Power amp Engine Runs Rough Probable Cause Mixture too rich indicated by sluggish engine operation red exhaust flame at night Extreme cases indicated by black smoke from exhaust Mixture too lean indicated by overheating or back firing Leaks in induction system Defective spark plugs Improper fuel Magneto breaker points not working properly Defective ignition wire Defective spark plug terminal connectors Correction Readjustment of fuel injector or carburetor may be required by authorized personnel Check fuel lines for dirt or other restrictions Readjustment of fuel injector or carburetor may be required by authorized personnel Tighten all connections Replace damaged parts Clean and gap or replace spark plugs
136. ons are preferred Cylinder Barrel Inspections Visually inspect cylinder barrel for general condition Refer to Figure 72 00 08 4 e Cracks Reject Visually inspect cylinder barrel cooling fins Blend with hand grinder e Notches and nicks orfile See Repair No 10 Visually inspect cylinder barrel skirt e Bent cracked or Reject broken Visually inspect cylinder barrel mounting flange Blend with file or crocus di cloth See Repair No 2 Visually inspect cylinder barrel interior e Minor scoring or Repair by corrosion honing Repair 9 scoring or Reject pitting Visually inspect cylinder barrel interior Repair by Gaziaorpessble honing Se Repair No 9 72 00 08 Inspection and Check Overhaul Manual N27 anlage Engine O 360 and IO 360 Series Engines SUPER IZIR A R P Cylinder Barrel Dimensional Inspections Visually inspect cylinder barrel dimensions Refer to Figure 72 00 08 4 e Fit between piston skirt cylinder ee e Maximum taper of to Fits cylinder walls Clearances e Maximum out of ER roundness Clearances Refer to Fits e Bore diameter and Clearances NOTE All cylinder barrel diameter measurements must be taken at a two 2 locations 90 degrees apart at the plane specifically being measured Cylinder Assembly Inspection Perform a fluorescent dye penetrant inspection of the cylinder head e Cracks Reject Piston Inspections Visually
137. oove or lip 17 Verify that the front main bearing on the crankshaft has the correct part number and check its alignment marks Inspection 2 A D Inspect and verify the correct installation of cylinders and assembly hardware including proper torque and safety techniques Verify the internal timing of the crankshaft gear camshaft gear and idler gear as well as proper clearances and gear lash This quality inspection shall include visual and physical inspection of parts and assemblies in accordance with the assembly guidelines in this Overhaul Manual This inspection shall be accomplished during the engine assembly process as noted in the Assembly section of this manual Perform the inspections as follows SUP A R P NOTE mM 1 Check the torque of cylinders and assembly hardware a Check the torque on the cylinder base nuts in accordance with the Fits and Clearances section of this manual b Check the torque crankcase assembly hardware in accordance with the Fits and Clearances section of this manual 2 Verify correct safety techniques a Verify the safety of the slotted nut and drilled stud at accessory location under the camshaft gear b Verify the safety of the drilled belly bolts nuts at sump location c Verify the safety of the idler shaft hardware Ensure clearance between the idler shaft stud and idler gear 3 Verify that the timing marks align correctly b
138. ot available remove the pushrod socket with fingers or by using needle nose pliers Insert a piece of wire bent at a right angle into the plunger between the plunger and the lifter body Turn 90 degrees to engage a coil of spring and draw out the plunger assembly Crankcase Disassembly 1 Remove nuts 25 45 70 85 Figure 72 00 09 11 and 72 00 09 12 bolts 5 30 55 90 95 and washers 15 20 35 40 60 65 80 Draw or pull the thru bolts 1 from the crankcase using cylinder base nuts and washers and or spacers Separate crankcase using care not to allow camshaft to fall to floor Caution should be used to keep the right case thru studs from becoming misaligned when separating the crankcase halves 60 Figure 72 00 09 5 S NOTE Carefully pull crankshaft nose seal from crankcase forward on crankshaft to aid in crankcase half separation 72 00 06 Engine Disassembly N27 i antage Engine Overhaul Manual N27 anlage Engine O 360 and 360 Series Engines SUIPER IZ AIR PARTS N C 3 Remove the bearing inserts 5 10 Figure 72 00 09 2 lifter bodies 20 and camshaft Remove and discard o ring seals 10 75 Place each lifter body in its proper location in a cleaning basket The bodies must be assembled their original locations if reused NOTE 4 Remove all threaded plugs and discard oil seals Crankshaft Disassembly 1 With the crankshaft firmly supported at
139. ound and Silk Thread Application 72 00 09 14 Crankcase Halves Assembly Xi N27 i antage Engine General Information March 2005 Superior Air Parts Inc SUIPER IZR Overhaul Manual AIR PARTS INC O 360 and 360 Series Engines LIST OF FIGURES cont d c z E Figure S 5 o amp d 2 72 00 09 15 Cylinder Valve Train and Spring Assembly 72 00 09 72 00 09 16 Piston Assembly to Connecting Rod 72 00 09 17 Cylinder Assembly and Head Oil Drain Line 72 00 09 18 Piston Assembly with Ring Compressor Tool 72 00 09 19 Cylinder Base Nuts Sequence of Tightening 72 00 09 20 Idler Gear and Tachometer Shaft Assemblies 72 00 09 21 Idler Gear and Tachometer Shaft Assemblies cont d 72 00 09 22 Accessory Drive Gear Arrangement 72 00 09 23 Accessory Housing 72 00 09 24 Oil Pump Assembly 72 00 09 25 Accessory Housing Gasket Trimming 72 00 09 26 Inner Cylinder Cooling Baffle 72 00 09 27 Oil Sump and Induction System 72 00 09 28 Cil Level Gage 72 00 09 29 Induction System 72 00 09 30 Intake Tube Assembly 72 00 09 31 Vacuum Pump Drive 72 00 09 32 Fuel Pump 72 00 09 33 Propeller Governor Adapter 72 00 09 34 Propeller Governor Oil Line 72 00 09 35 Cil Filter Assembly 72 00 09 36 Fuel Priming System 72 00 09 37 Carburetor Installation 72 00 09 38 Fuel Injection Servo Installation 72 00 09 39 Fuel Injection Manifold Installation 72 00 09 40 Magneto and Adapter Installation 72 00 09 41 Starter Ring Gear Alignment 72 00 09 43 Alternator Installati
140. r CHT Cylinder Head Temperature DIA Diameter F Fahrenheit Fig Figure Ft Lb Foot Pounds IAW In Accordance With LD Inside Diameter In Lb Inch Pounds Lb Pounds No Number NPT National Pipe Thread 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 2 Degree 01 00 00 March 2005 Superior Air Parts Inc Introduction Overhaul Manual N27 anlage Engine O 360 and 360 Series Engines SUPERIAR Consumable Materials List Refer to Table 01 00 00 2 below for consumable materials used during repair of the Vantage O 360 and 360 series engines NOTE Equivalent substitutes may be used Table 01 00 00 2 Consumable Materials Material Acetone or Methyl Ethyl Ketone MEK Assembly Grease Lubriplate No 105 Cleaning Solvent Copper Based Anti seize Fel Pro C5 A Fuelube Isopropyl alcohol Loctite 271 P N 27183 Loctite No 2 Gasket Sealant P N 30514 Lubricating Cil SAE 10 Lubricating Oil SAE 50 Mineral Oil MIL L 6082 SAE 50 weight Permatex P N 27100 Pliobond 20 Pre Lube Mixture approx 15 pre lubricant STP brand or equivalent plus 85 SAE 50 straight weight mineral oil Preservative oil mix MIL C 6529 type 1 plus MIL L 6082 RTV 102 Silicon Sealant Safety Wire 0 032 Type 304 Stainless Steel P N MS20995 C3
141. re 0 032 in Refer to Figure 72 00 09 24 13 Lubricate and install the fuel pump plunger 1 Figure 72 00 09 24 in the accessory housing STOP PERFORM IN PROCESS QUALITY INSPECTION 3 REFER TO APPENDIX A Assembly of Accessory Housing to Engine 1 Apply pre lube oil to the tach shaft 15 Figure 72 00 09 8 as well as to the gear teeth of cam crank and idler gears 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 INA WELL VENTILATED AREA FREE FROM SPARKS WEAR PROTECTIVE GEAR 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 Ensure the mating surfaces of the crankcase and accessory housing are clean flat and free from burrs scoring 3 Verify the dowels are installed in the proper location in the crankcase 4 Install the accessory housing gasket 35 Figure 72 00 09 23 to the crankcase over the dowels 72 00 09 Engine Assembly N27 anlage Engine SUPERIAR 5 Install the accessory housing assembly 1 over the tach shaft taking care to align oil pump drive with the crankshaft gear a Lightly tap the accessory housing in place over the dowels with a soft face or dead blow hammer as required 6 Secure the accessory housing with washer 5 lock washer 10 and bolt 15
142. res All journal surfaces must be checked for galling Scores misalignment and out of round condition Pins and shafts must be inspected for straightness Examine gears for evidence of pitting and excessive wear This evidence is of special importance when found on the involute of the gear teeth Deep pit marks in this area are reason to reject the part Bearing surfaces of all gears may have minor abrasions dressed out with fine abrasive cloth but should be free from deep scratches Excessively worn or mutilated threads should be rejected Small defects such as slight nicks or burrs may be dressed out with a small file fine abrasive cloth crocus cloth or oil stone distortion galling or mutilation resulting from over tightening is discovered the part must be replaced Inspection of highly stressed areas for corrosion is necessary These areas are susceptible to pitting and can cause failure of the part The following are components requiring particular attention with respect to this issue the fillets at the edges of crankshaft main and crankpin journal surfaces and thrust bearing races f pitting is discovered in these areas and cannot be removed by polishing with crocus cloth or other fine abrasive the part must be replaced For polishing procedures see the Repairs section of this manual Inspect all threaded inserts fasteners studs fittings plugs etc for condition of threads March 2005 Superior Air
143. rform repair procedures as listed in Table 72 00 13 1 when components do not meet requirements specified in the Inspection and Check section of this manual March 2005 Superior Air Parts Inc Overhaul Manual R PARTS INC O 360 360 Series Engines N27 i antage Engine SUPERIAR Repair Procedure 72 00 15 1 72 00 15 2 72 00 15 3 72 00 15 4 72 00 15 5 72 00 15 6 72 00 15 7 72 00 15 8 72 00 15 9 72 00 15 10 72 00 15 11 72 00 15 12 72 00 15 13 72 00 15 14 Overhaul Manual N27 a anlage Engine O 360 and IO 360 Series Engines Table 72 00 13 1 List of Repairs Title Threaded area repair and stud replacement Nick and scratch repair Crankshaft or crankpin repair Crankshaft counterbored gear mounting surface Painted parts Crankshaft oil seal surface Crankshaft flange Crankshaft forward counterbore Oylinder interior surface Oylinder head cooling fins Valve valve seat and valve guide Spark plug threaded insert Rocker bushing replacement Connecting Rod bushing replacement Description Repairs threaded areas and replaces studs and threaded inserts Blends nicks scratches in mounting mating flanges and other flat surfaces Repairs crankshaft or crankpin bearing journals Repairs the gear mounting surface Paints parts stripped during degreasing or inspection procedures Reconditions the oil seal area at the prop flange surface Allows grinding o
144. roper size Heat the cylinder to between 350 F 425 F for a minimum of 1 hour Position the new guide onto the end of a valve guide installation drift and insert the guide in the hole in the Overhaul Manual O 360 and IO 360 Series Engines N27 i antage Engine e Drive the guide into the hole with firm hammer blows on the end of the drift WARNING USE THE CORRECT PERSONAL PROTECTION USE OF A HAMMER CAN CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES f Allow the cylinder to cool Ream the valve guide with an appropriate ID reamer Check the finished ID with a hole plug gage cylinder head Table 72 00 13 9 Exhaust Valve Guide Standard and Oversize Dimensions Exhaust Valve Guide Part Number SL74230A SL74230A P05 SL74230A P10 SL74230A P20 SL74230A P30 SL74230A P40 Standard and Oversize In STD 0 005 0 010 0 020 0 030 0 040 A Diameter In 0 6638 0 6633 0 6688 0 6683 0 6738 0 6733 0 6838 0 6833 0 6938 0 6933 0 7038 0 7033 Table 72 00 13 10 Intake Valve Guide Standard Oversize Dimensions Intake Valve Guide Part Number SL61681A SL61681A P05 SL61681A P10 SL61681A P20 SL61681A P30 SL61681A 40 March 2005 Superior Air Parts Inc Standard and Oversize In STD 40 005 0 010 0 020 0 030 40 040 21 A Diameter In 0 5932 0 5940 0 5982 0 5990 0 6032 0 6040 0 6132 0 6140 0 6232 0 6240 0 6332 0 6340 SUPERIZ Overhaul Manua
145. s 15 lock March 2005 Superior Air Parts Inc 48 washers 20 1 nut 25 and 3 screws 30 Torque to 96 108 in Ibs WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE Installation of Spin On Oil Filter 1 Apply light coat of Dow Corning 4 lubricant or equivalent to the rubber seal at base of the oil filter 40 72 00 09 35 and lightly lubricate the filter threads then install to the adapter 10 and torque to 192 216 in lbs Reference SVIMM01 Maintenance Manual Install safety wire 0 032 in from the oil filter to the adapter WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE 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 INA 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 72 00 09 Engine Assembly e 2 SUPERIZ Overhaul Manual Vantage Engine NAR PARTS UNE O 360 and 360 Series Engines 1 GEAR SHAFT 5 VVASHER THRUST 10 GASKET ACCESSORY DRIVE 15 ADAPTER ASSY 20 WASHER FLAT 25 WASHER LOCK 30 NUT PLAIN 45 PIN SPRING 55 RING RETAINING 60 GASKET 65 COVER Figure 72 00 09 33 Propeller Governor Adapter 49 March 2005 Superior Air Parts Inc 72 00 09
146. s any more than necessary prior to their reassembly into the engine as this handling reintroduces dirt corrosive substances to the parts 72 00 08 Inspection and Check N27 i antage Engine A SUPERIZR R P Accessory Housing Initially inspect accessory housing as illustrated in Figure 72 00 08 2 Remove all accessories magnetos pumps valves etc for separate inspection e Obvious excessive Reject damage Visually inspect accessory housing 1 Inspect accessory housing flange and drive pad surfaces e Deep scratches Reject Blend hand polish per Repair No 2 2 Inspect accessory case threaded and drilled areas and passages e Minor scratches e Worn or mutilated Reject distorted galled Slight nicks or SC Kure polish per Repair No 1 e Obstructions or See Cleaning plugs section of this manual Crankcase Assembly Perform initial inspection of crankcase assembly per Figure 72 00 08 3 e Obvious excessive damage or wear 1 Inspect all crankcase bearing bores and journals saddle supports support webs tang slots and flange surfaces e Deep scratches Reject e Fretting heavy wear flat spots Reject Reject March 2005 Superior Air Parts Inc Overhaul Manual O 360 and 1 360 Series Engines N27 i antage Engine Blend hand Minor scratches polish per Repair No 2 Misalignment of 1 surfaces SES Out of round conditions on Reject journals 2 Inspec
147. sed air 2 Disposable external oil filter elements are not cleaned C Airinduction system filters 1 Foam air filters may be rinsed in clean solvent then washed with mild detergent and water and reinstalled Paper air filter elements are not cleaned WARNING 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 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 Accessories Refer to the various manufacturers manuals for information regarding the cleaning of these components 72 00 07 Cleaning N27 a anlage Engine LT N27 SUIPER IZAR Overhaul Manual antage Engine NIR PARTS gg O 360 and 360 Series Engines Preservation and Corrosion Prevention A Upon conclusion of visual inspection and all cleaning operations rinse parts with petroleum solvent Dry and remove any loose particles by air blast Apply a liberal coating of preservative oil to all surfaces B For parts that will be repainted do the following 1 Be sure that the part is thoroughly degreased clean and dry 2 Prime and paint in accordance
148. shers 25 and nuts 35 14 places Install the bolts 20 lock washers 30 washers 25 and nuts 35 2 places Install the lock washers 30 washers 25 and nuts 35 on the sump studs 4 places Torque the bolts 15 20 and nuts 35 to 96 108 in lbs Refer to Figure 72 00 09 27 Installation of the Oil Pressure Relief Valve Assembly 1 Apply pre lube oil in the crankcase at the oil pressure relief valve location Insert the ball 40 Figure 72 00 09 2 into the hole in the crankcase Install the spring 35 into the oil pressure relief valve housing 25 Install the gasket 30 to the relief valve housing 25 Apply pre lube oil to the threads of the oil pressure relief valve housing and install the housing in the crankcase Tighten the relief valve assembly 25 Figure 72 00 09 2 until the valve body contacts gasket 30 then turn an additional approx 90 Install safety wire 0 032 in from the relief valve assembly 25 to the hole provided in the crankcase Oil Level Gage and Housing 1 Install the oil level gage housing 5 Figure 72 00 09 28 with the gasket into the crankcase Tighten the assembly to 300 in Ibs Install safety wire 0 032 in between the oil level gage housing 5 and crankcase Install the oil level gage 10 with its O ring seal 15 into the housing 72 00 09 Engine Assembly N27 i antage Engine SUPERIZR Overhaul Manual Engine AIR PARTS ING O 3
149. spect the oil pump gears 105 110 and oil pump drive shaft 115 for damage 7 Install the oil pump gears 105 110 and drive shaft 115 into oil pump housing Inspect gear backlash and housing clearance per specifications in Fits and Clearances section of this manual an 4 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 CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER 8 Apply pre lube oil liberally to gears and shaft in housing 9 Install the oil pump assembly 80 over studs in accessory housing 10 Install the flat washers 85 and slotted nuts 90 to the studs Tighten the installation hardware to snug 11 Rotate the oil pump drive shaft 115 to ensure smooth fit The gears must rotate smoothly March 2005 Superior Air Parts Inc Overhaul Manual O 360 and 360 Series Engines 33 NOTE It may be necessary to twist or move the oil pump housing slightly to achieve a smooth rotation of the oil pump assembly gears WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE 12 Tighten the slotted nuts 90 per torque specifications in the Fits and Clearances section of this manual Install safety wi
150. sumption Probable Cause Low grade of oil Failing or failed bearings Worn piston rings Incorrect installation of piston rings Failure of rings to seat on new cylinders Oil siphoned from engine in flight March 2005 Superior Air Parts Inc Correction Fill tank with oil of proper weight and grade Check sump oil for metal particles Install new rings Install new rings Use mineral base oil Climb to cruise altitude at full power and operate at 7596 cruise power setting until oil consumption stabilizes See Break In Procedures Special Procedures Section of this manual Insure that oil filler cap is tight and that o ring is in good condition Insure that breather hose exit is cut and located to avoid creating a vacuum in the breather hose 72 00 03 Testing Fault Isolation SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines SPECIAL PROCEDURES General Break In Procedures This section provides the Break In Procedures to achieve satisfactory ring seating and long cylinder life On all new Vantage engines after top overhaul or major engine overhaul break in is Critical NOTE Refer to the engine warranty Violation of these procedures will void the engine s warranty Special Tools and Equipment e Standard aviation shop tools are required e Engine test stand e aircraft can be a suitable test stand for running in cylinders Break In Procedures WARNING OPERATION OF A DEFECTIVE
151. t crankcase threaded studs and drilled holes and passages NOTE NOTE NOTE Worn mutilated Reject See distorted or Repair No 1 galled Blend hand Se nicks or polish per Repair No 1 Surfaces may be checked visually and by feel for roughness flaking and pitting of races and for scoring on the outside of the bearing races Shafts pins etc may be checked using vee blocks and dial indicators Aluminum surfaces can withstand considerable scratching and light scoring without harming the engine integrity or performance provided these problems fall within the limits set forth in the Fits and Clearances section of this manual Fretting on the saddle supports in the crankcase has a frosted appearance and tiny pit holes This usually indicates a change in the size of the bearing saddles that can be sufficient to cause an excessively tight crankshaft bearing fit 72 00 08 Inspection and Check SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines PASSAGE FLANGE MATING SURFACE 8 DRILLED SURFACE OIL PUMP ASSEMBLY THREADED STUDS INSIDE SURFACES PASSAGE ACCESSORY MOUNTING SURFACES THREADED AREA EXTERIOR SURFACES Figure 72 00 08 2 Accessory Housing 72 00 08 March 2005 Superior Air Parts Inc inspection andiCheek SUPERIZR Overhaul Manual Engine ATR PARTS INC O 360 and 360 Series Engines MATING BEARING JOURNALS N
152. t 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 b Secure spring clip with lock plate 55 and 0 25 in nut 60 6 Torque nut 60 to 50 70 in lbs 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 LD of each pushrod to verify each is clear clean and open 99 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 March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines 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 8 Install pushrods in pushrod tubes NOTE There are different lengths of pushrods available for this engine model to aid in adjusting the dry tappet clearance Use the appropriate length to achieve proper clearance of 0 028 to 0 080 in 9 Install exhaust valve rotator cap 115 on valve stem of each exhaust valve 65 NOTE drop of pre lube or spot of grease on the inside of each rotator cap will help retain it in place until the rocker arms are installed 10 Inspect rocker arms 5 for general condition a Ensure bushing 10 is properly installed b Check r
153. tappet bodies are installed 9 Rotate the camshaft in each case half to verify smooth fit 10 Verify that all mating surfaces are clean and absent of burrs and or scoring 11 Verify thrust bearing and slinger clearance of crankshaft Verify the end clearance of camshaft See Fits and Clearances section of this manual 12 lnspect fit of connecting rods to crankshaft a Verify the correct rod installation with rod serial numbers in the same plane and oriented toward oil sump b Verify the correct rod nut assembly with the lip out c Rotate or spin each rod on the crankshaft to verify smooth rotation March 2005 Superior Air Parts Inc d Verify proper side clearance of each rod in accordance with the Fits and Clearances section of this manual e Check the torque on each rod nut in accordance with the Fits and Clearances section of this manual 13 Verify that nose bolts are installed with o rings in the right case half 14 Verify the presence of o rings on rear through bolts in right case half 15 Verify the crankshaft gear installation a Ensure the gear is properly seated in the crankshaft recess in accordance with the Fits and Clearances section of this manual Verify security of the lock tab 16 Verify the nose seal installation a Verify that the seal is installed with the flat side toward crankshaft prop flange b Verify that the seal spring is correctly installed in the seal gr
154. ted nuts 40 to 360 in Ib 11 Torque and safety all other attaching hardware in accordance with values listed in the Fits and Clearances section of this manual Engine Removal 1 Remove the engine from nose stand and place horizontal on transfer cart Final Magneto Timing and Adjustment NOTE Magneto assembly to the engine is outlined in the accessory installation instructions of this section 1 Install the ring gear to the crankshaft propeller flange and retain with one slave bolt 2 Rotate the crankshaft using ring gear to compression stroke of number one cylinder NOTE t may be necessary to rotate the crankshaft just beyond top dead center to allow the magneto impulse couplings to release Upon release of the couplings rotate the crankshaft back in the opposite direction to correct timing degree mark March 2005 Superior Air Parts Inc 3 Align the correct timing mark on the ring gear with the mark on the starter housing See Figure 72 00 09 41 4 Attach the timing indicator leads of the magneto synchronizer timing box to the magneto P lead connections and ground lead to an appropriate ground b Rotate or adjust the magnetos until each magneto synchronizer lights indicate that the magneto points are just opening 6 Snug the magneto nut 30 Figure 72 00 09 40 and rotate the crankshaft back a few degrees before the correct timing Slowly rotate the crankshaft in the direction of rotati
155. 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 Fits and Clearances section of this components manual for limits 2 If necessary lap mating surfaces on a surface plate to remove abnormal damage March 2005 Superior Air Parts Inc LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUPERIAR Overhaul Manual O 360 and IO 360 Series Engines REPAIR NO 3 CRANKSHAFT OR CRANKPIN REPAIR Repairs Measure crankshaft main and crankpin journals 1 Determine if the components in question are standard or undersize bearing journals Determine this information prior to beginning any polishing or grinding operation Measure the OD of the crankshaft main and rod bearing journals and compare results to the limits shown in the Fits and Clearances section of this manual If dimensions do not fall within specified limits the shaft must be brought to undersize 5 3 Check the crankshaft flange for a code symbol stamped as a suffix to the part number Possible code symbols are M03MP main and crankpin journals 0 003 in undersize M03M main bearing journals 0 003 in undersize M03P crankpin bearing journals 0 003 in undersize If the maxi
156. the primer nozzles 1 Figure 72 00 09 36 Install the primer nozzles in cylinder numbers 1 2 and 4 lower ports Fig 72 00 09 36 Torque the nozzles 1 to 60 in Ibs Install the primer lines 5 10 15 20 to the nozzles and T junctions Clamp to the induction elbows and sump flange Installation of Fuel Injection System NOTE 1 This section applies to fuel injected engines only Verify the correct part number of the fuel injection unit servo flow divider and nozzles Install the servo to the sump with gaskets 1 Figure 72 00 09 38 spacer 5 washer 15 lock washers 20 and nuts 25 Torque the attaching nuts 25 to 200 in Ibs Install the fuel injector fittings appropriate pipe plugs and nipples per Figure 72 00 09 39 into the flow divider Use anti seize on the male threads and torque as follows e Plug 30 to 40 in Ibs e Elbow 35 to 40 in Ibs e Fitting 40 to 40 in lbs e Nipple 50 to 60 in Ibs e Nipple 45 to 60 in lbs Install the flow divider bracket 1 to the flow divider with screws 25 and lock washers 20 Torque the screws to 49 in Ibs Install the flow divider and bracket assembly to the engine backbone top per Figure 72 00 09 39 and torque the attaching hardware to 96 108 in lbs March 2005 Superior Air Parts Inc 52 NOTE Overhaul Manual O 360 360 Series Engines Remove and reinstall the appropriate backbone hardware to accommodate brac
157. the O 360 and 360 engine series pursuant to certification requirements of the Federal Aviation Regulations Mandatory Replacement Time Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification the O 360 and IO 360 engine series do not contain any components having mandatory replacement times required for type certification Mandatory Inspection Intervals Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification the O 360 and IO 360 engine series do not contain any components having mandatory inspection intervals other than 100 and 500 hour inspections of magnetos as required by Unison Slick Service Bulletin SB2 80C March 2005 Superior Air Parts Inc Other Mandatory Intervals or Procedures Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification the O 360 360 engine series do not have any inspection related or replacement time related procedures required for type certification Distribution of Changes to Airworthiness Limitations Changes to this Airworthiness Limitations Chapter constitute changes to the type design of the O 360 and 360 engine series and require FAA approval pursuant to Federal Aviation Regulations Such changes will be published in FAA Approved Mandatory Service Bulletins Super
158. the bushing ID to size per the Fits and Clearances section of this manual N27 i antage Engine LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK 32 March 2005 Superior Air Parts Inc A SUPER IZIR R P Overhaul Manual O 360 and IO 360 Series Engines TESTING General This section defines the testing that each Superior Vantage O 360 AND 360 series engine shall undergo to determine its acceptability after assembly overhaul The Fault Isolation Trouble Shooting section of this manual should be consulted as required Review all probable causes given The fault isolation sequence is in order of approximate ease of checking not necessarily in order of probability NOTE Refer to the Disassembly Assembly sections of this manual for replacement of defective components Special Tools and Equipment Standard aviation shop tools and equipment are required Engine Installation and Testing Procedures Refer to appropriate Test Installation Procedures For Testing Procedures refer to Superior Air Parts Engine Break in Procedure 72 00 04 March 2005 Superior Air Parts Inc 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 US
159. the front and rear main bearing journals or secured on a nose stand remove rod nuts 15 Figure 72 00 09 6 Remove the rods 5 by tapping on the March 2005 Superior Air Parts Inc NOTE rod bolts 10 with a soft hammer Discard the connecting rod bearing 1 bolts 10 and nuts 15 Maintain each cap and rod as an assembly Rods and caps are not interchangeable To remove the crankshaft gear 5 Figure 72 00 09 3 flatten the lockplate 10 and remove screw 15 Tap the gear lightly with a soft mallet or brass drift Remove the crankshaft seal and discard 72 00 06 Engine Disassembly Overhaul Manual Ariane Engine O 360 and IO 360 Series Engines SUPERIAR CLEANING General Cleanliness of the aircraft engine is crucial to its optimum performance This section provides information on materials tools and guidelines for cleaning After the initial visual inspection of internal engine parts it is necessary to thoroughly clean the engine components for detailed inspection Since this visual inspection is made during and after disassembly the components should be cleaned afterwards and tagged to facilitate further non destructive inspection methods This identification procedure will also help prevent these components from being overlooked It is important to remember to visually inspect an engine prior to cleaning Residue from the engine s operation can provide information as to hidden de
160. ting rod with the piston pin Refer to Figure 72 00 09 16 March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines NOTE Ensure that piston is installed with ring gaps towards the top of the engine 7 Slide the ring compressor tool over the piston and rings far enough to allow the cylinder bore to fit over the piston top Install cylinder 1 Position the top of cylinder facing the top of the engine over the piston Push on until the ring compressor is pushed off the piston skirt and can be removed at notch over the connecting rod Continue to slide the cylinder over the cylinder base studs until flush with the case deck Refer to Figure 72 00 09 18 9 Secure the cylinder assembly with the cylinder base nuts 15 20 Figure 72 00 09 17 as required and tighten to snug 10 Continue process with cylinders 2 then 33 and 44 in that order Rotate the case and crank so that the connecting rod of the cylinder to be installed is at top dead center 11 Torque the large cylinder hold down nuts 15 Figure 72 00 09 17 to 600 in lbs Torque the small hold down nuts 20 to 300 in lbs Do this in the sequence shown in Figure 72 00 09 19 12 Torque crankcase assembly hardware in accordance with Fits and Clearances Table 72 00 11 2 Do this in the sequence shown in Figure 72 00 09 19 8 WARNING PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE 13 Torque slotte
161. to and Adapter Installation 95 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Z Engine AIR PARTS ING O 360 and 360 Series Engines MAGNETO REPLACEMENT AND TIMING PROPELLER ATTACHING BUSHINGS ARE INDEXED AS SHOWN WHEN NO 1 PISTON IS ON TOP DEAD CENTER MAGNETO TIMING MARKS ALIGN WITH 0 07 DIA HOLE IN STARTER HOUSING STARTER TIMING MARKS SUPPORT FRONT VIEW MAGNETO TIMING MARKS BACK SIDE OF SUPPORT ALIGN WITH PARTING LINE OF CRANKCASE Y ROTATION TIMING MARKS SUPPORT REAR VIEW Figure 72 00 09 41 Starter Ring Gear Alignment 88 72 00 09 March 2005 Superior Air Parts Inc Engine Assembly SUPERIZR Overhaul Manual Engine PARTS Re O 360 and 360 Series Engines I 775 Se 70 N AS 65 25 lt wd 45 d N D X 229 S 52 SNE a N WV KAS 35 2 DAB ka Za asi NN rx ett Y i DE one a 2 Hi Re 4 2 11 REF lt lt D oe JL PR 4 d rhe Sal J a AA UU Z AN ERN QN C UY ez ei STARTER 60 Gi aw Sak deg Zd i SE Do N AN m M 74 P 90 Weeer e 80 5 15 5 WASHER 50 LOCK PLATE 20 10 BOLT 55 15 WASHER 60 BOLT 20 BOLT 65 ADJUSTING LINK 25 BOLT 70 WASHER 30 BOLT 75 BOLT 35 SHIMS 80 STRUT SUPPORT 40 NUTS 85
162. to recondition this area 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 13 March 2005 Superior Air Parts Inc LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc A SUPER IZIR R P Overhaul Manual O 360 and IO 360 Series Engines REPAIR NO 6 CYLINDER INTERIOR SURFACE Cylinder Interior Surface Reconditioning The Superior Vantage O 360 AND IO 360 series engines utilize cylinders constructed of through hardened steel These do not include nitride hardened or chrome plated interior surfaces WARNING USE THE CORRECT PERSONAL PROTECTION POLISHING AND GRINDING WILL CAUSE LOOSE PARTICLES THAT CAN GET IN YOUR EYES CAUTION DO NOT ALLOW THE HONING WHEEL TO RUN PAST THE BARREL MORE THAN 1 8 IN INTO THE COMBUSTION CHAMBER 1 Place the cylinder on a honing stand If the cylinder exceeds allowable service limits in taper diameter or out of roundness regrind to 0 010 oversize 2 Recommended equipment information for honing is as follows a Wheel e Friable bond material
163. ud Retaining Nut 50 70 1 20 Rocker Cover Screws 50 Oil Spray Nozzles 1 16 27 NPT 100 Oil Gage Tube 1 1 8 27 NPT 300 Drain Back Tube Nut 35 Drain Back Hose Clamp 10 Intake Hose Clamps 45 Fuel Pump and Prop Governor Hose Nuts 35 Fuel Injector Hose Nuts 30 Fuel and Prop Governor Elbow Locknuts 30 Spin on Oil Filter 192 216 Fuel Pump Socket Head Bolts 3 8 16 225 250 Vernatherm Valve 300 Injector and Primer Nozzle 60 Nut and Capscrews 10 24 10 32 49 Primer and Injector Tubing Nuts 25 Cylinder Hold Down Studs 3 8 16 100 Cylinder Hold Down Studs 1 2 13 250 Other Studs Minimum Driving Torque 14 20 15 5 16 18 25 3 8 16 50 72 00 11 March 2005 Superior Air Parts Inc Fiteand Clearances N27 SUPERIZR Overhaul Manual antage Engine AUR PARTS UNE O 360 and 360 Series Engines Table 72 00 11 3 Backlash and End Clearance Limits Description of Limit Minimum in Maximum in 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 Oil Pump Gears 0 010 0 030 Propeller Governor Gear to Idler Gear 0 004 0 015 Idler Gears End Clear 0 005 0 040 Propeller Governor Gear End Clear 0 002 0 024 Vacuum Pump Gear End Clear 0 010 0 057 Table 72 00 11 4 Valve Spring Dimensional Limits Compression Force Lb Description of Limit Wire Dia Compressed P Lb Height in Min Max Spring V
164. vice and install spark plugs and ignition leads and carburetor or fuel injection servo IAW the manufacturer s instructions Service engine and aircraft in accordance with the manufacturer s instructions Thoroughly clean the aircraft and engine Perform visual inspection Correct any discrepancies Conduct a normal engine start Perform a test flight in accordance with Operation Instructions of the Installation and Operation Manual Correct any discrepancies Perform a test flight in accordance with airframe manufacturer s instructions Correct any discrepancies prior to returning aircraft to service Change oil and filter after 25 hours of operation N27 anlage Engine LT N27 SUPERIZR Overhaul Manual antage Engine NIR PARTS O 360 360 Series Engines THIS PAGE INTENTIONALLY LEFT BLANK March 2005 Superior Air Parts Inc SUIPER IZ A REPAIR General The following sections contain major 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 list of repairs is provided in Table 72 00 13 1 e Materials required for repair are listed Table 72 00 13 2 e Equipment used for repair is listed in Table 72 00 13 3 e Codes used for repair are listed in Table 72 00 13 4 e Symbols used for repair are listed in Table 72 00 13 5 Repair Procedures Pe
165. vice limits for used parts are provided where they have been established H no service limits are provided new limits must be e Torque Limits are provided in Table 72 00 11 2 e Spring Limits are provided in Table 72 00 11 4 e Crush Type Gasket Tightening Angles are provided in Table 72 00 11 5 maintained NOTE Limits followed by the letter T indicate a tight i e an interference fit An Service Limits example is the fit of the valve guide in e Dimensional Limits are provided in Table 72 the cylinder head Where no T exists 00 11 1 the fit is a clearance dimension Backlash and Clearances Limits are provided in Table 72 00 11 3 Table 72 00 11 1 Dimensional Limits Description of Limit Minimum in Maximum in Piston Piston in Cylinder Bottom of Skirt Clear 0 0065 0 0095 Piston Weight Difference Opposing Pairs 4 oz Piston Rings Piston Ring in Groove Side Clearance Top Compression 0 0025 0 0055 Piston Ring in Groove Side Clearance 27 Compression 0 0000 0 0040 Piston Ring in Groove Side Clearance 3 Oil 0 0020 0 0040 End Gap Top Compression 0 0450 0 0550 End Gap 274 Compression 0 0450 0 0550 End Gap Oil Control 0 0150 0 0300 NOTE Measure end gaps 1 0 to 4 0 from bottom of barrel Minimum ring gap at top of stroke is 0 0075 measure compression ring gaps approx 6 5 from bottom of barrel and oil ring gap approx 6 from bottom of barrel Piston Pin Piston Pin and Plug in Cyli
166. y brushing scraping or grit blasting After cleaning rinse the parts in petroleum solvent dry and remove loose particles by blowing the particles out with compressed air Use a shop air supply with an appropriate water trap Decarbonizing solutions will usually remove most of the enamel from machined surfaces All remaining enamel should be removed by grit blasting particularly in the narrow areas between cylinder cooling fins Valve seats may be left unprotected during decarbonizing processes This will facilitate the reconditioning of the valve seat in later procedures CAUTION EXTREME CAUTION SHOULD BE EXERCISED WHEN USING A DECARBONIZING SOLUTION IT IS RECOMMENDED THAT THE USE OF HEATED SOLUTIONS BE AVOIDED UNLESS THE OPERATOR IS THOROUGHLY FAMILIAR WITH THE PARTICULAR SOLUTION BEING USED IN ADDITION THE OPERATOR 15 March 2005 Superior Air Parts Inc Overhaul Manual O 360 and IO 360 Series Engines STRONGLY ADVISED AGAINST IMMERSING STEEL AND MAGNESIUM PARTS IN THE SAME DECARBONIZING TANK BECAUSE THIS PRACTICE OFTEN RESULTS IN DAMAGE TO THE MAGNESIUM PARTS FROM CORROSION CAUTION DO NOT DAMAGE MACHINED SURFACES MASK MACHINE SURFACES PLUG DRILLED OIL PASSAGES TO PREVENT DAMAGE OR ENTRY OF FOREIGN MATTER CAUTION WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 20 PSI DO NOT DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS PUT ON GOGGLES OR A F
167. yable status on or before the 90 day expiration it must be preserved in accordance with Indefinite Storage procedures 72 00 12 Preservation Storage N27 anlage Engine SUPERIAR Indefinite Storage After following the step in the general section above and while the engine is still warm prepare the engine for long term storage in the following manner Do not drain preservative oil Re spray each cylinder To thoroughly cover all surfaces of the cylinder interior move the nozzle or spray gun from the top to the bottom of the cylinder 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 Install desiccant bags in exhaust ports Attach red Remove Before Flight streamer to each bag of desiccant in the exhaust ports and seal the openings Seal all engine openings exposed to the atmosphere using suitable plugs and covers Preserve crankshaft propeller flange with Mil C 16173 Grade 2 equivalent preservative oil On aircraft tag each propeller or if propeller is not installed on the propeller flange with the following notation on the tag Do Not Turn Propeller Engine Preserved Preservation Date Aircraft prepared for indefinite storage must have the cylinder dehydrator plugs visually inspected every 15 days The plugs must be changed as soon as they indicate other than a dark blue color If t

o-360 & io-360 series engines overhaul manual

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o-360 &amp; io-360 series engines overhaul manual

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o-360 & io-360 series engines overhaul manual