Superior IO-360 SERIES - Overhaul Manual

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O-360 & IO-360 SERIES ENGINES

OVERHAUL MANUAL

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

www.superiorairparts.com

Manual P/N SVOHM01 Revision A, March 2005

Main Page

Table of Contents11
Abbreviations15
About this Manual15
Consumable Materials17
Continued Airworthiness19
Engine Model Number Designation19
Manufacturer's General Specifications21
- 02-00-00.2 Accessory Drive Specifications21
- Engine Components General Description21
- O-360 Engine Front View23
- O-360 Engine Left Side View23
- O-360 Engine Top View23
- O-360 Engine Rear View23
- Engine Rear View Ignition Wiring Diagram Oil System Schematic23
- Illustrated Views of the Engine23
  - Features and Operating Mechanisms34
  - Mandatory Inspection Intervals37
- Special Tools and Equipment39
- Engine will Not Start39
- 72-00-03.4 Rough Idling39
- 72-00-03.5 Engine Not Able to Develop Full Power39
- Rough Engine Operation39
- 72-00-03.7 Low Power & Engine Runs Rough39
- Low Oil Pressure on Engine Gage39
- 72-00-03.9 High Oil Temperature39
72-00-03.10 Excessive Oil Consumption39
- Troubleshooting39
- Break-In Procedures42
- Prior to Break-In Start-Up43
- Special Tools and Equipment43
- Post Break-In Procedures44
- 72-00-05.1 Equipment and Materials List45
- General45
Disassembly Materials47
- Discard Parts47
- 72-00-06.3 Special Tools and Equipment47
- General Disassembly Procedures48
Equipment Required for Cleaning53
- 72-00-07.2 Materials Required for Cleaning53
Inspection Materials57
- 72-00-08.2 Special Tools and Equipment57
- Accessory Housing60
- Crankcase Bearing and Flange Surfaces61
  - Cylinder Head62
  - Cylinder Barrel Dimensional Inspections63
- Cylinder Assembly64
- Piston Assembly65
- Piston Rings and Lands66
- Valve Rockers67
- Valve Train68
  - Crankshaft69
  - Camshaft Inspection70
- Camshaft Assembly71
Assembly Materials73
- Fits, Clearances and Torque Values73
- Crankcase Bearing Retention Dowel76
- Crankshaft Bearing and Oil Pressure Relief Valve77
- Crankshaft Assembly78
Crankcase Assembly80
- Connecting Rod and Piston Assembly84
- Connecting Rod Installation85
- Camshaft Assembly86
Crankcase Attaching Hardware89
Crankcase Attaching Hardware (Cont'D.)90
Cylinder Valve Train and Spring Assembly94
Piston Assembly to Connecting Rod95
Cylinder Assembly and Head Oil Drain Line97
Piston Assembly with Ring Compressor Tool98
Cylinder Base Nuts Sequence of Tightening99
Idler Gear and Tachometer Shaft Assemblies102
Idler Gear and Tachometer Shaft Assemblies (Cont'D.)103
Accessory Drive Gear Arrangement104
Accessory Housing107
Accessory Housing Gasket Trimming109
Oil Sump and Induction System112
Oil Level Gage113
Induction System114
Engine Accessory Assembly Installation118
Fuel Pump119
Propeller Governor Adapter121
Propeller Governor Oil Line122
Fuel Injection Servo Installation127
Fuel Injection Manifold Installation128
Storage after Assembly130
Starter Ring Gear Alignment132
Alternator Installation133
Equipment and Materials List135
- Preparing Engine for Service135
- Crush Type Gasket Tightening Angles137
- Dimensional Limits137
- Service Limits137
- Torque Limits139
- Storage Materials141
- List of Repairs146
- Consumable Materials for Paint Procedures155
- Cylinder Interior Resurface Crosshatch160
- Exhaust Valve Seat Standard and Oversize Dimensions164
- Intake Valve Seat Standard and Oversize Dimensions164
- Exhaust Valve Guide Standard and Oversize Dimensions165
Intake Valve Guide Standard and Oversize Dimensions165

Superior IO-360 SERIES - Overhaul Manual

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