Superior O-360 SERIES User manual

i
© February 2007 Superior Air Parts Inc.
02-00-00
Description and Operation
RW
O-360 & IO-360 SERIES ENGINES
MAINTENANCE MANUAL
621 South Royal Lane, Suite 100 / Coppell, TX 75019 / 800-277-5168
www.superiorairparts.com
Manual P/N SVMM01, Revision B, February 2007

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O-360 and IO-360 Series Engines
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General Information
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O-360 and IO-360 Series Engines
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General Information
Manual Number SVMM01
Revision History
Revision
Letter Effective Date Description Pages Revised
IR 02/27/06 Initial Release All
A 3/6/06 SAP CR# 8004, del magneto 100 hr insp. from ALS, add “or
annual” to & del mag cap removal from 100 hr insp 05-00-00, p1 05-20-00, p3
B 02/28/07 Add Celsius Temperature conversions to Fahrenheit
temperatures
72-00-10 All
72-00-12 All
72030-00 All
72-50-00 All

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O-360 and IO-360 Series Engines
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O-360 and IO-360 Series Engines
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General Information
SAFETY ADVISORY
WARNING: BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE
HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE
MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE
MANUFACTURER’S OR SUPPLIER’S RECOMMENDATION CAN RESULT IN
PERSONAL INJURY.
CAUTION: INFORMATION IS TO EMPHASIZE INSTRUCTIONS OR PREVENT POSSIBLE
EQUIPMENT DAMAGE.
The user must know the manufacturer or supplier information and obey the procedures,
recommendations, warnings, and cautions set forth for the use, handling, storage, and disposal of
materials.
The WARNINGS used in this manual inform the user about dangerous materials or equipment that can
cause injury. They do not replace the manufacturer's instructions.
This Safety Advisory has all the warnings included in this manual.
WARNING: OPERATION OF A DEFECTIVE ENGINE WITHOUT A PRELIMINARY EXAMINATION
CAN CAUSE FURTHER DAMAGE TO A DISABLED COMPONENT AND POSSIBLE
INJURY TO PERSONNEL. MAKE SURE THOROUGH INSPECTION AND
TROUBLESHOOTING PROCEDURES ARE ACCOMPLISHED. THIS WILL HELP TO
PREVENT INJURIES TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.
WARNING: FUEL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE IN A WELL-
VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON
SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND
SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND
WATER.
WARNING: HOT OIL MAY CAUSE BURNS TO EYES AND SKIN. PUT ON SPLASH GOGGLES,
INSULATED GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL
ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
WARNING: DO NOT INSTALL THE IGNITION HARNESS "B" NUTS ON THE SPARK PLUGS UNTIL
THE PROPELLER INSTALLATION IS COMPLETED. FAILURE TO COMPLY COULD
RESULT IN BODILY INJURY WHEN THE PROPELLER IS ROTATED DURING
INSTALLATION.
WARNING: SOLVENT IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN
CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH
WITH WATER. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

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General Information
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE SURE THAT
THE PRESSURE IS NOT MORE THAN 30 PSI. DO NOT DIRECT THE AIRSTREAM AT
PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE SHIELD TO
PROTECT YOUR EYES. THIS WILL HELP PREVENT INJURIES TO PERSONNEL OR
DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET MEDICAL
ATTENTION.
WARNING: USE METHYL ETHYL KETONE (MEK) SOLVENT CORRECTLY. THE SOLVENT IS
FLAMMABLE AND REACTIVE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY DATA
SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL
AND READ IT CAREFULLY. BEFORE YOU USE THE SOLVENT, PUT ON SAFETY
SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES (BUTYL RUBBER), RUBBER
APRON, AND CHEMICAL-SAFETY SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES BELOW THE MSDS LIMIT.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN AND EYES. PUT
ON RUBBER GLOVES AND GOGGLES.
WARNING: PLACE A SUITABLE STAND UNDER THE AIRCRAFT TAILCONE IF NEEDED BEFORE
REMOVING THE ENGINE. THE LOSS OF WEIGHT MAY CAUSE THE AIRCRAFT TAIL
TO DROP.
WARNING: USE THE CORRECT PERSONAL PROTECTION. SOME CHEMICAL SOLUTIONS CAN
CAUSE SKIN, EYE AND LUNG DAMAGE. FOLLOW THE MANUFACTURER'S
INSTRUCTIONS FOR EACH CLEANING SOLUTION.
WARNING:TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH, BEFORE
MOVING THE PROPELLER DO THE FOLLOWING:
•DO NOT STAND WITHIN THE ARC OF THE PROPELLER BLADES WHILE
TURNING THE PROPELLER.
•VERIFY ALL SPARK PLUG LEADS ARE DISCONNECTED.
•VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT
THEY ARE IN THE “OFF” POSITION AND P-LEADS ARE GROUNDED.
•THROTTLE POSITION “CLOSED”.
•MIXTURE CONTROL POSITION “IDLE-CUT OFF”.
•SET BRAKES AND BLOCK AIRCRAFT WHEELS. ENSURE THAT AIRCRAFT
•TIE DOWNS ARE INSTALLED AND VERIFY THAT THE CABIN DOOR LATCH IS
OPEN.

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O-360 and IO-360 Series Engines
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General Information
TABLE OF CONTENTS
Chapter
Section
Sub-Section
Page Number
General Information
Revision History iii
Safety Advisory v
Table of Contents vii
List of Figures xi
List of Tables xiii
01 00 00 Introduction
About This Manual 1
Related Publications 1
Obtaining Revisions to Instructions for Continued
Airworthiness 1
02 00 00 Description and Operation
General Description 1
Continued Airworthiness 1
Model Designations 1
Engine Components General Description 3
Specifications 3
Features and Operating Mechanisms 5
04 00 00 Airworthiness Limitations Section
Mandatory Replacement Time 1
Mandatory Inspection Intervals 1
05 00 00 Scheduled Inspection and Maintenance
General 1
20 00 25 Hour Inspection 1
50 Hour Inspection 1
100 Hour or Annual Inspection 3
500 Hour Inspection 6
1000 Hour Inspection 6
Recommended TBO 6
Recommended Accessory Replacement 6
50 00 Unscheduled Inspection and Maintenance 1

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TABLE OF CONTENTS (cont’d)
Chapter
Section
Sub-Section
Page Number
72 00 00 Engine Section
General 1
01 Testing and Fault Isolation
General 1
Troubleshooting 1
05 Engine Removal
General 1
Removal 1
Preservation 1
06 Engine Disassembly
General 1
07 Cleaning
General 1
Cleaning Instructions 1
Overall Engine Cleaning 1
Spark Plugs and Electrical Components 1
Oil System Components 2
Degreasing 2
Decarbonizing 2
Corrosion Removal 3
Parts Preservation and Corrosion Prevention 3
09 Engine Assembly
General 1
10 Engine Installation
General 1
Preparing Engine for Service 1
Installation of Engine 1
11 Torques, Fits, and Clearances
General 1
Service Limits 1

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General Information
TABLE OF CONTENTS (cont’d)
Chapter
Section
Sub-Section
Page Number
72 00 12 Preservation and Storage
General 1
Temporary Storage 2
Indefinite Storage 3
Returning an Engine To Service After Storage 3
00 13 Repair Procedures
General 1
15 Servicing
General 1
Fuels 1
Lubricants 1
Consumables 2
10 00 Front Section
General 1
Starter 1
Alternator 3
Propeller Governor System 6
30 00 Cylinder Section
General 1
Cylinder Replacement 1
Cylinder Break-in Procedures 10
50 00 Lubrication Section
General 1
Oil Pressure Adjustment 1
Oil Filter Adapter and Vernatherm Valve 1
Oil Sump Suction Screen 2

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General Information
TABLE OF CONTENTS (cont’d)
Chapter
Section
Sub-Section
Page Number
73 00 00 Engine Fuel System
General 1
Fuel System Leaks 1
Fuel Pump Replacement 3
Fuel Screen 3
10 00 Fuel Injection System
Fuel Injector Nozzle Cleaning 1
20 00 Carburetion System
Idle Speed and Mixture Adjustment 1
Primer Nozzle Cleaning 1
74 00 00 Ignition Section
General 1
Magneto Replacement 1
Ignition Harness Replacement 2
Appendix 1
Unison Industries L-1363B, 4300/6300 Series Magneto
Maintenance and Overhaul Manual

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O-360 and IO-360 Series Engines
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General Information
LIST OF FIGURES
Figure
Chapter
Section
Sub-Section
Page
02-00-00.1 Engine Model Number Designation 02 00 00 2
02-00-00.2 O-360 Engine Front View 7
02-00-00.3 O-360 Engine Left Side View 8
02-00-00.4 O-360 Engine Top View 9
02-00-00.5 O-360 Engine Rear View 10
02-00-00.6 IO-360 Engine Front View 11
02-00-00.7 IO-360 Engine Left Side View 12
02-00-00.8 IO-360 Engine Top View 13
02-00-00.9 IO-360 Engine Rear View 14
72-10-00.1 Starter Installation 72 10 00 2
72-10-00.2 Alternator Installation 3
72-10-00.3 Alternator and Mounting Hardware Detail 5
72-10-00.4 Propeller Governor Oil Line 7
72-30-00.1 Assembled Cylinders 30 00 3
72-30-00.2 Piston Pin and Piston Assembly 4
72-30-00.3 Piston Ring Compressor 5
72-30-00.4 Cylinder Base Nut Tightening Sequence 6
72-30-00.5 Installation of Pushrods 7
72-30-00.6 Rocker Arm and Pushrod Assembly 8
72-30-00.5 Intercylinder Baffle Assembly 9
72-50-00.1 Oil System Schematic 50 00 2
72-50-00.2 Oil Filter and Adapter Assembly 3
72-50-00.3 Oil Sump Assembly 5
72-50-00.4 Oil Pressure Relief Valve 6
73-00-00.1 Engine Fuel Pump Assembly 73 00 00 2
74-00-00.1 Magneto Components 74 00 00 3
74-00-00.2 Timing Diagram 4
74-00-00.3 Ignition Wiring Diagram 5

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General Information
LIST OF TABLES
Table
Chapter
Section
Sub-Section
Page
01-00-00.1 Special Tools and Equipment 01 00 00 1
02-00-00.1 General Specifications 02 00 00 3
02-00-00.2 Accessory Drive Specifications 3
02-00-00.3 Manufacturer’s Physical Specifications 4
02-00-00.4 Primary Engine Accessories 4
02-00-00.5 Illustrated Views of the Engine 5
02-00-00.6 Secondary Engine Accessories 5
05-00-00.1 Scheduled Inspection and Maintenance Intervals 05 00 00 1
72-00-01.1 Abnormal Operation Troubleshooting Procedures 72 00 01 1
72-00-01.2 Engine Will Not Start 2
72-00-01.3 Rough Idling 2
72-00-01.4 Engine Not Able To Develop Full Power 2
72-00-01.5 Rough Engine Operation 3
72-00-01.6 Low Power & Engine Runs Rough 3
72-00-01.7 Low Oil Pressure On Engine Gage 3
72-00-01.8 High Oil Temperature 4
72-00-01.9 Excessive Oil Consumption 4
72-00-05.1 Equipment and Materials List 05 1
72-00-07.1 Equipment Required for Cleaning 07 1
72-00-07.2 Materials Required for Cleaning 1
72-00-10.1 Equipment and Materials List 10 1
72-00-11.1 Dimensional Limits 11 2
72-00-11.2 Backlash and End Clearance Limits 2
72-00-11.3 Torque Limits 3
72-00-11.4 Valve Spring Dimensional Limits 4
72-00-11.5 Crush Type Gasket Tightening Angles 4
72-00-12.1 Preservation and Storage Materials 12 1

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LIST OF TABLES (cont’d)
Table
Chapter
Section
Sub-Section
Page
72-00-15.1 Oil Grades 72 00 15 1
72-00-15.2 Oil Sump Capacity 1
72-00-15.3 Minimum Octane Fuels 2
72-00-15.4 Consumables 2
72-00-15.4 Hoses 2
72-10-00.1 Alternator Belt Tension Requirements 10 00 4
72-30-00.1 Equipment and Material List 30 00 1
72-50-00.1 Oil Pressure Springs 50 00 1
73-00-00.1 List of Materials 73 00 00 1
74-00-00.1 List of Equipment 74 00 00 1

Maintenance Manual
O-360 and IO-360 Series Engines
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01-00-00
Introduction
INTRODUCTION
About This Manual
Information contained in this Engine
Maintenance Manual fulfills the content
requirements of FAR 33.4 Appendix A33.3(a)
and has been found acceptable to the Federal
Aviation Administration (FAA). The purpose of
this Maintenance Manual is to provide the
necessary instructions for performing
maintenance on the Superior Vantage Engine.
Repair and replacement information may be
found in the overhaul manual.
The information in this publication is based on
data available at the time of publication and is
updated, supplemented, and automatically
amended by Publication Revisions and Service
Bulletins that are issued by Superior Air Parts.
This manual is divided into separate sections
relating to the general and specific maintenance
instructions required for the engine. These
general and specific instructions are organized
and numbered per the recommendations of the
General Aviation Manufacturers Association
(GAMA). In this way, information may be
located in a conventional manner to aid in both
accuracy and timeliness.
Page numbering is organized within each
section. The section number (e.g., 72-00-01) is
displayed in the right hand section of the footer
on each page. The page number is displayed in
the center of the footer on each page.
All measurements are noted in English (U.S.)
units. Conventional unit abbreviations are used.
Be sure to ground magneto P-leads prior to any
maintenance and perform normal pre-run
checks and inspections upon completion any
maintenance.
Superior Air Parts has made clear and accurate
information available for those who maintain,
own and repair the Vantage O-360 and IO-360
Series Engines. Superior Air Parts values your
input regarding revisions and additional
information for our manuals. Please forward
your comments and input to:
Superior Air Parts
Attn: Engineering Department
621 South Royal Lane Suite 100
Coppell, Texas 75019
Related Publications
The following are related engine publications.
•SVIOM01, O-360 & IO-360 Installation and
Operation Manual
•SVOHM01, O-360 & IO-360 Overhaul
Manual
Obtaining Revisions to Instructions for
Continued Airworthiness
All Vantage Engine manuals and service
information may be downloaded at
www.superiorairparts.com
Or may be purchased by contacting:
Superior Air Parts
621 South Royal Lane, Suite 100
Coppell, Texas 75019
or call: 972-829-4600
Table 01-00-00.1 • Special Tools and Equipment
Item Vendor
Electrical Tester Commercially Available

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Introduction
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O-360 and IO-360 Series Engines
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Description and Operation
DESCRIPTION AND OPERATION
General Description
Superior Vantage Engines are four-cylinder,
horizontally opposed, air-cooled, direct drive
powerplants incorporating a wet sump, bottom
mounted induction, bottom exhaust with either
carbureted or port injected fuel systems.
Provisions exist for both front and rear mounted
accessories. All engine components will be
referenced as they are installed in the airframe.
Therefore, the “front” of the engine is the
propeller end and the “rear” of the engine is the
accessory mounting drive area. The oil sump is
on the “bottom” of the engine and the cylinder
shroud tubes are on the “top”. The terms “left”
and “right” are defined as being viewed from the
rear of the engine looking toward the front.
Cylinder numbering is from the front to the rear
with odd numbered cylinders on the right side of
the engine. The direction of crankshaft rotation
is clockwise as viewed from the rear of the
engine looking forward unless otherwise
specified. Accessory drive rotation direction is
defined as viewed from the rear of the engine
looking forward.
Continued Airworthiness
Vantage Engines discussed in this document
must be installed and operated in accordance
with the limitations, conditions and operating
procedures described in the Installation and
Operation Manual (SVIOM01). They must also
be maintained and repaired in accordance with
this manual and the Overhaul Manual
(SVOHM01).
Model Designations
The model number designation is defined in a
way that the digits of the model number can
easily identify the basic configuration of the
engine as described in Figure 02-00-00.1.
Engine Components General Description
The Vantage Engine O-360 and IO-360 series
engines are air-cooled, four cylinder, horizontally
opposed, direct drive engines. See Table 02-
00-00.1 for General Specifications.
The complete engine includes the following
components and assemblies:
Crankcase Assembly
Crankshaft Assembly
Camshaft Assembly
Valve Train Assembly
Cylinder Assemblies
Connecting Rod Assemblies
Oil Sump Assembly
Intercylinder Baffles
Starter
Lubrication System (Includes Oil Filter)
Accessory Drive
Ignition System (Includes Spark Plugs)
Fuel System
Starter Support Assembly
Oil Level Gage
Induction System
NOTE: Complete engine does not include outer
cylinder baffles, airframe to engine control
cables, attaching hardware, hose clamps,
vacuum pump, exhaust system, or fittings.
Unless otherwise specified, the fuel pump is
included on carbureted engines. Alternator or
propeller governor systems may be included, if
specified the Model Specification Data (MSD) .

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Description and Operation
Fuel System Type
O Denotes a Carbureted system and “opposed cylinder” arrangement.
IO Denotes a Fuel Injection system and “opposed cylinder” arrangement.
Cylinder Type
360 Parallel valve cylinder, 361 cubic inches.
Model Suffix Denotes detail engine configuration
1st Digit Crankshaft & Propeller Type
A Fixed-Pitch, Thin-wall front main
B Constant-Speed, Thin-wall front main
C Fixed-Pitch, Heavy-wall front main
D Constant-Speed, Heavy-wall front main
E Fixed-Pitch, Solid front main
2nd Digit Crankcase & Engine Mount Type
1 #1 Dynafocal Mount
2 #2 Dynafocal Mount
3 Conical Mount
4 #1 Dynafocal Mount, Front Propeller Governor
5 #2 Dynafocal Mount, Front Propeller Governor
6 Conical Mount, Front Propeller Governor
3rd Digit Accessory Package
Ignition System Fuel System
A Unison Magnetos Precision Fuel System
4th Digit Power Rating: Piston Compression Ratio
CR HP
2 8.5:1 180
Figure 02-00-00.1 • Engine Model Number Designation

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O-360 and IO-360 Series Engines
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Description and Operation
Specifications
The physical specifications of the O-360 and IO-
360 series engines are listed in Table 02-00-
00.3. Accessory Drive Specifications are
provided in Table 02-00-00.2. Information on
Primary Accessories, fuel and ignition systems,
are provided in Table 02-00-00.4. The Model
Specification Data (MSD) in the Installation and
Operation Manual may provide more specific
information, such as secondary engine
accessories provided.
Illustrated views of the O-360 and IO-360
engines identifying key components and sub-
assemblies are provided in Figures 02-00-00.1
thru 02-00-00.9 of this section and are listed in
Table 02-00-00.5 for convenience.
Table 02-00-00.1 • General Specifications
Model O-360 and IO-360 series
Rated Power Hp 180
Rated Speed, RPM RPM 2700
Bore, inches In 5.125
Stroke, inches In 4.375
Displacement cubic inches In3361.0
Compression Ratio 8.5:1
Firing Order 1-3-2-4
Spark timing °BTDC 25
Propeller drive ratio 1:1
Propeller drive rotation
(viewed from rear) Clockwise
Table 02-00-00.2 • Accessory Drive Specifications
Accessory Drive
Ratio Direction of Rotation
Starter 16.556:1 Counter-
Alternator 3.250:1 Clockwise
Tachometer 0.500:1 Clockwise
Magneto 1.000:1 Clockwise
Vacuum Pump 1.300:1 Counter-
Propeller Governor 0.866:1 Clockwise
Fuel Pump 0.500:1 Plunger Operated

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Description and Operation
Table 02-00-00.3 • Physical Specifications
Model Height
(In) Width (In) Length (In) Weight* (Lb)
O-360-Axxx 24.6 33.4 32.8 288
O-360-Bxxx 24.6 33.4 32.8 291
O-360-Cxxx 24.6 33.4 32.8 291
O-360-Dxxx 24.6 33.4 32.8 294
O-360-Exxx 24.6 33.4 32.8 295
IO-360-Axxx 24.0 33.4 32.8 290
IO-360-Bxxx 24.0 33.4 32.8 293
IO-360-Cxxx 24.0 33.4 32.8 293
IO-360-Dxxx 24.0 33.4 32.8 296
IO-360-Exxx 24.0 33.4 32.8 297
*Base engine weight with accessories listed in Table 02-00-00.4 below and a 7.8 lb.
starter, the front propeller governor crankcase option adds 7 lb. to the engine weight.
Table 02-00-00.4 • Primary Engine Accessories*
Model Left
Magneto Right Magneto Ignition Harness Fuel System Fuel Pump (if furnished)
O-360 Unison
4371 Unison 4371 Unison M4001 Precision MA-4-5 Aero Accessories AF15472
IO-360 Unison
4371 Unison 4371 Unison M4001 Precision RSA-5-AD1 Aero Accessories AF15473
* See Table 72-00-15.4 for approved consumables (spark plugs, oil filters, belts, hoses)
and Table 02-09-00.6 below for approved secondary engine accessories.