Overhaul Manual - IO-360-N1A Engine 02-2016

Engine Overhaul Manual
IO-360-N1A Engine
February 2016
Part No. OM-IO-360-N1A
© 2016 Avco Corporation. All Rights Reserved.

IO-360-N1A Engine Overhaul Manual
Lycoming Part Number: OM-IO-360-N1A
Contact Us:
Mailing Address:
Lycoming Engines
652 Oliver Street
Williamsport, PA 17701 USA
Phone:
U.S. and Canada Toll Free: +1 (800) 258-3279

Factory
Direct: +1 (570) 323-6181
Lycoming’s regular business hours are Monday through Friday from 8:00AM through 5:00PM
Eastern Time (-5 GMT).
Visit us Online: www.Lycoming.com

RECORD OF REVISIONS
Revision Revised
Revision Date By Revision Description
Original Original Release of Overhaul Manual - Part No. OM-IO-360-N1A
© 2016 Avco Corporation. All Rights Reserved Record of Revisions

February 2016 Page i
This page intentionally left blank.
Record of Revisions © 2016 Avco Corporation. All Rights Reserved

Page ii February 2016
SERVICE DOCUMENT LIST

NOTICE: The following is a list of service documents referenced in or incorporated into the
information in this manual. Always refer to the latest revision of any service document
for changes or additional information.
Number Incorporation Subject

Date
S.B. 201 02/16 Inspection After Engine Stoppage
S.B. 240 02/16 Mandatory Parts Replacement at Overhaul and During
Repair or Maintenance
S.I. 1009 02/16 Recommended Time Between Overhaul
S.I. 1011 02/16 Tappets and Lifters
S.I. 1098 02/16 Propeller Flange Bushing Location
S.I. 1285 02/16 Non-Destructive Testing of Lycoming Engine Parts
L114 02/16 Reciprocating Engine and Accessory Maintenance
Publications
© 2016 Avco Corporation. All Rights Reserved Service Document List

February 2016 Page iii
Service Document List © 2016 Avco Corporation. All Rights Reserved

Page iv February 2016
TABLE OF CONTENTS
Subject Page
Title Page _______________________________________________________________________
Record of Revisions ............................................................................................................................. i
Service Document List ......................................................................................................................iii
Table of Contents ............................................................................................................................... v
Abbreviations and Acronyms ......................................................................................................... vii
Introduction ....................................................................................................................................... ix
Chapter 5 – Time Limits / Maintenance Checks ________________________________________
Overhaul - General ..................................................................................... 05-00
— Overhaul .................................................................................................................................. 1
— Engine Overhaul vs. Engine Rebuild ...................................................................................... 1
— When to Complete an Overhaul .............................................................................................. 1
— Overhaul Checklists ................................................................................................................ 1
— Engine Overhaul Sequence ..................................................................................................... 1
— Overhaul Practices .................................................................................................................. 2
— Mandatory Parts Replacement During Overhaul .................................................................... 2
— List of Tools Used for Overhaul ............................................................................................. 3
Time Limits .................................................................................................. 05-10
— Time Between Overhaul (TBO) ............................................................................................... 5
Overhaul Cleaning ...................................................................................... 05-30
— Cleaning Guidelines ................................................................................................................. 7
Chapter 72 – Reciprocating Engine __________________________________________________
Engine Overhaul Checklists ....................................................................... 72-00
— Initial Visual Inspection at Overhaul Checklist for IO-360-N1A Engine Models ................. 10
— Overhaul Inspection Checklist for IO-360-N1A Engine Models ........................................... 12
— Crankcase Dimensional Inspection Checklist at Overhaul
for IO-360-N1A Engine Models ............................................................................................. 22
— Connecting Rod Inspection Checklist at Overhaul for IO-360-N1A Engine Models ............ 23
— Crankshaft Inspection Checklist at Overhaul for IO-360-N1A Engine Models ..................... 26
— Assembly Checklist at Overhaul for IO-360-N1A Engine Models ........................................ 33
© 2016 Avco Corporation. All Rights Reserved Table of Contents

February 2016 Page v
Table of Contents © 2016 Avco Corporation. All Rights Reserved

Page vi February 2016
ABBREVIATIONS AND ACRONYMS

A
ATA Air Transport Association
C
C. Celsius
F
F. Fahrenheit
FAA Federal Aviation Administration
FAR Federal Aviation (and Space) Regulation
FPI Fluorescent Penetrant Inspection
I
ICA Instructions for Continued Airworthiness
ID Inside Diameter or Inner Diameter
in.-lb. Inch Pound (torque)
in. Inch, inches
L
lb Pound
LL Low Lead (fuel)
M
MEK Methyl-ethyl-ketone
MPI Magnetic Particle Inspection
N
NAS National Aircraft Standard
NPT National Pipe Taper (thread)
O
OD Outside Diameter or Outer Diameter
oz Ounce
P
P/N Part Number
S
SAE Society of Automotive Engineers (oil viscosity)
SB Service Bulletin
SI Service Instruction
T
TBO Time Between Overhaul
TDC Top Dead Center
TIR Total Indicator Runout
© 2016 Avco Corporation. All Rights Reserved Abbreviations and Acronyms

February 2016 Page vii
Abbreviations and Acronyms © 2016 Avco Corporation. All Rights Reserved

Page viii February 2016
INTRODUCTION
The Lycoming IO-360-N1A engine is a direct-drive, four-cylinder, horizontally opposed, fuel-
injected, air-cooled engine (Figure 1). The engine has tuned induction and a down exhaust.
Figure 1
IO-360-N1A
Engine Model Nomenclature
The table below shows the definition of each letter and number for IO-360-N1A.
Model Number Meaning

I Fuel Injected
O Horizontally Opposed
360 Displacement in cubic inches
Engine Serial Number
Every engine sent from the factory is identified by a
unique serial number. The engine serial number is
identified on an engine data plate on the oil sump on
the right side of the engine (Figure 2). Do not remove
the engine data plate.
Figure 2
Engine Data Plate
© 2016 Avco Corporation. All Rights Reserved Introduction

February 2016 Page ix
Cylinder Number Designations

 The propeller is at the front of the engine.
 When viewed from the top of the engine, the left side cylinders are 2-4. Cylinder 2 is at the
front of the engine. Refer to Figure 3.
 When viewed from the top of the engine, the cylinders on the right are 1-3. Cylinder 1 is at the
front of the engine. Refer to Figure 3.
 The firing order of the cylinders is 1-3-2-4.
Figure 3
Top View of Engine – Cylinder Number Designations
Scope of this Manual

This manual contains instructions (in compliance with FAR 33.4) overhaul of the IO-360-N1A
Lycoming engine. The manual contains general overhaul information, an overview of steps and
references to procedures necessary for engine overhaul, as well as inspections. Overhaul checklists
are included as a comprehensive guide for engine overhaul. Refer to the IO-360-N1A Engine
Maintenance Manual for airworthiness limitations.
Before engine overhaul, read this entire manual. Complete all inspections, obey all procedures, and
replace all of the required parts for overhaul per this manual and in accordance with the latest
revision of Service Bulletin No. SB-240.
Introduction © 2016 Avco Corporation. All Rights Reserved

Page x February 2016
While some specified components can be replaced during overhaul in the field per instructions in
this manual, engines also can be sent either to the factory or to an authorized service center for
overhaul.
Refer to the IO-360-N1A Engine Installation and Operation Manual for engine features, system
description, uncrating procedures, acceptance check, engine lift procedure, engine preservation and
storage, depreservation, engine installation requirements, engine installation, engine start, operation,
and stop procedures, pre-flight test, operational test, fuels to be used, operating specifications, and
fuel curves.
Refer to the IO-360-N1A Engine Service Manual for service information for oil changes, oil
addition, oil suction screen cleaning, oil filter replacement, routine time-interval inspections, routine
service, spark plug replacement/inspection procedures, cylinder inspection, fuel system inspection,
and scheduled servicing procedures.
Refer to the IO-360-N1A Engine Maintenance Manual for airworthiness limitations, procedures for
fault isolation, component replacement, engine disassembly, and engine assembly.
Refer to the IO-360-N1A Illustrated Parts Catalog to identify spare parts.
Refer to the latest revision of the Service Table of Limits - SSP-1776, for dimensions, clearances,
measurements, and torque values as referenced in this manual.
Environmental Compliance
Lycoming recommends that engine owners and engine service personnel be in compliance with all
federal, state, and local environmental regulations when solvents, paint, fuel, oil, chemicals, or other
consumables are used in engine service.
Warnings, Cautions, and Notices
Be sure to read and obey the Warnings and Cautions in this manual and in service documents.
Although Lycoming Engines cannot know all possible hazards or damages, it makes a reasonable
effort to supply the best known guidance and recommended practices for safe operation of its
engines.
The table below defines the four types of safety advisory message used in this manual per the
American National Standard and ANSI Z535-6-2006.
Safety Advisory Conventions
Advisory Word Definition
DANGER: Indicates a hazardous situation which, if not avoided, will result
in death or serious injury. This signal word is to be limited to the
most extreme situations.
Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury. It also can be used without
the safety alert symbol as an alternative to "NOTICE."
NOTICE: The preferred signal word to address practices not related to
personal injury.
NOTICE: In this manual, the word "recommend" refers to "best practices."

February 2016 Page xi
Service Bulletins, Service Instructions, and Service Letters

As advancements in technological applications on this engine continue, Lycoming will make future
revisions to this manual. However, if more timely distribution is necessary, Lycoming supplies
subscribers with up-to-date Service Bulletins (SBs), Service Instructions (SIs) and Service Letters
(which are abbreviated with a capital “L” followed by the number, example L180). Special
Advisories (SAs) are supplied as necessary without a subscription.
For subscription information, look on Lycoming’s website (Lycoming.com) or speak to Lycoming
by telephone: U.S. and Canada toll free: +1-800-258-3279; International Customers: - +1-570-323-
6181.
Applicable information from Lycoming Engines' Service Bulletins, Service Instructions, and Service
Letters are included in this manual at the time of publication. Any new service information will be
included in the next update of the manual.
Reminder: Unless otherwise specified, Lycoming Engines' service documents override procedures
in this manual.
For reference, the Service Document List at the front of this manual shows the editions of the service
documents referenced or included in this manual.
Supplemental Service Information
Refer to the latest revision of Service Letter No. L114 for a list of Lycoming Engines' publications
available for purchase.
Instructions for Continued Airworthiness
The IO-360-N1A Engine Service Manual, IO-360-N1A Engine Maintenance Manual, latest
revision of the Service Table of Limits - SSP-1776, service documents and related publications
make up the complete set of Instructions for Continued Airworthiness (ICAs). The ICAs are
prepared by Lycoming Engines and are approved by the Federal Aviation Administration (FAA).
Simplified Technical English
The text in the manual is written in the form of Simplified Technical English in compliance with
FAA requirements and to make translation into other languages easier.
Format
Chapters in this manual are written as modules in Air Transport Association (ATA) format.
Figures
Figures in this manual are for illustration purposes only. Figures always start as Figure 1 in each
chapter.
Copyright
This publication is a copyrighted work. All rights reserved by Lycoming Engines. Content in this
manual cannot be changed or released as a reprint, electronic media output, or web communiqué
without written permission from Lycoming Engines.
Feedback
To supply comments, suggestions, or corrections to this manual, either make a call to customer
service or use the Lycoming.com website.

Page xii February 2016
Customer Service
Additionally, Lycoming has a Customer Service Hot Line to supply information and assistance to
owners, operators, and maintenance personnel servicing Lycoming engines.
Phone:
Factory: U.S. and Canada toll free - +1(800) 258-3279
International Customers - +1(570) 323-6181
Sales Department: +1(570) 327-7278
Fax: +1(570) 327-7101
Lycoming’s regular business hours are Monday through Friday from 8:00 A.M. through 5:00
P.M. Eastern Time (-5 GMT)
Change of Address Notification
The owner of the manual is responsible for supplying a change of address to Lycoming Engines.

February 2016 Page xiii

Page xiv February 2016
05-00 OVERHAUL - GENERAL
1. Overhaul
You will need the following manuals to complete engine overhaul:
 IO-360-N1A Engine Installation and Operation Manual
 IO-360-N1A Engine Service Manual
 IO-360-N1A Engine Maintenance Manual
 The latest revision of the Service Table of Limits - SSP-1776
2. Engine Overhaul vs. Engine Rebuild
Engine overhaul is different from engine rebuild as follows:
A. Engine overhaul – After an overhauled engine is returned to service the engine operating
hours continue without interruption as recorded in the engine logbook.
B. Engine rebuild - A rebuilt engine is "like new" and issued a zero-time logbook.
3. When to Complete an Overhaul
A. Refer to Chapter 05-10 “Time Limits” for Time Between Overhaul (TBO).
B. Engine disassembly or overhaul could be necessary as part of corrective action. Refer to
Chapter 05-50 in the IO-360-N1A Engine Maintenance Manual.
4. Overhaul Checklists
A. Overhaul Checklists in Chapter 72-00 identify all of the basic necessary inspections and
procedures that must be done during engine overhaul.
B. Make copies of all of the Overhaul Checklists and complete them during engine overhaul as a
record of overhaul. All items on the checklist must be done on the engine during overhaul.
5. Engine Overhaul Sequence
Refer to Table 1 for the Engine Overhaul sequence.
Table 1
Engine Overhaul Sequence
Step Task Reference
1 Review overhaul practices in this chapter “Overhaul Practices” in this chapter
2 Make sure you have the necessary special tools Chapter 05-00 of the IO-360-N1A
on hand Engine Maintenance Manual
3 Complete the initial visual inspection a Overhaul Chapter 72-00 in this manual
Checklist” (before cleaning); record findings on
checklist
4 Disassemble the engine Chapter 72-05 of the IO-360-N1A
Engine Maintenance Manual for
engine disassembly instructions
5 Complete the Overhaul Inspection Checklist, Chapter 72-00 in this manual
record findings on the checklist.
© 2016 Avco Corporation. All Rights Reserved 05-00

February 2016 Page 1
Table 1 (Cont.)
Engine Overhaul Sequence
Step Task Reference
6 Clean the components Chapter 05-30 of the IO-360-N1A
Engine Maintenance Manual
7 Examine components; complete checklists and Chapter 72-00 in this manual
record findings
8 Replace components “Mandatory Parts Replacement
During Overhaul” in this chapter
9 Assemble the engine Chapter 72-10 of the IO-360-N1A
Engine Maintenance Manual for
engine assembly instructions
10 Install the engine in the airframe IO-360-N1A Engine Installation
and Operation Manual and airframe
manufacturer’s instructions
11 Complete an operational ground run-up IO-360-N1A Engine Installation
and Operation Manual
6. Overhaul Practices
A. Do not re-use a gasket, O-ring, or seal. Always install a new gasket, O-ring, or seal during
component replacement.
B. Remove all traces of dirt, dust, debris and accumulated matter from parts. All parts must be
clean and examined for compliance before they are installed on the engine.
C. If adhesive tape has been applied to any part, remove all tape and residue, clean the part
completely.
D. If it is necessary to use a hammer to install a part, use only a plastic or rawhide hammer.
E. Hardware
(1) All lockwire and cotter pins that are removed must be discarded and not reused. New
safety lockwire and new cotter pins must be installed.
(2) All safety lockwire and cotter pins must be made of corrosion-resistant steel and
installed as a snug fit in holes in the castellation of the nut, stud, and bolt for correct
locking. Unless otherwise specified, bend one end of the cotter pin back over the stud
or bolt and the other end flat against the nut.
7. Mandatory Parts Replacement During Overhaul
NOTICE: Some parts, regardless of apparent condition, must be replaced with new parts during
engine overhaul (mandatory replacement) and some specified parts must be replaced
with new parts whenever the part is removed.
A. Refer to the latest revision of Service Bulletin No. SB-240 and the Lycoming Engines IO-
360-N1A Illustrated Parts Catalog to identify replacement parts and associated part numbers
for those parts which must be replaced (regardless of apparent condition) with new parts
either during overhaul or whenever a part is removed. For rebuilt engines, used parts in
compliance with fits, limits, and acceptance criteria can be used.
05-00 © 2016 Avco Corporation. All Rights Reserved

Page 2 February 2016
NOTICE: For parts ordering assistance, contact Lycoming sales 570-327-7278 or go to the
Lycoming.com website for details.
B. Service Kits for gasket sets, cylinders, crankshaft and the crankcase for IO-360-N1A engine
are identified in the IO-360-N1A Illustrated Parts Catalog.
8. List of Tools Used for Overhaul
Refer to the tools identified in Chapter 05-00 in the IO-360-N1A Engine Maintenance Manual.


05-10 TIME LIMITS

1. Time Between Overhaul (TBO)
The TBO takes into account service experience, variations in operating conditions, and frequency
of operation. However, because of variations in the manner in which engines are operated and
maintained, Lycoming Engines cannot give assurance that any individual operator will achieve
the TBO. The TBO for the IO-36-N1A engine model is 2000 hours or 12 years (whichever
occurs first). Refer to the latest revision of Service Instruction No. SI-1009 for any changes or
special circumstances for the recommended TBO.
NOTICE: Continuous service assumes that the aircraft will not be out of service for more than 30
consecutive days. However, if the engine is out of service on a usual basis for 30 days
or more or it has been flown or stored in humid, dusty, or volcanic ash conditions,
engine overhaul or rebuild could be necessary before the 2000 hours for IO-360-N1A
engines. Refer to the latest revision of Service Instruction No. SI-1009 for any change to
the recommended TBO.
Engine deterioration in the form of corrosion (rust) and the drying out and hardening of composition
materials such as gaskets, seals, flexible hoses and fuel pump diaphragms can occur if an engine is
out of service for an extended period of time. Due to the loss of a protective oil film after an
extended period of inactivity, abnormal wear on soft metal bearing surfaces can occur during engine
start. Therefore, all engines that do not accumulate the hourly period of TBO specified in this
publication are recommended to be overhauled in the 12th year.
NOTICE: Engine accessories and propellers could require overhaul or replacement before TBO.


05-30 OVERHAUL CLEANING

NOTICE: For overhaul cleaning of components, refer to Chapter 05-30 of the IO-360-N1A
Engine Maintenance Manual.


72-00 ENGINE OVERHAUL CHECKLISTS
Complete all of the checklists in this chapter as a record of overhaul. These checklists are guidelines
for a complete engine overhaul.
This chapter contains all of the necessary checklists as a guide for engine overhaul of IO-360-N1A
engine models. Before each engine overhaul, copy and complete each checklist as a record of
overhaul. Completion of all of these checklists ensures a complete engine overhaul.
The checklists contain references to procedures in this overhaul manual and the IO-360-N1A Engine
Maintenance Manual.
Initial Visual Inspection at Overhaul is to be completed before engine disassembly of the
Checklist engine as a record of external engine condition before
overhaul
Overhaul Inspection Checklist is to be completed after engine disassembly as a record of

inspection at overhaul and the condition of each engine
component and criteria to replace an engine component
Crankcase Dimensional Inspection is used to record the measurements of the crankshaft

Checklist at Overhaul bearings and camshaft bearings formed by the crankcase
Connecting Rod Inspection Checklist is used to record the condition of all four connecting rods
at Overhaul and any corrective action
Crankshaft Inspection Checklist at is used to record the condition of the crankshaft and any
Overhaul corrective action
Assembly Checklist at Overhaul is an overhaul guide and a record of completion for the
engine assembly sequence

The Initial Visual Inspection at Overhaul Checklist is to be completed before engine disassembly of
the engine as a record of external engine condition before overhaul.
Initial Visual Inspection at Overhaul Checklist for IO-360-N1A Engine Models
Engine Model Number__________________ Engine Serial Number:__________________
Engine Time:______________________ Date Inspection Done: _____________________
Inspection done by:______________________________
VISUAL INSPECTION
Before cleaning and disassembly of the engine, visually examine for the following conditions.
Engine Compartment
Findings/
Item Comments Done
Corrective Action
Look for and remove any dirt, The engine and nacelle
dust, volcanic ash, sand, or must be clean and free
particles on the engine and in of all dirt and unwanted
its compartment. materials.
Examine the cowling, engine
and its compartment for
evidence of fluid leaks,
residues, or discoloration.
Identify.
Cylinders
Item to Examine Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4
Head to barrel leakage? Yes O Yes O Yes O Yes O
No O No O No O No O
Oil leakage? Yes O Yes O Yes O Yes O
No O No O No O No O
Exhaust or combustion residue? Yes O Yes O Yes O Yes O
No O No O No O No O
Examine the following for cracks,
rust/pitting and damage.
External cylinder barrel Yes O Yes O Yes O Yes O
No O No O No O No O
Cylinder barrel fins Yes O Yes O Yes O Yes O
No O No O No O No O
Areas between and adjacent to the Yes O Yes O Yes O Yes O
fins No O No O No O No O
External surface of the cylinder head Yes O Yes O Yes O Yes O
and fins No O No O No O No O
Top and bottom spark plug bosses Yes O Yes O Yes O Yes O
No O No O No O No O

Initial Visual Inspection at Overhaul Checklist for IO-360-N1A Engine Models (Cont.)
Crankcase
Findings/
Item Comments Done
Corrective Action
Examine the external surface of
the crankcase for damage,
cracks.
Accessories and Accessory Housing
Findings/
Item Comments Done
Corrective Action
Examine the accessory housing
and its attached accessories for
damage and defects.
Wiring Harness
Findings/
Item Comments Done
Corrective Action
Examine the wiring harness,
electrical connectors and
engine for broken or frayed
wire, signs of chafing,
deterioration, abrasion or heat-
related damage.
Induction System
Look for cracks or damage on
the intake pipes.

The Overhaul Inspection Checklist is to be completed after engine disassembly as a record of

inspection at overhaul and the condition of each engine component and the criteria to replace an
engine component.
Overhaul Inspection Checklist for IO-360-N1A Engine Models
Findings/
Item Comments Done
Corrective Action
Electrical & Ignition System
NOTICE: Corrosion and deposits are evidence of leaking spark plugs or incorrect cleaning of
the spark plugs or connector ends.
Clean the spark plugs, ignition Refer to Chapter 05-30*
leads, and cable ends.
Examine spark plug and Refer to the “Spark Plug
ceramics for deposits, chafing, and Ignition Lead Acceptable O
corrosion, wear, and cracking Inspection“ section in Replace O
Chapter 74-20**
Examine the spark plug port
seals.
Examine each ignition lead for Refer to the “Spark Plug
chafing, insulation breakdown, and Ignition Lead Acceptable O
frayed wiring, deterioration, Inspection“ section in
heat damage, wear, and Chapter 74-20** Replace O
cracking
Examine the ignition harness Replace a broken or Acceptable O
for kinks or breaks in the kinked wiring harness.
wiring. Replace O
Examine the magneto in Replace a damaged or

accordance with the magneto malfunctioning
manufacturer's instructions magneto.
Complete a magnetic particle Refer to the “Non-
inspection on the magneto Destructive Testing” Acceptable O
gears. section in Chapter 05- Replace O
50*.
* IO-360-N1A Engine Maintenance Manual
** IO-360-N1A Engine Service Manual

Overhaul Inspection Checklist for IO-360-N1A Engine Models (Cont.)

Findings/
Item Comments Done
Corrective Action
Electrical & Ignition System (Cont.)
Examine the alternator bracket Replace any damaged,
for damage. Examine the stripped or galled
bracket fasteners for wear, bracket fasteners.
stripping or galling. Replace a damaged
bracket.
Refer to Chapter 72-70*
Examine the starter for Replace a damaged
damage. starter or
malfunctioning starter Acceptable O
per instructions in Replace O
“Starter Replacement”
in Chapter 72-70*.
Examine the starter mounting Replace a cracked or
bracket for cracks or damage. damaged starter
mounting bracket per Acceptable O
instructions in “Starter Replace O
Replacement” in
Chapter 72-70*.
inspection on the alternator Destructive Testing” Acceptable O
bracket and the starter bracket. section in Chapter 05- Replace O
50*.
Examine the alternator for Replace a damaged or
damage. malfunctioning
Acceptable O
alternator per
Replace O
instructions in Chapter
72-70*.
Examine the alternator belt for Replace a damaged,
cracks, damage or wear cracked, or worn
Acceptable O
alternator belt per
Replace O
instructions in Chapter
72-70*.
Lubrication System
Clean lubrication system Refer to Chapter 05-30*.
components.
Examine the oil level gage tube Replace a damaged oil
and dipstick for wear or level gage tube or a
damage. damaged dipstick. Refer
to Chapter 72-50*.


Findings/
Item Comments Done
Corrective Action
Lubrication System (Cont.)
Discard all oil lines or hoses. Replace all oil lines and
hoses during overhaul
per the “Oil Line
Replacement”
procedure in Chapter
72-50*.
Examine the oil sump and oil Replace a damaged or
sump bolt holes for damage or cracked oil sump per
cracks. Examine the mounting Chapter 72-50*. Acceptable O
surface on the oil sump for Replace O
scratches, warpage, and cracks
or leaks.
Examine the studs on the oil Replace any stripped,
sump for corrosion, distortion, corroded, distorted or
stripped or incomplete threads, damaged stud per
or looseness. Use a tool Chapter 72-50*.
maker’s square to complete a
check of the stud alignment.
No stud is to exceed the setting
per the latest revision of SSP-
1776, Table of Limits.
Examine the oil suction screen. Refer to the “Oil
Suction Screen
Removal/Inspection/ Acceptable O
Cleaning/Installation” Replace O
12-10**.
Examine the oil drain plug boss Replace the oil drain
and drain plug for damaged plug if the threads are
threads and damaged wrench damaged or stripped per
flats. Chapter 12-10**. Acceptable O
Replace the oil sump if Replace O
the drain plug boss is
damaged per Chapter
72-50*.
Discard the oil drain tube. Replace all oil drain
tubes during overhaul
per Chapter 72-30*.


Findings/
Item Comments Done
Corrective Action
Lubrication System (Cont.)
Examine the oil pump. Replace a damaged or

Use a flashlight and 10X malfunctioning oil
magnifying glass to examine pump per instructions in Acceptable O
the exterior and cavity of the Chapter 72-25*. Replace O
oil pump housing for damage
or cracks.
Discard the oil pump impellers. Replace all oil pump

impellers during
overhaul per Chapter
72-25*.
Examine all oil passages in the Clean and remove any

oil pump housing interior for obstructions to oil flow
flow restrictions; all oil in the oil pump housing.
passages must be clear and free Identify and correct the
of clogs. cause. Refer to Chapter
5-30* for cleaning
guidelines.
Examine the oil cooler bypass Replace a damaged or

valve. malfunctioning oil Acceptable O
cooler bypass valve per Replace O
Chapter 72-50*.
Use a flashlight and 10X Replace a damaged oil

magnifying glass to examine filter base per Chapter Acceptable O
the oil filter base (if it was 72-50*. Identify and
installed on the engine) for correct the cause. Replace O
cracks and warpage.
Examine the oil pressure relief The oil pressure relief

valve spring per Chapter 72-50*. valve spring must meet
specifications in Acceptable O
accordance with the
latest revision of the Replace O
Table of Limits, SSP-
1776


Findings/
Item Comments Done
Corrective Action
Fuel System
Clean the fuel system Refer to Chapter 05-30*.
components. Remove any
blockages in the injection
nozzle.
Examine the injection nozzles Replace any damaged Acceptable O
for damage. injection nozzle per
Chapter 73-10*. Replace O
Although fuel lines are Replace all fuel lines
replaced during overhaul, during overhaul per the
examine each fuel line for “Fuel Line Replacement”
damage and stains caused by procedure in Chapter 73-
fuel leakage. 10*.
Identify and correct the
cause of any fuel leakage.
Examine the fuel injector for Replace a damaged fuel
damage. injector per the “Fuel
Injector Replacement”
Acceptable O
procedure in Chapter 73-
10*. Replace O
Examine the fuel manifold for Replace a damaged fuel
damage. manifold per the “Fuel
Manifold Replacement”
Acceptable O
10*. Replace O
Examine the fuel pump for Replace an AC diaphragm
damage and leakage. fuel pump during
Discard an AC diaphragm fuel overhaul or a damaged,
pump (if applicable). leaky or malfunctioning Acceptable O
fuel pump per the “Fuel Replace O
Pump Replacement”
10*.
Remove and discard the fuel Replace the fuel pump
pump plunger plunger during overhaul


Findings/
Item Comments Done
Corrective Action
Accessory Housing
Clean the accessory housing Refer to Chapter 05-
30*.
Examine the accessory housing Replace a damaged,
external surface and mating gouged, or cracked Acceptable O
flanges for damage, cracks, and accessory housing per Replace O
gouges. Chapter 72-25*.
Examine the accessory housing Replace any stripped or
thru-bolts for damage, wear. damaged thru-bolts. Acceptable O
Make sure the threads are not Replace O
stripped.
Induction System
Examine each intake pipe for Replace any damaged intake pipe per the “Intake
damage per Chapter 72-80*. Pipe Replacement” procedure in Chapter 72-80*.
Intake Pipe 1
Intake Pipe 2
Intake Pipe 3
Intake Pipe 4
Cylinder Assembly
Examine the intercylinder Refer to the
baffles for wear or contact with “Intercylinder Baffle
cylinder fins. Inspection” section in
Chapter 72-30**.
Examine the cylinder and Refer to the “Visual
cylinder head. Cylinder Inspection”
72-30**.
Discard the exhaust valves. Replace exhaust valves
Although the exhaust valves during overhaul.
are replaced during overhaul,
examine for any tuliping or
damage.


Findings/
Item Comments Done
Corrective Action
Cylinder Assembly (Cont.)
Discard the intake and exhaust Replace intake and
valve guides. exhaust valve guides
Although the intake and during overhaul.
exhaust valve guides are
replaced during overhaul,
examine for any tuliping or
damage.
inspection on the push rods, Destructive Testing” Acceptable O
rocker arms, and rocker shafts. section in Chapter 05- Replace O
50*.
Examine the engine cylinders. Complete the “Cylinder
Assembly Inspection
Checklist” in Chapter
72-30*.
Clean the cylinders Refer to the “Cylinder
Cleaning” procedure in
Chapter 05-30*.
Complete a magnetic particle Cylinder Barrel Acceptable O
inspection on the cylinder Cylinder 1 Replace O
barrel on all cylinders.
Cylinder Barrel Acceptable O
Refer to the “Non-Destructive
Testing” section in Chapter 05- Cylinder 2 Replace O
50*. Cylinder Barrel Acceptable O
Cylinder 3 Replace O
Cylinder Barrel Acceptable O
Pistons
Clean the pistons. Refer to the “Piston
Cleaning” section in
Chapter 05-30*.
Examine the pistons. Complete the “Piston
Inspection Checklist” in
Chapter 72-30*.


Findings/
Item Comments Done
Corrective Action
Pistons (Cont.)
Complete a magnetic particle Piston Pin Acceptable O
inspection on the piston pins. Cylinder 1 Replace O
Refer to the “Non-Destructive Piston Pin Acceptable O
Testing” section in Chapter 05- Cylinder 2 Replace O
50*. Piston Pin Acceptable O
Piston Pin Acceptable O
Connecting Rods
Clean and examine the Complete the
connecting rods. “Connecting Rod
Inspection Checklist at
Overhaul for IO-360-
N1A Engine Models” in
this chapter.
Crankcase
Clean the crankcase. Refer to Chapter 05-30*.
Examine the external surface of Replace both crankcase
the crankcase for damage, halves if the mating
cracks, and defects. flanges on one or both Acceptable O
Examine the crankcase mating crankcase halves are Replace O
flanges for cracks, dents, damaged, dented,
gouges, and damage gouged, or cracked.
Examine the crankcase thru- Replace any stripped or
Acceptable O
bolts and studs to make sure damaged thru-bolt and
Replace O
the threads are not stripped. stud.
inspection on the crankcase Destructive Testing” Acceptable O
thru-studs. section in Chapter 05- Replace O
50*.
Complete a crankcase Complete the “Crankshaft
dimensional inspection. Dimensional Inspection
Acceptable O
Checklist at Overhaul for
Replace O
IO-360-N1A Engine
Models” in this chapter.
Camshaft
Clean the camshaft Refer to Chapter 05-30*.
Examine the camshaft Refer to the “Camshaft
Inspection” section in
Chapter 72-20*.


Findings/
Item Comments Done
Corrective Action
Crankshaft
inspection on the camshaft. Destructive Testing” Acceptable O
section in Chapter 05- Replace O
50*.
Clean the crankshaft. Refer to the “Crankshaft
Cleaning” section in
Chapter 05-30*.
Examine the crankshaft. Refer to the “Crankshaft
Inspection” section in
Chapter 72-20* and
complete the “Crankshaft
Inspection Checklist at
Overhaul” in this chapter.
Examine the alignment dowel. Refer to the “Alignment
Dowel Inspection”
section in Chapter 72-
20*.
inspection on the crankshaft. Destructive Testing” Acceptable O
50*.
Tappets
Discard roller tappets. Replace roller tappets
during overhaul per
Chapter 72-20*.
Discard all hydraulic tappet Replace hydraulic
plunger assemblies. tappet plunger
assemblies at overhaul.
Propeller Governor
Remove and discard propeller Replace at overhaul.
shaft sleeve rings
Examine the propeller Replace during overhaul
governor drive gear and gear per Chapter 72-20*.
slots for damage or wear
Examine the idler gear shaft, Replace any worn or
plug, and governor drive cover damaged component.
for wear or damage.


Findings/
Item Comments Done
Corrective Action
Exhaust System
Examine the exhaust system Refer to the “Exhaust
for cracks and corrosion. System Inspection” in
Chapter 78-00**.
Miscellaneous
Examine all bearing surfaces Replace a component
for scoring, galling, gouges, where the bearing
and wear. surface is scored, galled
gouged, or worn.
Examine all journal surfaces Replace a galled,
for galling, scores, scored, out-of-round, or
misalignment, and out-of- misaligned journal.
round.
Examine the involutes of the If pit marks are found,
gear teeth for pitting and replace the gear.
excessive wear
Examine shafts and pins for Replace any warped or
straightness or warpage. damaged shaft or pin.
inspection on all steel gears Destructive Testing”
and shafts. section in Chapter 05-
50*.
Examine the threads on Replace screwed fittings
screwed fittings for galled or that are galled or have
stripped threads. stripped threads.
inspection on all brackets. Destructive Testing” Acceptable O
50*.

The Crankcase Dimensional Inspection Checklist at Overhaul is used to record the measurements of
the crankshaft bearings and camshaft bearings formed by the crankcase. Refer to the “Crankcase
Inspection” section in Chapter 72-20 of the IO-360-N1A Engine Maintenance Manual.
Crankcase Dimensional Inspection Checklist at Overhaul for IO/AEIO-390-A Engine Models

Findings/
Item Comments Done
Corrective Action
Measure the I.D. of the Refer to the “Crankcase Center main bearing measurement
crankshaft bearings Dimensional Inspection” _________ inches
installed in the crankcase. in this chapter. Rear main bearing measurement
_________ inches
Measure the O.D. of the Crankshaft at center main bearing

crankshaft at the center measurement _________ inches
and rear bearing Crankshaft at rear main bearing
locations. measurement _________ inches
Compare the difference between each main bearing I.D. measurement and crankshaft O.D.
measurement to the Main Bearings and Crankshaft allowable clearance in the latest revision of the
Service Table of Limits - SSP-1776.
Measure the I.D. of the Refer to the “Crankcase Front bearing measurement
camshaft bearings formed Dimensional Inspection” ___________ inches
by the crankcase. in this chapter. Center bearing measurement
___________ inches
Rear bearing measurement
___________ inches
Measure the O.D. of the Front camshaft bearing location

camshaft at the bearing measurement ___________ inches
locations. Center camshaft bearing location
measurement ___________inches
Rear camshaft bearing location
measurement ___________inches
Compare the difference between each camshaft bearing I.D. measurement and camshaft O.D.
measurement to the Camshaft and Crankcase allowable clearance in the latest revision of the Service
Table of Limits - SSP-1776.

The Connecting Rod Inspection Checklist at Overhaul is used to record the condition of all four
connecting rods and any corrective action.
Connecting Rod Inspection Checklist at Overhaul for IO-360-N1A Engine Models
Task or Inspection Measurements, Findings and/or Corrective Action
Disassemble the connecting rod; clean
the rod and its cap thoroughly. Visually
examine the connecting rod for damage.
Examine the connecting rod bore for If rod bore is worn, replace the connecting rod
wear. assembly.
o Rod bore not worn o Worn rod bore/connecting rod
replaced
Examine the mating face of the If fretting is found, replace the connecting rod
connecting rod and its cap face for assembly.
fretting (Figure 1). o No fretting o Fretting found/connecting rod
replaced
Use a 6 power magnifying glass If galling is found, replace the connecting rod assembly.
(minimum) or bench microscope to o No galling o Galling found/connecting rod
examine the critical areas identified in replaced
Figure 1 for galling.*
* Do not mistake stains or discoloration for galling. Surface blemishes are easily removed with a
fine abrasive cloth, chemical cleaner or steel wool, whereas, galling cannot be removed. If galling
is found in the bearing bore, replace the connecting rod. To identify whether blemishes (stains or
discolorations) are caused by galling, try to remove the surface blemishes with a fine abrasive
cloth, chemical cleaner or steel wool. Blemishes caused by galling cannot be removed. Also, gall
marks vary in size and shape. Some gall marks can be as small as pin heads. Other gall marks can
be circular, oval, or thin, or look like rods.
Figure 1
Areas on Connecting Rod to Examine for Fretting and Galling

Connecting Rod Inspection Checklist at Overhaul for IO-360-N1A Engine Models (Cont.)
Findings/
Item Comments Done
Corrective Action
Measure the Inner If the connecting rod bushing Bushing ID Measurement
Diameter (ID) of is worn beyond service limits
the connecting Connecting Rod 1
per the latest revision of the
rod bushing using Service Table of Limits -
an inside SSP-1776, remove the Connecting Rod 2
micrometer bushing per “Connecting
(Figure 2). Rod Removal” in Chapter Connecting Rod 3
72-20*.
Connecting Rod 4
Complete a Magnetic Particle Inspection on

all connecting rods that pass the visual
inspection per “Non-Destructive Testing”
section in Chapter 05-50*.
Findings/ Corrective Action of
Done
Magnetic Particle Inspection
Acceptable O
Connecting Rod 1
Replace O
Acceptable O
Connecting Rod 2
Replace O
Acceptable O
Connecting Rod 3
Replace O
Figure 2 Acceptable O
Connecting Rod 4
Connecting Rod Replace O
Item Findings
Complete the “Connecting Rods - Parallelism Squareness
Parallelism/Squareness Check” in Chapter 72-20*. Measurement Measurement
Connecting
Rod 1
Connecting
Rod 2
Connecting
Rod 3
Connecting
Rod 4

Connecting Rod Bearing and Crankshaft Clearance
To complete this inspection:

NOTICE: For this inspection the connecting rods, bearings, connecting rod bolts, and nuts
(Figure 2) are assembled, but not installed on the crankshaft.
1. Assemble and torque each connecting rod with acceptable bearings per instructions in the
“Connecting Rod Installation” section in Chapter 72-20 of the IO-360-N1A Engine
Maintenance Manual.
2. Measure the inside diameter of the bearing in each connecting rod and record the
measurement below.
3. Measure the crankshaft diameter at the crankpin journal for each connecting rod and record
the measurement below.
4. Subtract the crankshaft diameter at the crankpin journal from the inside diameter of the
bearings for each connecting rod to calculate the connecting rod and crankshaft clearance.
Record the measurement below.
5. Compare the connecting rod bearing and crankshaft clearance to the acceptable clearance
measurement in the latest revision of the Service Table of Limits - SSP-1776.
6. Remove and discard the connecting rod bolts and nuts from the connecting rod assembly.
7. If the connecting rod bearing and crankshaft clearance is within limits the connecting rod
bearings are acceptable.
8. If the connecting rod bearing and crankshaft clearance is not within limits the connecting
rod bearings must be replaced with oversize bearings to bring the clearance within
acceptable limits.
Inside Diameter Crankshaft Diameter at Connecting Rod Bearing
Measurement
of the Bearings the Crankpin Journal and Crankshaft Clearance
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4

The Crankshaft Inspection Checklist at Overhaul is used to record the condition of the crankshaft
and any corrective action.
DO NOT MAKE SCORES, SCRATCHES, OR ETCH MARKINGS OF ANY
KIND ON THE CRANKSHAFT. A MARK CAN CAUSE THE PART TO
WEAKEN AND TO FAIL.
NOTICE: Before crankshaft inspection, clean the crankshaft per instructions in Chapter 5-30.
Crankshaft Inspection Checklist at Overhaul for IO-360-N1A Engine Models
Findings/
Item Comments Done
Corrective Action
Carefully examine all surfaces If a crack is found, replace the
of the crankshaft for cracks, crankshaft. Do NOT try to repair Acceptable O
gouges, nicks, dents, or a cracked or damaged Replace O
damage. crankshaft.
Complete a magnetic particle
inspection on the crankshaft Acceptable O
per the latest revision of
Replace O
Service Instruction No. SI-
1285.
Use a flashlight, magnifying If corrosion is found, refer to the
glass, and angled inspection section “Crankshaft Corrosion
mirror to visually examine the Removal Guidelines” in Chapter 72-
inner diameter of the 20*. If the corrosion cannot be
crankshaft bore, starting at the removed, replace the crankshaft. Acceptable O
crankshaft flange end. Look If pitting is found, complete a Replace O
for pit marks and corrosion. Fluorescent Penetrant Inspection
"Pitting" looks like holes, (FPI) (per the section "Non-
cracks, or fissures of Destructive Testing" in Chapter 05-
unspecified depth or direction. 50*.
Measure the inner diameter of For a crankshaft to be acceptable, Inner diameter
the crankshaft. Record the the inner diameter must not be measurement:
measurement. Refer to Figure 3 more than 1.910 in. (4.851 cm). If _______ inches
and the latest revision of Service the inner diameter of the or
Bulletin No. SB-505. crankshaft is more than 1.910 in.
______ centimeters
(4.851 cm), replace the crankshaft.
Examine the crankshaft Refer to the “Crankshaft Bearing
bearing surfaces. Surfaces Inspection” section in
Chapter 72-20*.

Crankshaft Inspection Checklist at Overhaul for IO-360-N1A Engine Models (Cont.)

Findings/
Item Comments Done
Corrective Action
Examine the counter-bored If galling or fretting is found,
mounting surface of the replace the crankshaft.
crankshaft for galling or fretting.
Figure 3
Area to be Examined


LYCOMING ENGINES NO LONGER APPROVES STRAIGHTENING OR
GRINDING OF BENT CRANKSHAFT FLANGES TO RESTORE MAXIMUM
RUN-OUT. IF THE CRANKSHAFT FLANGE IS BENT, REPLACE THE
CRANKSHAFT. DO NOT TRY TO STRAIGHTEN OR GRIND THE
CRANKSHAFT FLANGE.
Findings/
Item Comments Done
Corrective Action
Measure the crankshaft flange If the crankshaft flange is
thickness and compare it with the bent, replace the crankshaft.
dimensions below to calculate the Do NOT straighten or grind
minimum permissible thickness. a bent crankshaft. Refer to
the latest revision of Service
Bulletin No. SB-201 for any
additional details.
Crankshaft Flange Thickness
Inches Millimeters Inches Millimeters
0.440 ± 0.010 11.176 ± 0.254 0.420 10.668
Measure the run-out of the If run-out exceeds 0.002 in.
crankshaft flange with a dial (0.051 mm) total indicator
indicator at the location shown in reading, replace the
Figures 4 and 5. The maximum crankshaft.
Total Indicator Reading (TIR) Do not try to repair or grind
must not be more than 0.005 in. a warped or bent crankshaft
(0.127 mm). As shown in Figure flange.
4, make sure that the pilot
diameter runs true with the front
and rear main bearings within
0.003 in. (0.076 mm).
Measure the front face of the

crankshaft flange between the
flange bushings and the edge of
the chamfer.
Figure 4 Figure 5
Crankshaft Flange Crankshaft Flange Run-out and Pilot Diameter


Crankshaft Gear Inspection
Lycoming Engines no longer approves rework or repair of an unacceptable crankshaft gear.
Replace the crankshaft gear. Any time the crankshaft gear bolt and lockplate are removed from the
crankshaft gear, the bolt and lockplate are to be discarded and replaced with a new bolt and new
lockplate for the applicable crankshaft gear. Refer to Figure 6.
Figure 6
Crankshaft Gear Bolt and Lockplate
Findings/
Item Comments Done
Corrective Action
The crankshaft gear has three
scallops as shown in Figure 7.
Figure 7
Pilot Flange


Findings/
Item Comments Done
Corrective Action
Crankshaft Gear Inspection (Cont.)
Measure the diameter of the If the diameter of the pilot flange
crankshaft gear pilot flange is less than 2.125 in. (53.975
(Figure 8). mm) do not install this gear on
the crankshaft. Replace the
crankshaft gear with a
serviceable crankshaft gear.
Measure dimensions on the Acceptable O
crankshaft gear per those
shown in Figure 8. Replace O
Figure 8
Details for Crankshaft Gear
Examine the crankshaft gear Replace a pitted or worn Acceptable O
for pitting and wear. crankshaft gear. Replace O
Examine the pilot flange If the pilot flange of the
diameter of the crankshaft gear crankshaft gear is damaged, Acceptable O
for damage from galling or replace the crankshaft gear. Replace O
fretting.
If there is a hole or slot on the If nicks or dents are found, Acceptable O
crankshaft gear, examine the replace the crankshaft gear.
slot for any nicks or dents. Replace O
Complete a magnetic particle Refer to the “Non-Destructive Acceptable O

inspection of the crankshaft Testing” section in Chapter 05-
gear. 50. Replace O


Findings/
Item Comments Done
Corrective Action
Crankshaft Counterbore Inspection
DO NOT TRY TO REPAIR THE CRANKSHAFT COUNTERBORE
THREADS IN THE FIELD. IF THIS TYPE OF REPAIR IS NECESSARY,
SEND THE CRANKSHAFT TO THE FACTORY (THROUGH AN
AUTHORIZED LYCOMING DISTRIBUTOR) WITH PAPERWORK THAT
IDENTIFIES THE NECESSARY REPAIR.
NOTICE: Prior to inspection, the crankshaft counterbore must be clean, dry, and free of debris.
Refer to Chapter 05-30* for cleaning instructions.
Make sure the threads in the If the threads are galled, stripped
counterbored end of the or damaged, send the crankshaft
crankshaft are intact and not to the factory through an
galled, stripped, or damaged. authorized Lycoming Distributor
with paperwork that identifies
the type of damage. Do not try to
repair the threads in the field.
Measure the Inside Diameter If the diameter is oversized,
(ID) of the crankshaft replace the crankshaft.
counterbore at the rear of the Lycoming Engines no longer
crankshaft to make sure there is approves rework or repair of a
a correct fit between the ID of crankshaft with an unacceptable
the crankshaft and the Outside crankshaft counterbore diameter.
Diameter (OD) of the
crankshaft gear pilot flange.
The crankshaft counterbore
diameter at the rear of the
crankshaft must not be more
than 2.126 in. (54.000 mm)
when measured at any location.
Examine the gear mounting If the counter-bore face of the
face of the crankshaft crankshaft gear is damaged,
counterbore and the pilot flange replace the crankshaft gear
diameter of the crankshaft gear (Figure 7).
for damage from galling or
fretting.
If there is a hole or tang on the If nicks or dents are found,
crankshaft gear (instead of a replace the crankshaft gear with a
slot), examine the tang for any new three-scallop pilot flange
nicks or dents. gear.
Examine the condition of the
pilot and face at the rear of the
crankshaft.


Findings/
Item Comments Done
Corrective Action
Crankshaft Counterbore Inspection (Cont.)
Examine and measure the
alignment dowel per
instructions in the “Alignment
Dowel Inspection” procedure
in Chapter 72-20 of the IO-
360-N1A Engine Maintenance
Manual.
Rejection Criteria for a Crankshaft
A crankshaft must be replaced under any of the following conditions:
 Inner diameter measures more than 1.910 in. (4.851 cm)
 Corrosion cannot be removed
 Crack(s) or pitting with crack(s) in the crankshaft inner bore
 Crankshaft fails FPI
Findings/Comments:

The Assembly Checklist at Overhaul is an overhaul guide and a record of completion for the engine
assembly sequence.
Assembly Checklist at Overhaul for IO-360-N1A Engine Models

 Replace all eight roller tappets as a complete set during overhaul.
DO NOT INTERMIX TAPPET TYPES ON THE SAME ENGINE. DO
NOT MIX TAPPETS WITH DIFFERENT PART NUMBERS IN THE
SAME CRANKCASE.
NOTICE Refer to the latest revision of Service Instruction No. SI-1011 for guidelines on
replacing the camshaft when new tappets are installed in the engine.
 If a new or reconditioned camshaft is to be installed, install new tappet bodies.
Item Comments Done
Review the “General Assembly Practices” in
Chapter 72-10.*
FOR CORRECT ENGINE OPERATION, THE CRANKSHAFT GEAR

MUST BE INSTALLED CORRECTLY WITH NO GAP IN THE MATING
SURFACES BETWEEN COUNTERBORED-END OF THE
CRANKSHAFT AND THE CRANKSHAFT GEAR.
Start with a clean crankshaft which passed the
inspection, complete the “Crankshaft Assembly”
procedure in Chapter 72-20*.
Install a new expansion plug in the crankshaft per
the “Expansion Plug Installation” procedure in
Chapter 72-20*.
Either install a new solid-ring oil seal on the
crankshaft per the “Solid-Ring Oil Seal
Installation” procedure in Chapter 72-20* or later
on install a split oil seal per the “Crankshaft Oil
Seal Installation” procedure in Chapter 72-20*.
Assemble and install the connecting rods (on the
crankshaft) each with a pair of new bearing inserts,
a new connecting rod bolt, and a new nut – per the
“Connecting Rod Installation” procedure in Chapter
72-20*.

Assembly Checklist at Overhaul for IO-360-N1A Engine Models (Cont.)

Item Comments Done
Measure the inside diameter per the “Connecting **Measurement:
Rod Installation“ section in Chapter 72-20*.
Start with a clean crankcase which passed the
“Crankcase Inspection” in Chapter 72-20*.
Complete the “Piston Cooling Nozzle Installation”
Complete the “Crankshaft Idler Gear Shafts
Installation” procedure in Chapter 72-20*.
Install the oil plugs (if removed) per the “Oil Plug
Complete the “Oil Pressure Relief Valve
Complete the “Tappet Installation” procedure on
Chapter 72-20*.
Complete the “Crankshaft Bearing and O-Ring
Complete the “Propeller Governor Drive
Complete the “Camshaft Assembly and
Measure the camshaft endplay in the left crankcase **Measurement:
half per the “Camshaft Installation” procedure in
Chapter 72-20*.
Measure the camshaft endplay in the right **Measurement:
crankcase half per the “Camshaft Installation”
Measure the crankshaft bearing journals. Refer to **Measurement:
the “Crankshaft Bearing Surface Inspection”
section in Chapter 72-20*.
Complete the “Crankshaft Installation” procedure in
Chapter 72-20*.
Measure the slinger clearance per the “Measure the **Measurement:
Thrust Face Clearances Between the Crankshaft
and Crankcase” section in Chapter 72-20*.
Measure the crankshaft endplay per the “Measure **Measurement:
the Thrust Face Clearances Between the Crankshaft
and Crankcase” section in Chapter 72-20*.
** Measurements must be within tolerances specified in the latest revision of the Service Table
of Limits - SSP-1776.


Item Comments Done
Assemble the crankcase halves per the “Crankcase
Assembly” procedure and follow the torque
sequence in Chapter 72-20*.
Complete the “Crankshaft Oil Seal Installation in
the Crankcase” procedure in Chapter 72-20*.
Complete the “Crankshaft Idler Gear Installation”
Complete the “Fuel Pump Plunger Installation”
procedures in Chapter 72-25*.
Complete the “Oil Pump Installation” procedure in
Chapter 72-25*.
Complete the “Accessory Housing Installation”
Complete the “Oil Filter Base Installation”
Complete the “Oil Cooler Bypass Valve
Complete the “Fuel Pump Installation” procedure in
Chapter 73-10*.
Complete the “Oil Sump Installation” procedure in
Chapter 72-50*.
Complete the “Piston Installation” procedure in
Chapter 72-30* for all four pistons.
Complete the “Cylinder Installation” procedure in
Chapter 72-30*.
Install the starter ring gear support per the “Starter
Ring Gear Support Installation” procedure in
Chapter 72-70*.
Complete the “Intake Pipe Installation” procedure
in Chapter 72-80*.
Complete the “Oil Level Gage Installation”
procedure in Chapter 72-50.
Complete the “Intercylinder Baffle Installation”
Install a new oil drain tube at each cylinder head
and at the crankcase per the “Oil Drain Tube


Item Comments Done
Examine, set the gap, and install the spark plugs per
the “Spark Plug Gap Setting” and Spark Plug
Installation” procedures in Chapter 74-20 of the IO-
360-N1A Engine Service Manual.
Complete the “Magneto Installation” procedure in
Chapter 74-30*.
Complete the “Ignition Harness Installation”
Complete the “Fuel Manifold Installation”
Complete the “Fuel Injector Installation” procedure
in Chapter 73-10*.
Complete the “Injection Nozzle Installation”
Install new fuel lines and complete the “Fuel Line
Complete the “Starter Installation” procedure in
Chapter 72-70*.
Complete the “Alternator and Bracket Installation”
and “Alternator Belt Installation” procedures in
Chapter 72-70*.
Install the engine in the airframe per instructions in
the IO-360-N1A Engine Installation and
Operation Manual and applicable Airframe
Maintenance Manual.
Add oil to the engine in accordance with the
procedure “Add Oil to the Engine” in Chapter 12-
10 of the IO-360-N1A Engine Service Manual.
Complete an “Operational Ground Check” per
Chapter 72-00 of the IO-360-N1A Engine Service
Manual.


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Engine Overhaul Manual

© 2016 Avco Corporation. All Rights Reserved.

U.S. and Canada Toll Free: +1 (800) 258-3279

Visit us Online: www.Lycoming.com

© 2016 Avco Corporation. All Rights Reserved Record of Revisions

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Record of Revisions © 2016 Avco Corporation. All Rights Reserved

SERVICE DOCUMENT LIST

Number Incorporation Subject

© 2016 Avco Corporation. All Rights Reserved Service Document List

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Service Document List © 2016 Avco Corporation. All Rights Reserved

© 2016 Avco Corporation. All Rights Reserved Table of Contents

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Table of Contents © 2016 Avco Corporation. All Rights Reserved

ABBREVIATIONS AND ACRONYMS

© 2016 Avco Corporation. All Rights Reserved Abbreviations and Acronyms

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Abbreviations and Acronyms © 2016 Avco Corporation. All Rights Reserved

Model Number Meaning

© 2016 Avco Corporation. All Rights Reserved Introduction

Cylinder Number Designations

Scope of this Manual

Introduction © 2016 Avco Corporation. All Rights Reserved

© 2016 Avco Corporation. All Rights Reserved Introduction

Service Bulletins, Service Instructions, and Service Letters

Introduction © 2016 Avco Corporation. All Rights Reserved

© 2016 Avco Corporation. All Rights Reserved Introduction

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Introduction © 2016 Avco Corporation. All Rights Reserved

05-00 OVERHAUL - GENERAL

© 2016 Avco Corporation. All Rights Reserved 05-00

05-00 © 2016 Avco Corporation. All Rights Reserved

© 2016 Avco Corporation. All Rights Reserved 05-00

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05-00 © 2016 Avco Corporation. All Rights Reserved

05-10 TIME LIMITS

© 2016 Avco Corporation. All Rights Reserved 05-10

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05-10 © 2016 Avco Corporation. All Rights Reserved

05-30 OVERHAUL CLEANING

© 2016 Avco Corporation. All Rights Reserved 05-30

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05-30 © 2016 Avco Corporation. All Rights Reserved

72-00 ENGINE OVERHAUL CHECKLISTS

Overhaul Inspection Checklist is to be completed after engine disassembly as a record of

Crankcase Dimensional Inspection is used to record the measurements of the crankshaft

© 2016 Avco Corporation. All Rights Reserved 72-00

72-00 © 2016 Avco Corporation. All Rights Reserved

© 2016 Avco Corporation. All Rights Reserved 72-00

The Overhaul Inspection Checklist is to be completed after engine disassembly as a record of

Examine the magneto in Replace a damaged or

72-00 © 2016 Avco Corporation. All Rights Reserved

Overhaul Inspection Checklist for IO-360-N1A Engine Models (Cont.)

© 2016 Avco Corporation. All Rights Reserved 72-00

Overhaul Inspection Checklist for IO-360-N1A Engine Models (Cont.)

72-00 © 2016 Avco Corporation. All Rights Reserved

Overhaul Inspection Checklist for IO-360-N1A Engine Models (Cont.)

Examine the oil pump. Replace a damaged or

Engine Model Number Engine Serial Number: