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Engine Assembly Checklist
The Engine Assembly Checklist for IO-390-D Series Engines is a guide and a record of completion
for engine assembly.
Engine Model Number__________________ Engine Serial Number:__________________
Engine Time:______________________
Engine Assembly done by:______________________________
Review the "General Assembly Practices" in this
chapter and the latest revision of Service Bulletin
No. SB-240 to identify all parts that must be
replaced with new parts upon removal..
Start with a clean crankshaft which passed the
"Crankshaft Inspection" in Chapter 72-20
Complete the "Alignment Dowel Inspection" and if
necessary, replace the alignment dowel per
instructions in Chapter 72-20.
CAUTION
Complete the "Crankshaft Gear Installation" with a
new crankshaft gear bolt and new lockplate Chapter
72-20.
Install a new expansion plug in the crankshaft per
the "Expansion Plug Installation" procedure in
Chapter 72-20.
Either begin installation of a new solid-ring oil seal
on the crankshaft per the "Solid-Ring Crankshaft
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.
Complete the "Connecting Rod Inspection" in
Chapter 72-20.
Per the "Connecting Rod Installation" section in
Chapter 72-20:
• Measure the inside diameter of the bearing The
clearance is to be 0.004 to 0.016 in. (service) and
0.004 to 0.010 in. (on rebuilt engines). Compare
the results to the measurements previously
recorded.
• 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.
72-10
Page 122
Engine Assembly Checklist for IO-390-D Series Engines
Item
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.
IO-390-D Series Engine Maintenance Manual
IO-390-D Series Engine Maintenance Manual
Date of Engine Assembly: __________________
Comments
Measurement
#1
#2
#3
#4
© 2020 Avco Corporation. All Rights Reserved
Done
March 2020
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