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REASON FOR REVISION:

1) O-320/360 Exhaust System installation instructions revised to include greater clarity,


as well as information covering filtered air box options and scat tube routing.
OP54-1 REV 1: Steps rewritten for clarity.
Figure 3 moved to page OP54-3.
OP54-2 REV 1: Steps rewritten for clarity.
In Figure 1, 2 & 3, callouts revised to more accurately reflect installation.
OP54-3 REV 0: New page
OP54-4 REV 0: New page

VAN'S AIRCRAFT, INC.

OP-54: O-320/360 EXHAUST


NOTE: Details of the engine installation that do not pertain to the exhaust system are shown for
reference only as some features may have been omitted or are obsolete.

EX-00001

Step 1: Fabricate the EX-00001F Heat Muff Clamp from the HW-00001 Hose Clamp by clamping it over
the Heat Muff Assembly. Mark the bend locations on the
clamp, then remove the hose clamp and bend as
required to ensure a close fit around the Heat Muff
Assembly.

2X EX-00001F
AIR INTAKE TUBE

WARNING: The Heat Muff Assembly must not be


installed over the Exhaust Crossover Slip Joints.
Doing so could cause exhaust gasses to enter the
Heat Muff Assembly & associated ducting.
Step 2: For installations using O-320 engines, trim the
exhaust tube ends to be inserted into the Exhaust
Crossover Slip Joints by 1 (25.4 mm) and install as
shown in Figure 1 and Figure 2.
Only install lock washers upon final installation.
Step 3: For installations using O-360
engines, install as shown in Figure 1
and Figure 2.
Only install lock washers upon
final installation.

CABIN HEAT
TUBE

EX-00004A

EX-00002

EX-00005
EX-00008
CARB HEAT
TUBE

EX-00003
EX-00003B,
8 PL

FIGURE 2:
HEAT MUFF ASSEMBLY

EA GASKET 77611
HEAT MUFF ASSEMBLY

NAS1149F0563P
MS35333-41 (LOCK WASHER)
EXHAUST
CROSSOVER
SLIP JOINT, 2 PL

NUT-00003

FIGURE 1: EXHAUST ASSEMBLY OVERVIEW


DATE: 09/11/14

REVISION:

1 RV 3,4,6,7,8,9

PAGE

OP 54-1

VAN'S AIRCRAFT, INC.


2X EX-00004E
OIL SUMP
6X EX-00004B
2XEX-00004E
6X AN737TW-4

3X EX-00004C

3X EX-00004C

2X EX-00004A

6X EX-00004B
6X

AN3-4A
NAS1149F0363P
MS21042-3

2X EX-00004A

FWD

LEFT
UP
RIGHT

FWD

FIGURE 3:
EXHAUST HANGER ASSEMBLY

FIGURE 1:
EXHAUST HANGER
ASSEMBLY

Step 1: Position the exhaust tubes as desired for cowl and engine mount clearance. Use safety wire to temporarily hold them in place if necessary.
Step 2: Temporarily install the EX-00004A Exhaust Hanger Brackets onto the exhaust tubes.
NOTE: The EX-00004E Exhaust Hanger Support Tab locations shown may vary between aircraft firewall forward installations, use the most convenient bolt locations on the Oil
Sump.
Step 3: Install the EX-00004E Exhaust Hanger Support Tabs in positions somewhat forward and above the EX-00004A Exhaust Hanger Brackets. See Figure 1.
Step 4: Trim all the EX-00004B Exhaust Support Tubes so that the ends reside in the center of their respective spans. Gaps between exhaust support tube ends should be between
1/4 [6.35 mm] and 1/2 [12.7 mm] to allow for motion due to engine vibration. Straight lines between the EX-00004A Exhaust Hanger Brackets and EX-00004E Exhaust Hanger Support Tabs are
prefferable, but may not be possible depending on engine configuration. Slight angles in the connecting geometry formed by the exhaust support tubes are acceptable.

1/4 [6.4 mm]

Step 5: Once the optimum orientation and lengths for the EX-00004B Exhaust Support Tubes have been found, bend the flat ends as necessary to ensure a flat fit against the faces of the
mounting hardware EX-00004A Exhaust Hanger Brackets & EX-00004E Exhaust Hanger Support Tabs. This will help reduce wear and tear on the exhaust support tubes. Ensure each exhaust
support tube is still aligned in an approximately straight line with its counterpart.
ROUND CORNERS
Step 6: Slightly crimp the open ends of all the EX-00004B Exhaust Support Tubes, creating a tube flare that will help to retain the EX-00004C Support Tubing. Round down the sharp corners
created by crimping as shown in Figure 2.

FIGURE 2: TUBING DETAIL

Step 7: Trim the EX-00004C Support Tubing approximately as shown in Figure 2.

(TYPICAL)

DATE: 09/11/14

REVISION:

RV 3,4,6,7,8,9

Step 8: Install all Exhaust Hanger Assembly hardware as shown in Figure 1.


PAGE

OP 54-2

VAN'S AIRCRAFT, INC.


Step 1: If carb heat is not required, bend the EX-00008G
Carb Heat Cover as shown in Figure 1 and match drill the
three #30 holes into the EX-00008 Carb Heat Tube.
Step 12: Match-Drill #40 the FF-01407 FAB Carb Heat Inlet to the VA-130B or VA-131B Air Box Top Plate as
shown in Figure 3.

Step 2: Rivet the EX-00008G Carb Heat Cover to


the EX-00008 Carb Heat Tube as shown in Figure 1.

Step 13: Coordinate the final installation of the FF-01407 FAB Carb Heat Inlet with the final assembly of the filtered air box,
particularly with respect to the carb heat door.

3X LP4-3

FIGURE 1:
CARB HEAT COVER
(OPTIONAL)

CARB HEAT TUBE

HT
IG
RA
ST

EX-00008G

LIN
E

CARBURETOR

NOTE: Perform Steps 3 thru 13 as part of the VA-130 or VA-131 Filtered Air Box fabrication and assembly
instructions. Steps provided here are only a guide, Individual aircraft firewall forward installations may vary.
The position of the carb heat tube from the EX-00001 Heat Muff will affect placement of the filtered air box
door and cutout. See Step 4.
Step 3: Begin assembly and installation of the VA-130 or VA-131 Filtered Air Box as described in the filtered air box
instructions. Perform enough assembly work to determine the physical alignment of the filtered air box to the induction
air inlet on the cowling, then proceed with the steps below.

MATCH-DRILL #40
AN470AD3-4

VA-130B OR VA-131B

6X

CARB HEAT INLET ASSEMBLY

VA-130A OR VA-131A

FIGURE 3:
CARB HEAT INLET INSTALLATION

Step 4: Temporarily install the VA-130B or VA-131B Air Box Top Plate onto the carburetor as described in the Filtered
Air Box instructions.

(O-320 INSTALLATION SHOWN FOR TIGHTEST CLEARANCE)

Step 5: Use a grinder to remove the "lip" inside the tube of the FF-01407 FAB Carb Heat Inlet.
Step 6: Position the FF-01407 FAB Carb Heat Inlet on as straight a line as possible with the carb heat tube from the
EX-00001 Heat Muff on top of the VA-130B or VA-131B Air Box Top Plate. This is especially critical for O-320
installations where there is a very short distance between the filtered air box and the heat muff carb heat tube due to
the shorter height of the O-320 carburetor.

TRIM AS NECESSARY
TO FIT INSIDE VA-130B OR VA-131B
FF-01407

Step 7: Mark and trim the FF-01407 FAB Carb Heat Inlet to fit inside the VA-130B or VA-131B Air Box Top Plate
in the position found in Step 6. Be aware of the location and travel of the VA-122 Arm per the Filtered
Air Box instructions and make allowances in the trim of the FAB carb heat inlet accordingly.

FINAL-DRILL #40
AN470AD3-4

Step 8: Clamp the FF-01407 FAB Carb Heat Inlet Mounting Brackets to the FF-01407
FAB Carb Heat Inlet as shown in Figure 2.

6X

Step 9: Final-Drill #40 six rivet holes into the FF-01407 FAB Carb Heat Inlet
and FF-01407C FAB Carb Heat Inlet Mounting Brackets approximately as shown
in Figure 2.
Step 10: Mark and trim the FF-01407C FAB Carb Heat Inlet Mounting Brackets
as shown in Figure 2.

FF-01407

2X FF-01407C,
TRIM AS NECESSARY TO FIT
INSIDE VA-130B OR VA-131B

Step 11: Cleco and rivet the FF-01407C FAB Carb Heat Inlet Mounting
Brackets to the FF-01407 FAB Carb Heat Inlet as shown in Figure 2.

FIGURE 2: CARB HEAT INLET ASSEMBLY


(EXACT SHAPE MAY VARY BY AIRCRAFT)
DATE: 09/11/14

REVISION:

0 RV 3,4,6,7,8,9

PAGE

OP 54-3

VAN'S AIRCRAFT, INC.


POSITION AIR
INTAKE HOLE
AFT OF THIS BEND
LINE

2 [50.8 mm]
FINAL-DRILL #30
AN470AD3-4

NOTE: The CB-907A or CB-1007A Right Aft Case Baffle may already have an air intake hole pre-punched. If present, seal this hole with a block-off.

4X

VENT DL-03

Step 1: Create the air intake hole in the CB-902A or CB-1002A Forward Left Air Ramp as shown in Figure 1. Position the hole aft of the bend line in the CB-907A or
CB-1007A Right Aft Case Baffle as shown in Figure 1.
Position the hole left and right so that the scat tube will naturally route from the Heat Muff Air Intake to the VENT DL-03 Scat Tube Flange while avoiding interference
from the starter or any other components.
Experiment with the scat tube routing prior to creation of the air intake hole. If necessary, the flange of the VENT DL-03 Scat Tube Flange may be bent to facilitate
positioning. Clamp the VENT DL-03 Scat Tube Flange into position.

CB-902A
OR CB-1002A

Step 2: Clamp, then final-drill #30 the holes in the VENT DL-03 Scat Tube Flange to the CB-902A or CB-1002A Forward Left Air Ramp as shown in Figure 1.
WARNING: Install a vent screen in this location if the vent hole is ONLY to provide cabin heat. A vent screen installed upstream of a carburetor heat
system may obstruct airflow and drastically reduce engine performance.

FIGURE 1: AIR INTAKE HOLE LOCATION

Step 3: Rivet the VENT DL-03 Scat Tube Flange and VENT SCREEN 3X3 (optional) to the CB-902A or CB-1002A
Forward Left Air Ramp as shown in Figure 1.
WARNING: For proper carb heat performance, a vent screen must be installed over the cabin heat tube at the location
shown in Figure 3.
STARTER

INT
AK
E

Step 4: (If using carb heat) Form the VENT SCREEN 3X3 over the end of the cabin heat tube coming from the Heat Muff Assembly.
See Figure 3 for location.

AIR

Step 5: Cut lengths of scat tubing to connect the VENT DL-03 Scat Tube Flange to the heat muff air intake tube; the FF-01407
FAB Carb Heat Inlet to the heat muff carb heat tube; and the heat muff cabin heat tube to the VENT TG-10 Assembly installed on the
firewall in OP-29 or OP-33. See Figure 2 and Figure 3.

VENT DL-03
AN737TW, 2 PL

Step 6: Secure the Scat Tubes as shown in Figure 2 and Figure 3. Use additional tie-wraps and clamps as necessary to ensure
the scat tubes do not interfere with the oil sump drain, exhaust tube, engine mount or any other components.
HEAT MUFF
HEAT MUFF

AIR INTAKE TUBE


3X3 VENT SCREEN

CARB HEAT TUBE

AN737TW, 2 PL

CARB
HEAT

MS21919-DG12

AB
IN

RB
CA AT
HE

HE
AT

H EAT

CA
BIN

AN737TW, 2 PL
FF-01407

AN3-4
AN310-3

MS21919-WDG34
FF-01407
SAFETY WIRE
WRAPPED AROUND
CLAMP

DATE: 09/11/14

REVISION:

RV 3,4,6,7,8,9

PAGE

OP 54-4

FIGURE 2: SCAT TUBE ROUTING

FIGURE 3: SCAT TUBE ROUTING

(O-360 INSTALLATION SHOWN)

(O-360 INSTALLATION SHOWN)