60297 36 Lycoming IO 360 M1a Operating Manual

User Manual: Lycoming-IO-360-m1a-operating-manual

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(L)IO-360-M1A Operation and Installation Manual

July 2008

FAA Approved

Williamsport, PA 17701

Part No. 60297-36

(L)IO-360-M1A Operation and Installation Manual

Lycoming Part Number: 60297-36

Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of

Lycoming.

Lycoming Engines, a division of AVCO Corporation, a wholly owned subsidiary of

Textron Inc.

All brand and product names referenced in this publication are trademarks or registered

trademarks of their respective companies.

For additional information:

Mailing address:

Lycoming Engines

652 Oliver Street

Williamsport, PA 17701 U.S.A.

Phone:Factory: 570-323-6181

Sales Department: 570-327-7278

Fax: 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)

Visit us on the World Wide Web at:

http://www.lycoming.com

Lycoming is a Textron Company

LYCOMING OPERATION AND INSTALLATION MANUAL (L)IO-360-M1A

ATTENTION

OWNERS, OPERATORS, AND

MAINTENANCE PERSONNEL

This manual contains a description of the engine, its specifications, and detailed information on how to

operate and install it. This manual is FAA Approved and complies with FAR 33.5 and is intended for use by

owners, pilots and maintenance personnel responsible for care of Lycoming powered aircraft. Modifications

and repair procedures are contained in the Lycoming Maintenance and Overhaul Manual; maintenance

personnel must refer to these for such procedures.

SAFETY WARNING

MAINTENANCE MUST BE PERFORMED BY QUALIFIED AND PROPERLY CERTIFIED

PERSONNEL. NEGLECTING TO FOLLOW THE OPERATING INSTRUCTIONS AND TO

CARRY OUT PERIODIC MAINTENANCE PROCEDURES CAN RESULT IN POOR

ENGINE PERFORMANCE AND POWER LOSS. ALSO, IF POWER AND SPEED

LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED, FOR ANY REASON,

DAMAGE TO THE ENGINE AND PERSONAL INJURY CAN HAPPEN. CONSULT YOUR

LOCAL FAA APPROVED MAINTENANCE FACILITY.

SERVICE PUBLICATIONS

Lycoming service publications and subscriptions are available through Lycoming distributors or direct

from the factory.

NOTE

The illustrations, pictures and drawings shown in this publication are typical of the subject

matter they portray; in no instance are they to be interpreted as examples of any specific

engine, equipment or part thereof.

(L)IO-360-M1A LYCOMING OPERATION AND INSTALLATION MANUAL

IMPORTANT SAFETY NOTICE

Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. The

service procedures recommended by Lycoming are effective methods for performing service operations.

Some of these service operations require the use of tools specially designed for the task. These special tools

must be used when and as recommended.

It is important to note that this manual uses the following Notes, Cautions and Warnings which must be

carefully read in order to minimize the risk of personal injury or the use of improper service methods that

may damage the engine or render it unsafe.

NOTE Read for added information and reminders.

CAUTION Equipment damage may result if instructions are not followed.

WARNING Personal injury could result if instructions are not followed.

It is also important to understand that these Warnings and Cautions are not all inclusive. Lycoming

could not possibly know, evaluate or advise the service trade of all conceivable ways in which service might

be done or of the possible hazardous consequences that may be involved. Accordingly, anyone who uses a

service procedure must first satisfy themselves thoroughly that neither their safety nor aircraft safety will be

jeopardized by the service procedure they select.

LYCOMING OPERATION AND INSTALLATION MANUAL (L)IO-360-M1A

iii

TABLE OF CONTENTS

Page

SECTION I OPERATION

PART 1 DESCRIPTION SECTION I, 3

PART 2 SPECIFICATIONS SECTION I, 9

PART 3 OPERATING INSTRUCTIONS SECTION I, 13

SECTION II INSTALLATION

PART 1 PREPARATION SECTION II, 25

PART 2 PROCEDURES SECTION II, 29

(L)IO-360-M1A LYCOMING OPERATION AND INSTALLATION MANUAL

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A DESCRIPTION

SECTION I

PART 1

DESCRIPTION

Page

General .............................................................................................................................................................3

Cylinders...........................................................................................................................................................3

Valve Operating Mechanism .........................................................................................................................3

Crankcase ........................................................................................................................................................3

Crankshaft .......................................................................................................................................................3

Accessory Housing ..........................................................................................................................................3

Connecting Rods ..............................................................................................................................................4

Pistons ..............................................................................................................................................................4

Oil Sump ...........................................................................................................................................................4

Cooling System ................................................................................................................................................4

Induction System .............................................................................................................................................4

Lubrication System..........................................................................................................................................5

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DESCRIPTION (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A DESCRIPTION

SECTION I

PART 1

DESCRIPTION

The Lycoming (L)IO-360-M1A is a fuel injected, direct-drive, four-cylinder, horizontally opposed, and

air-cooled with a down exhaust. This engine is supplied with a starter. Mounting pad drives for two AN-

type accessories and a propeller governor are included.

FAA Type Certificate Number 1E10 has been issued for this engine.

The (L)IO-360-M1A engine has a rated maximum continuous power of 180 hp at 2700 RPM at standard

sea level conditions. The engine has a bore of 5.125 in., a stroke of 4.375 in., a piston displacement of 361

cubic inches, and a compression ratio of 8.5:1.

NOTE

The letter “L” in the model prefix denotes the reverse rotation of the basic model. Example:

model IO-360-M1A has clockwise rotation of the crankshaft. Therefore, LIO-360-M1A has

counterclockwise rotation of the crankshaft. Likewise the rotation of the accessory drives of

the LIO-360-M1A is opposite those of the basic model as listed in Section I, Part 2 of this

manual.

Operational aspects of engines are the same and performance curves and specifications for

the basic model will apply.

Cylinders - The nitrided cylinders are air-cooled with the major parts (head and barrel) screwed and shrunk

together. The heads are made from an aluminum alloy casting with a fully machined combustion chamber.

Valve guides and valve seats are shrunk into machined recesses in the head. Rocker shaft bearing supports

are cast integrally with the head along with the housings to form the rocker boxes for both intake and

exhaust valve rockers.

The Lycoming (L)IO-360-M1A engine incorporates a color coding system painted on the cylinder heads

to designate the specific cylinder barrels and spark plugs required. The (L)IO-360-M1A engine has nitrided

cylinders, indicated by blue paint between the shroud tubes, and requires long-reach spark plugs, indicated

by yellow paint between the spark plug and the rocker box cover.

Cylinder barrels are machined from a chrome nickel molybdenum steel forging with deep integral

cooling fins. The interiors of the barrels are ground and honed to a specified finish.

Valve Operating Mechanism - The valve-operating mechanism employs a conventional camshaft located

above and parallel to the crankshaft. The camshaft actuates tappets which operate the valves through push

rods and valve rockers.

Roller tappets are used to compensate for any expansion or contraction occurring in the valve train.

SECTION I LYCOMING OPERATION AND INSTALLATION MANUAL

DESCRIPTION (L)IO-360-M1A

Crankcase - The crankcase assembly consists of two reinforced aluminum alloy castings divided at the

centerline of the engine and fastened together by a series of body fit-through studs and bolts and nuts. The

mating surfaces of the two castings are joined without use of a gasket, and the main bearing bores are

machined for the use of precision-type main bearing inserts. The crankcase forms the bearings for the

camshaft.

Crankshaft - The crankshaft is made from a chrome nickel molybdenum steel forging and all journal

surfaces are nitrided. A system of dynamic counterweights eliminates torsional vibration.

Accessory Housing - An accessory housing is machined from an aluminum alloy casting and is fastened to

the rear of the crankcase and to the top of the oil sump. The two magnetos and the fuel pump are mounted

on machined pads on the accessory housing, and provisions for two additional accessories are provided.

Connecting Rods - Connecting rods are made in the form of “H” sections from alloy steel forgings. They

have replaceable bearing inserts in the crankshaft ends and split-type bronze bushings in the piston ends.

The bearing caps on the crankshaft ends of the rods are retained by two bolts through each cap secured by

nuts.

Pistons - The pistons are machined from an aluminum alloy forging. The piston pin is of the full-floating

type with a plug at each end of the pin.

The lubrication system in the (L)IO-360-M1A engine uses a wet sump. Figure 1-1 shows a schematic

diagram of the oil system.

Oil Sump - The sump incorporates the usual oil drain plug, oil suction screen, fuel injector mounting pad,

and the conventional intake riser and intake pipe connectors.

Cooling System - This engine is designed to be cooled by air pressure. Baffles are provided to build up a

pressure and force the air through the cylinder fins. The air is then exhausted to the atmosphere through gills

or augmenter tubes usually located at the rear of the cowling.

Induction System - Lycoming (L)IO-360-M1A engines are equipped with a Precision Airmotive RSA type

fuel injection system. The system is based on the principle of measuring air flow and using the air flow

signal in a stem type regulator to convert the air force of the air into a corresponding fuel force. This fuel

force (fuel pressure differential) applied across the fuel metering section (jet system) makes fuel flow

proportional to air flow. A manual mixture control and idle cut-off are provided. Particularly good

distribution of the fuel-air mixture is obtained through the center zone induction system, which is integral

with the oil sump and is submerged in the oil and aids in cooling the oil in the sump. From the riser,

distribution to each cylinder is by individual intake pipes. Fuel vaporization takes place at the intake ports.

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A DESCRIPTION

Figure 1-1. Oil System Schematic Diagram

Lubrication System - The lubrication system is of the pressure wet sump type. Figure 1-1 shows a schematic

diagram of the oil system. The main bearings, connecting rod bearings, camshaft bearings, valve tappets,

push rods and crankshaft idle gears are lubricated by means of oil collectors and spray. The oil pump, which

is located in the accessory housing, draws oil through a drilled passage leading from the oil suction screen

located in the sump. The oil from the pump then enters a drilled passage in the accessory housing, where a

flexible line leads the oil to the external oil cooler. In the event that cold oil or an obstruction should restrict

the flow of oil to the cooler, an oil cooler bypass valve is provided. Pressure oil from the cooler returns to a

second threaded connection on the accessory housing from which point a drilled passage conducts the oil to

the oil pressure screen, which is installed in a cast chamber located on the accessory housing below the

tachometer drive.

The oil pressure screen is provided to filter from the oil any solid particles that may have passed through

the suction screen in the sump. After being filtered in the pressure screen chamber, the oil is fed through a

drilled passage to the oil relief valve, located in the upper right side of the crankcase in the front of the

accessory housing.

This relief valve regulates the engine oil pressure by allowing excessive oil to return to the sump, while

the balance of the pressure oil is fed to the main oil gallery, the oil is distributed by means of separate drilled

passages to the main bearings of the rod journals. Oil from the main oil gallery also flows to the cam and the

valve gear passages, and is then conducted through branch passages to the roller tappets and camshaft

bearings. Oil enters the tappet through indexing holes and travels out through the hollow push rods to the

valve mechanism, lubricating the valve rocker bearings and the valve stems. Residual oil from the bearings,

accessory drives and the rocker boxes is returned by gravity to the sump.

The fuel injection systems control fuel flow in proportion to airflow with injection.

Dual ignition is furnished by two Slick magnetos and harnesses.

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DESCRIPTION (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A SPECIFICATIONS

SECTION I

PART 2

SPECIFICATIONS

Page

Specifications....................................................................................................................................................9

Standard Engine Weights ..............................................................................................................................9

Moments of Inertia ..........................................................................................................................................9

Accessory Drives .............................................................................................................................................9

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SPECIFICATIONS (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A SPECIFICATIONS

SECTION I

PART 2

SPECIFICATIONS

1. SPECIFICATIONS.

Model Designation..............................................................................................................(L)IO-360-M1A

FAA Type Certificate ..........................................................................................................................1E10

Rated horsepower ....................................................................................................................................180

Rated speed, RPM .................................................................................................................................2700

Bore, inches ..........................................................................................................................................5.125

Stroke, inches .......................................................................................................................................4.375

Displacement, cubic inches .....................................................................................................................361

Compression ratio ................................................................................................................................ 8.5:1

Firing order ...................................................................................................................................... 1-3-2-4

Spark occurs, degrees BTC .......................................................................................................................25

Valve rocker clearance (hydraulic tappets collapsed) .................................................................. .028-.080

Prop. drive ratio ...................................................................................................................................... 1:1

Prop. driven rotation ....................................................................................................................Clockwise

This engine has an alternate rating of 160 HP at 2400 RPM.

2. Standard Engine, Dry Weight (Includes all engine accessories except alternator.)

(L)IO-360-M1A ...............................................................................................................................300 lbs.

3. Moments of Inertia (Standard Dry Weight, all)

About the axis parallel to the crankshaft centerline (Ixg)...................................................47.58 in. lb. sec²

About the vertical axis (Izg) ...............................................................................................70.13 in. lb. sec²

About the axis parallel to the centerline (Iyg) ....................................................................42.41 in. lb. sec²

4. Accessory Drives

*Accessory Drive Drive Ratio **Direction of Rotation

Starter 16.556:1 Counterclockwise

Alternator 3.200:1 Clockwise

Vacuum Pump 1.300:1 Counterclockwise

Hydraulic Pump 1.385:1 Clockwise

Tachometer .500:1 Clockwise

Propeller Governor .947:1 Clockwise

Magneto Drive 1.000:1 Clockwise

Fuel Pump 1.000:1 Counterclockwise

* - When applicable.

** - Viewed facing drive pad. NOTE

Engines with the letter “L” in prefix will have opposite rotation to the above.

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SPECIFICATIONS (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A OPERATING INSTRUCTIONS

SECTION I

PART 3

OPERATING INSTRUCTIONS

Page

General ...........................................................................................................................................................13

Prestarting Items of Maintenance ...............................................................................................................13

Starting Procedures ......................................................................................................................................14

Cold Weather Starting .................................................................................................................................15

Ground Running and Warm-Up .................................................................................................................15

Ground Check ...............................................................................................................................................15

Operating in Flight .......................................................................................................................................16

Fuel Mixture Leaning Procedure ................................................................................................................16

Engine Flight Chart ......................................................................................................................................17

Engine Shut Down ........................................................................................................................................19

Performance Curves .....................................................................................................................................20

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OPERATING INSTRUCTIONS (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A OPERATING INSTRUCTIONS

SECTION I

PART 3

OPERATING INSTRUCTIONS

1. GENERAL.

Close adherence to these instructions will greatly contribute to the long life, economy and satisfactory

operation of the engine.

NOTE

YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN THE

FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIED

FUELS AND LUBRICANTS, REPAIRS AND ALTERATIONS. PERHAPS NO OTHER ITEM

OF ENGINE OPERATION AND MAINTENANCE CONTRIBUTES QUITE SO MUCH TO

SATISFACTORY PERFORMANCE AND LONG LIFE AS THE CONSTANT USE OF

CORRECT GRADES OF FUEL AND OIL, CORRECT ENGINE TIMING, AND FLYING

THE AIRCRAFT AT ALL TIMES WITHIN THE SPEED AND POWER RANGE SPECIFIED

FOR THE ENGINE. DO NOT FORGET THAT VIOLATION OF THE OPERATION AND

MAINTENANCE SPECIFICATIONS FOR YOUR ENGINE WILL NOT ONLY VOID YOUR

WARRANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTY

PERIOD HAS PASSED.

New engines have been carefully run-in by Lycoming and therefore, no further break-in is necessary

insofar as operation is concerned; however, operate new or newly overhauled engines using only the

recommended lubricating oils. Refer to Oil Requirements, Section 8.d.

NOTE

Cruise at 65% to 75% power until a total of 50 hours has been accumulated or the oil

consumption has stabilized. This is to insure the proper seating of the rings as is applicable

to new engines and engines in service following cylinder replacement or top overhaul of one

or more cylinders.

The minimum fuel octane rating is listed in the flight chart, Part 9 of this section. Do not use fuel of a

lower octane rating or automotive fuel (regardless of octane rating).

2. PRESTARTING ITEMS OF MAINTENANCE.

Before starting the aircraft engines for the first flight of the day, perform the following items of

maintenance inspection in conjunction with the aircraft Pilot’s Operating Handbook preflight check.

(a) Be sure all switches are in the “Off” position.

(b) Be sure magneto ground wires are connected.

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OPERATING INSTRUCTIONS (L)IO-360-M1A

(d) Check fuel level.

(e) Check fuel and oil line connections, note minor indications for repair at 50 hour inspection. Repair

any leaks before aircraft is flown.

(f) Open the fuel drain to remove any accumulation of water and sediment.

(g) Make sure all shields and cowling are in place and secure. If any are missing or damaged, repair or

replacement should be made before the aircraft is flown.

(h) Check engine controls for general condition, travel and freedom of operation.

(i) Inspect and service Induction system air filter in accordance with the airframe manufacturer’s

recommendations.

3 STARTING PROCEDURES.

The following starting procedures are recommended; however, the starting characteristics of various

installations will necessitate some variation from these procedures.

NOTE

Limit cranking periods to ten (10) to twelve (12) seconds with 5 minutes rest between

cranking periods.

(a) Cold Engine.

(1) Perform pre-flight inspection.

(2) Set propeller governor in “Full RPM”.

(3) Turn fuel valve to “on” position.

(4) Turn boost pump on and move mixture control to “Full Rich” position until a slight but steady

flow is indicated.

(5) Return mixture control to “Idle Cut-Off” position.

(6) Set magneto selector switch. Consult aircraft manufacturer’s handbook for correct position.

(7) Engage starter.

(8) When engine starts, place magneto selector switch in “Both” position.

(9) Move mixture control slowly and smoothly to “Full Rich”.

(10) Check oil pressure gage for indicated pressure. If oil pressure is not indicated within thirty

seconds, stop the engine and determine trouble.

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A OPERATING INSTRUCTIONS

NOTE

If engine fails to achieve a normal start, assume it to be flooded. Crank engine over with

throttle wide open and ignition off. Then repeat above procedure.

Hot Engine - Because fuel percolates, the system must be cleared of vapor; it is recommended that the same

procedure, as outlined above be used for starting a hot engine.

4. COLD WEATHER STARTING.

During extreme cold weather, it may be necessary to preheat the engine and oil before starting.

5. GROUND RUNNING AND WARM-UP.

Subject engines are air pressure cooled and depend on the forward movement of the aircraft to maintain

proper cooling. Particular care is necessary, therefore, when operating these engines on the ground. To

prevent overheating, it is recommended that the following precautions be observed.

NOTE

Any ground check that requires full throttle operation must be limited to three minutes, or

less if indicated cylinder head temperature exceeds the maximum stated in this manual.

(a) Head the aircraft into the wind.

(b) Leave mixture in “Full Rich”.

(d) Warm up at approximately 1000-1200 RPM. Avoid prolonged idling and do not exceed 2200 RPM on

the ground.

(e) Engine is warm enough for take-off when the throttle can be opened without the engine faltering.

6. GROUND CHECK.

(a) Warm up as directed above.

(b) Check both oil pressure and oil temperature.

(d) (Where applicable) Move the propeller control through its complete range to check operation and

return to full low pitch position. Full feathering check (twin engine) on the ground is not

recommended but the feathering action can be checked by running the engine between 1000-1500

RPM; then momentarily pulling the propeller control into the feathering position. Do not allow the

RPM to drop more than 500 RPM.

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OPERATING INSTRUCTIONS (L)IO-360-M1A

(e) A proper magneto check is important. Additional factors, other than the ignition system, affect

magneto drop-off. They are load-power output, propeller pitch and mixture strength. The important

thing is that the engine runs smoothly because magneto drop-off is affected by the variables listed

above. Make the magneto check in accordance with the following procedures.

(1) (Controllable Pitch Propeller) With propeller in minimum pitch angle, set the engine to produce

50-65% power as indicated by the manifold pressure gage. Mixture control should be in the full

rich position. At these settings, the ignition system and spark plugs must work harder because of

the greater pressure within the cylinders. Under these conditions, ignition problems can occur.

Mag checks at low power settings will only indicate fuel-air distribution quality.

NOTE

Aircraft that are equipped with fixed pitch propellers, or not equipped with manifold

pressure gage, may check magneto drop-off with engine operating at approximately 2100-

2200 RPM.

(2) Switch from both magnetos to one and note drop-off; return to both until engine regains speed

and switch to the other magneto and note drop-off, then return to both. Drop-off must not exceed

175 RPM and must not exceed 50 RPM between magnetos. A smooth drop-off past normal is

usually a sign of a too lean or too rich mixture.

(f) Do not operate on a single magneto for too long a period; a few seconds is usually sufficient to check

drop-off and will minimize plug fouling.

7. OPERATION IN FLIGHT.

(b) See airframe manufacturer’s instructions for recommended power settings.

8. FUEL MIXTURE LEANING PROCEDURE.

Improper fuel/air mixture during flight is responsible for many engine problems, particularly during

take-off and climb power settings. The procedures described in this manual provide proper fuel/air mixture

when leaning Lycoming engines; they have proven to be both economical and practical by eliminating

excessive fuel consumption and reducing damaged parts replacement. It is therefore recommended that

operators, of all Lycoming aircraft power-plants, utilize the instructions in this publication any time the

fuel/air mixture is adjusted during flight.

Manual leaning may be monitored by exhaust gas temperature indication, fuel flow indication, and by

observation of engine speed and/or airspeed. However, whatever instruments are used in leaning the

mixture, observe the following general rules.

GENERAL LEANING RULES

Never exceed the maximum red line cylinder head temperature limit.

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A OPERATING INSTRUCTIONS

For maximum service life, cylinder head temperatures must be maintained below 435°F.

(224°C.) during high performance cruise operation and below 400°F. (205°C.) for economy

cruise powers.

On engines with manual mixture control, maintain mixture control in “Full Rich”

position for rated take-off, climb and maximum cruise powers (above approximately 75%).

However, during take-off from high elevation airport or during climb, roughness or loss of

power may result from over-richness. In such a case adjust mixture control only enough to

obtain smooth operation - not for economy. Observe instruments for temperature rise. Rough

operation due to over-rich fuel/air mixture is most likely to be encountered at altitudes above

5,000 feet.

Always return the mixture to full rich before increasing power settings.

Operate the engine at maximum power mixture for performance cruise powers and at

best economy mixture for economy cruise power; unless otherwise specified in the airplane

owners manual.

During let-down flight operations it may be necessary to manually lean carbureted or

fuel injected engines to obtain smooth operation.

(a) Leaning to Exhaust Gas Temperature.

(Normally aspirated engines with fuel injectors or carburetors)

(1) Maximum Power Cruise (approximately 75% power) - Never lean beyond 150°F. on rich

side of peak EGT unless aircraft operator’s manual shows otherwise. Monitor cylinder head

temperatures.

(2) Best Economy Cruise (approximately 75% power and below) - Operate at peak EGT.T

(b) Leaning to Flowmeter.

Lean to applicable fuel-flow tables or lean to indicator marked for correct fuel-flow for each

power setting.

9. ENGINE FLIGHT CHART.T

(a) Fuel Requirements.

91/96 or 100LL Octane, Minimum Aviation Grade Fuel

(b) Fuel Pressure, psi -

Min. Max.

Inlet to fuel pump -2 35

Inlet to fuel injector 14 45

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OPERATING INSTRUCTIONS (L)IO-360-M1A

*Recommended Grade Oil

Average

Ambient Air

MIL-L-6082B or

SAEJ1966 Spec.

Mineral Grades

MIL-L-22851 or

SAEJ1899 Spec.

Ashless Dispersant

Grades

All Temperatures ---- SAE15W50 or SAE20W-50

Above 80°F SAE60 SAE60

Above 60°F SAE50 SAE40 or SAE50

30°F to 90°F SAE40 SAE40

0°F to 70°F SAE30 SAE40, SAE30, SAE20W40

Below 10°F SAE20 SAE30 or SAE20W30

* - In new, newly overhauled, or rebuilt engines or following the replacement of one or more

cylinders, use only mineral oil during the first 50 hours of operation.

(d) Oil Sump Capacity

(L)IO-360-M1A ...................................................................................................................8 U.S. Qts.

(Minimum safe quantity in sump) ....................................................................................4 U.S. Qts.

(e) Oil Pressure, psi -

Maximum Minimum Idling Start and Warm-up

Normal Operation 95 55 25 115

(f) Oil Temperature: The maximum permissible oil temperature is 245°F. (118°C.). For maximum engine

life, maintain desired oil temperature between 165°F. (73.8°C.) and 200°F. (93.3°C.) in level-flight

cruise conditions.

(g) Fuel and Oil Consumption

Operation RPM HP

Fuel

Cons.

Gal./Hr.

Max.

Oil Cons.

Qts./Hr.

*Max.

Cyl. Head

Temp.

Normal Rated 2700 180 ---- .80 500°F (260°C)

Performance Cruise

(75% Rated) 2450 135 11.0 .45 500°F (260°C)

Economy Cruise

(60R Rated) 2350 117 8.5 .39 500°F (260°C)

* - At Bayonet Location - For maximum service life of the engine maintain cylinder head temperatures

between 150°F. and 400°F. during continuous operation.

This engine has an alternate rating of 160 HP at 2400 RPM.

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A OPERATING INSTRUCTIONS

10. ENGINE SHUT DOWN.

(a) Set propeller at minimum blade angle.

(b) Idle until there is a decided decrease in cylinder head temperature.

(d) When engine stops, turn ignition switch off.

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OPERATING INSTRUCTIONS (L)IO-360-M1A

Figure 3-1. Part Throttle Fuel Consumption

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION I

(L)IO-360-M1A OPERATING INSTRUCTIONS

Figure 3-2. Sea Level and Altitude Performance Curve

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OPERATING INSTRUCTIONS (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION II

(L)IO-360-M1A PREPARATION

SECTION II

PART 1

PREPARATION Page

Preparation of Engine for Installation ........................................................................................................25

Uncrating.....................................................................................................................................................25

Uninhibiting................................................................................................................................................25

Preparation of Fuel Injector .........................................................................................................................26

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PREPARATION (L)IO-360-M1A

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LYCOMING OPERATION AND INSTALLATION MANUAL SECTION II

(L)IO-360-M1A PREPARATION

SECTION II

PART 1

PREPARATION OF ENGINE FOR INSTALLATION

Each Lycoming engine undergoes a thorough preservative treatment before leaving the factory. To

protect the cylinders and related parts, preservative oil is sprayed into each cylinder. Careful uncrating and

uninhibiting of the engine is very important to prevent any of the preservative oil from entering the

induction system.

1. UNCRATING.

The Lycoming (L)IO-360-M1A engine has been carefully packed for shipment to prevent damage in

transit and to ensure that the engine reaches its destination in perfect condition.

NOTE

Any engine that has been stored in a cold area must be brought into an area with a

temperature of at least 70°F (21°C) for 24 hours before uncrating. If this is not possible, the

preservative oil in the engine must be warmed to facilitate draining by heating the cylinders

with heat lamps.

a. Remove the top of the crate and set it aside.

b. Lift and set aside any packing materials from on top of the engine.

c. Connect an engine lifting cable to a winch, hoist, or crane able to support a minimum load of 750

lbs.

d. Connect the engine lifting cable to the lifting lugs on the top of the engine.

e. Lift the engine from the crate.

2. UNIHIBITING ENGINE.

CAUTION

Do not rotate the crankshaft of an engine containing preservative oil before removing the

bottom spark plugs. Engine damage will result.

CAUTION

Avoid contact of preservation oil with painted surfaces. If preservation oil does contact a

painted surface, clean it off with a solvent as soon as possible.

a. Remove all the bottom spark plugs.

SECTION II LYCOMING OPERATION AND INSTALLATION MANUAL

PREPARATION (L)IO-360-M1A

b. Turn the crankshaft three or four revolutions by hand.

c. Tilt the engine to one side until the spark plug holes on that side are oriented vertically.

d. Rotate the crankshaft at least two revolutions and allow the oil to drain out through the spark plug

holes.

e. Repeat steps (3) and (4) for the opposite side of the engine.

f. Inspect the spark plugs before reinstalling them. If they are not clean, wash them in clean oil-based

solvent. Dry them with compressed air.

g. Remove the oil sump plug and allow any preservative oil that has accumulated in the sump to drain.

h. Remove the oil screen and clean it with a hydrocarbon-based solvent such as Varsol or equivalent.

i. Reinstall the oil screen.

j. If a constant speed propeller is to be used, the expansion plug must be removed from the crankshaft.

Pierce a 1/8 in. to 3/16 in. hole in the center of the plug to remove it.

k. Replace the oil sump plug and install a safety wire. Refer to Maintenance and Overhaul Manual P/N

LMO-(L)IO-360-M1A for lockwire information.

l. Fill the sump with 8 quarts of aviation-grade oil. Refer to Section I, Part 2 for oil recommendations.

m. Inspect the induction riser to ensure that it is clean and dry. If a significant amount of preservative

oil is noted, clean, reinspect, and reinstall the intake pipes.

3. PREPARATION OF FUEL INJECTOR.

a. Remove the fuel inlet strainer and clean it with a hydrocarbon-based solvent such as Varsol or

equivalent.

b. Inspect the fuel supply lines, fuel manifold, throttle body, and “bullet nose” venturi to ensure they

are clean and dry.

c. Reassemble the injector. Inject clean fuel into the fuel inlet connection with the fuel outlets

uncapped until clean fuel flows from the outlets. Do not exceed 15 psi inlet pressure.

CAUTION

Dispose of used engine preservative and solvents in accordance with all applicable federal,

state, and local environmental regulations.

NOTE

If a small amount of preservative oil remains in the engine, it will not be harmful; however,

during the first oil change, the oil should be drained while the engine is hot. This will remove

any residual preservative oil.

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION II

(L)IO-360-M1A PROCEDURES

SECTION II

PART 2

PROCEDURES

Page

Installing Engine ............................................................................................................................................29

Connecting External Accessories..................................................................................................................29

Pre-Oiling Engine Prior to Start ..................................................................................................................33

SECTION II LYCOMING OPERATION AND INSTALLATION MANUAL

PROCEDURES (L)IO-360-M1A

This Page Intentionally Left Blank.

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION II

(L)IO-360-M1A PROCEDURES

SECTION II

PART 2

PROCEDURES

1. INSTALLING ENGINE.

a. Refer to Figures 2-1 through 2-3 for dimensions and connection locations.

b. If the engine is to be installed in an airframe from which an engine has previously been removed,

inspect the engine mounts to ensure they are not bent, misaligned, distorted, or damaged.

CAUTION

Distorted, misaligned, bent, or damaged engine mounts may cause engine or airframe

damage or engine failure.

c. Refer to the airframe manufacturer’s instructions for attaching the engine to the engine mounts.

2. CONNECTING EXTERNAL ACCESSORIES.

a. Refer to installation drawing, Figure 2-3. Remove cover plate and gasket. When installing the

accessory, use the gasket and hardware specified by the airframe manufacturer. Torque to the value

specified for the thread size in the Table of Limits, (L)IO-360-M1A Maintenance and Overhaul

Manual.

b. Connect oil and fuel supply lines and any reporting devices, sensors, and senders per the airframe

manufacturer’s instructions. Refer to Figures 2-2 and 2-3 for connection locations.

Table 2-1.

Accessory Location Thread Size

Accessory Pad 1 Upper Right Side of

Accessory Housing ¼-20

Accessory Pad 2 Lower Right Side of

Accessory Housing ¼-20

Prop. Governor Pad Upper Left Front of

Crankcase 5/16-18

SECTION II LYCOMING OPERATION AND INSTALLATION MANUAL

PROCEDURES (L)IO-360-M1A

Figure 2-1. Dimensions

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION II

(L)IO-360-M1A PROCEDURES

Figure 2-2. Installation, Left Side View

SECTION II LYCOMING OPERATION AND INSTALLATION MANUAL

PROCEDURES (L)IO-360-M1A

Figure 2-3. Installation, Rear View

LYCOMING OPERATION AND INSTALLATION MANUAL SECTION II

(L)IO-360-M1A PROCEDURES

3. PRE-OILING ENGINE PRIOR TO START.

CAUTION

To eliminate the possibility of high-speed bearing failure resulting from insufficient

lubrication during initial starts, all aircraft engines must be pre-oiled after an overhaul,

following oil cooler draining or replacement, or whenever the oil lines have been

disconnected.

WARNING

If a propeller is installed, remain clear of the propeller turning arc. The propeller will turn

during this procedure, and could cause injury.

a. Fill the oil cooler with oil.

b. Remove one spark plug from each cylinder of the engine.

c. If the aircraft is not equipped with an oil pressure gage, remove the STD-1102 allen plug from the

upper left front of the main galley, aft of the propeller governor pad.

d. Place the mixture control lever in the “IDLE CUT-OFF” position and the fuel selector switch in the

“OFF” position.

e. Turn the engine with the starter (or with an external power source, if available) until a minimum oil

pressure of 20 lb. is indicated on the oil pressure gage or until there is a steady flow of oil from the

opening on the engine.

CAUTION

Do not energize the starter for periods longer than 15 seconds. Allow the starter to cool after

each energizing period. Refer to the starter manufacturer’s instruction manual for additional

information.

NOTE

If oil pressure is not determined after the first cranking of 10 to 15 seconds, allow the starter

to cool and repeat the cranking/starter cooling sequence until 20 lb. is indicated on the oil

pressure gage or oil flow is observed.

CAUTION

If there is no indication of steady oil pressure after five attempts, the cause should be

determined and fixed

SECTION II LYCOMING OPERATION AND INSTALLATION MANUAL

PROCEDURES (L)IO-360-M1A

f. Turn the starter for an additional 10 seconds to verify that the oil pressure remains at latest 20 lb.

g. Reinstall the spark plugs and proceed with normal starting procedures immediately. Refer to Section

I, Part 3.

h. When the engine starts, observe the oil pressure gage. If there is no oil pressure indication, shut

down the engine until cause is determined.

i. Allow the engine to run for approximately 3 minutes at 1000 rpm.

j. Shut down in accordance with Section I, Part 3, Step 10.

60297 36 Lycoming IO 360 M1a Operating Manual

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