AZALEA AVIATION SPYDER 100 HP Manuale utente
AZALEAAVIATION, LLC
100/120
ENGINE ASSEMBLY MANUAL
AZALEAAVIATION, LLC
100/120
HP SPYDER
ENGINE ASSEMBLY MANUAL
AzaleaAviation.com
HP SPYDER
ENGINE ASSEMBLY MANUAL
SPYDER 100/120 HP
Engine Assembly Manual
TABLE OF CONTENTS
Section and Description
1. Introduction
2. Case Assembly (with IFB Update)
3. Accessory Housing Assembly
4. Accessory / Alternator Installation
5. Starter/Oil Cover Plate Installation
6. Piston/Cylinder Assembly
7. Piston/Cylinder Final Installation
8. Cylinder Head Installation
9. Valve Train Assembly and Adjustment
10. Oil Pan and Dipstick Installation
11. Top Cover Installation
12. Ignition Installation
13. Final Details
14. Conclusion
15. Specifications and Torque Charts
Introduction
This Assembly Manual is a guide to the final assembly or rebuilding of the
SPYDER 100/120 HP series engine. Basic power plant or mechanical skills are not
required but helpful. As the builder you are ultimately responsible for the proper
assembly of your engine. Azalea Aviation assumes no responsibility for improper
assembly or lack of pertinent information in this manual. If you have any questions
you can contact us or use several additional sources of information available. The
Chevrolet “Green” Shop Manual for 1965 Corvair and the SPYDER Service and
Operations Manual can be helpful. You can also contact the SPYDER Technical
Service department at Azalea Aviation for further assistance.
This section of the manual assumes that the engine teardown, rebuild, and
preparation of all components has been completed and are in airworthy condition.
For information about these procedures you can purchase the SPYDER Engine
Teardown and Preparation Manual through Azalea Aviation or join one of our
engine clinics that are held periodically.
.
Section 3 – 1
Azalea Aviation Copyright 2014
Accessory Housing Assembly
The accessory housing needs to be ready to assemble at this point with all cleaning,
painting and preparation finished.
Tools Required:
3/16” Allen wrench
Straight edge
Feeler gauge .004
13/16” wrench
Distributor shaft or Long screwdriver
Sealants Required:
Grey RTV
Loctite
Lithium Grease
Copper Spray adhesive
Oil
Parts Required:
Accessory Housing
Oil Pump Kit
(6) Stainless Drilled 10-32 Allen Screws
Oil Pressure Valve Nut – spring - piston
Oil Pump Cover
Rear Seal
Section 3 – 2
Azalea Aviation Copyright 2014
Oil Pump Installation
Lubricate the oil pump shafts lightly and install into the Accessory housing. With a
straightedge on the gears, check the clearance to the housing with the .004 feeler
gauge. If clearance is more that .004 then use the thicker gasket from the kit. If less,
then use the thin gasket. (Fig 1) Spray copper adhesive to both sides of the gasket
and let tack up. Spread a little bit of oil on the tops of the gears. Make sure to leave
the housing surface dry where the gasket will lay. (Fig 2) Apply a dab of loctite to
the six Allen bolts and install the oil pump cover and torque to specifications. (60-
80 inch/lbs) Insert either a long screwdriver or a distributor shaft into the housing
to rotate the oil pump gears. If it is tight then disassemble the oil pump to check for
binding and clearances. If the gears are tight then a thicker gasket may have to be
used. Once all is inspected then safety the bolts with standard .030 safety wire if
they have drilled heads. (Fig 3)
Section 3 – 3
Azalea Aviation Copyright 2014
Fig 1. – Checking clearance
Fig 2. – Installing Cover plate
Section 3 – 4
Azalea Aviation Copyright 2014
Fig 3. – Oil cover safetied and pressure relief valve installed
Oil Pressure Relief Valve Installation
Make sure the Oil Pressure Relive valve piston is very clean and well lubricated
with oil. Using a screwdriver or small tube insert the piston into the port and make
sure it has freedom of movement in the port. If it sticks, then clean the port and try
again. The piston has to move freely to function properly. Insert the spring and nut
(loctite applied) in the order shown. (Fig 4) Tighten the nut to proper torque. (10
ft/lbs) If drilled, safety the nut to the housing.
Fig 4. – Oil Pressure Relieve valve parts
Section 3 – 5
Azalea Aviation Copyright 2014
Rear Seal Installation
Apply Grey RTV (or equivalent) to out edge of seal and to inner edge of housing.
Using an appropriate tool (such as a large washer and socket) press the Seal down
into the housing until metal ring is flush with the housing lip. A new seal may have
to be carefully trimmed around the outside edge to fit inside the stator ring. (Fig 5)
Apply Lithium Grease to the inside of seal. This will be where the alternator puck
rides.
Fig. 5. - Rear Housing rear seal installed
The Accessory Housing now is ready for installation onto the Case.
Notes: If you choose to install the High Volume Oil pump kit be sure to follow the
instructions included in the kit. The use of a High Volume Oil pump is not
detrimental to the engine if installed correctly.
Section 4 – 1
Azalea Aviation Copyright 2014
Accessory Housing Installation
Tools Required:
Rubber hammer
½” socket and Ratchet
9/16” Socket
Large socket for gear installation
Sealants Required:
Copper spray
Loctite (red and green)
Lithium Grease
Parts Required:
Case assembly
Drive gears (4 parts)
Accessory bolts (7)
Accessory housing
3/8” washers and nuts
Alternator Kit (seen below)
Section 4 – 2
Azalea Aviation Copyright 2014
Drive Gear Installation:
The distributor drive gear and slinger need to be installed before the accessory
housing. This assembly is made up of four pieces and need to be in the right order
and orientation. The photos below show the order and the assembled unit. (Fig 1)
Use a large socket or pipe to lightly drive these pieces over the crankshaft end.
The order is…eccentric, spacer, gear, and slinger (facing out). Some engines may
be equipped with the wider spacer that eliminates the concentric and small spacer.
(Fig 1b) Be sure the woodruff keys are installed properly onto the crankshaft prior
to installation.
Fig 1. Rear gear parts installed on the crankshaft Fig 1b.
Housing Installation
Apply an even coat of copper spray on both sides of the rear gasket. Once it is
tacky install onto the case. Slide the Accessory housing on and tap into place with
the rubber hammer. Check to see that it has seated all the way around before
installing the hardware. Apply a dab of Loctite onto the threads of the 4 long and 2
short bolts prior to installing them. (Do not install the bolt at the 4 o’clock position
yet. Install three of the four washers and 3/8 nuts onto the studs. Leave the left
one open. (Fig 2) Torque the hardware to the proper specifications. (13 ft/lbs)
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