O-360 & IO-360 SERIES ENGINES - Superior Air Parts

Overhaul ManualO-360 and IO-360 Series EnginesRevision CWARNING: PUT ON SAFETY GOGGLES WHEN INSTALLING OR REMOVING SAFETY WIRE.WARNING: USE THE CORRECT PERSONAL PROTECTION EQUIPMENT TO AVOID INJURY.ENSURE AREA IS FREE OF MOVABLE OBJECTS THAT COULD IMPACT BYPROPELLER AIR BLAST.WARNING: ADHESIVE SEALANT IS TOXIC AND FLAMMABLE.DO NOT BREATHE VAPORS.AVOID EYE AND SKIN CONTACT. USE PROTECTIVE GEAR. IN CASE OF EYECONTACT, FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION.IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.WARNING: SOLVENT IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKINCONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSHWITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN CASE OF SKINCONTACT, WASH WITH SOAP AND WATER.WARNING: DO NOT INSTALL THE IGNITION HARNESS “B” NUTS ON THE SPARK PLUGS UNTILTHE PROPELLER INSTALLATION IS COMPLETED. FAILURE TO COMPLY COULDRESULT IN BODILY INJURY WHEN THE PROPELLER IS ROTATED DURINGINSTALLATION.WARNING: IF ONE SURFACE IS POLISHED TO UNDERSIZE, ALL CORRESPONDING SURFACESMUST BE POLISHED TO THE SAME SIZE.WARNING: PLACE A SUITABLE STAND UNDER THE AIRCRAFT TAILCONE IF NEEDED BEFOREREMOVING THE ENGINE. THE LOSS OF WEIGHT MAY CAUSE THE AIRCRAFT TAILTO DROP.WARNING: DO NOT DAMAGE THE NITRIDED SURFACES OF THE CRANKSHAFT.WARNING: USE CORRECT PERSONAL PROTECTION. SOME CHEMICAL SOLUTIONS CAN CAUSEEYE, SKIN, AND LUNG DAMAGE. FOLLOW THE MANUFACTURER’S INSTRUCTIONSFOR EACH STRIPPING SOLUTION.WARNING: USE THE CORRECT PERSONAL PROTECTION. USE OF A HAMMER CAN CAUSELOOSE PARTICLES THAT CAN GET IN YOUR EYES.WARNING: DO NOT ROTATE ENGINE OR CRANKSHAFT BEFORE REMOVAL OF TIMINGLOCATOR PINS.WARNING: TO PREVENT THE POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH, BEFOREMOVING THE PROPELLER DO THE FOLLOWING: VERIFY ALL SPARK PLUG LEADS ARE DISCONNECTED.VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT THEYARE IN THE “OFF” POSITION AND “P” LEADS ARE GROUNDED.THROTTLE POSITION “CLOSED.”MIXTURE CONTROL “IDLE-CUT OFF.”SET BRAKES AND BLOCK AIRCRAFT WHEELS. ENSURE THAT AIRCRAFT TIEDOWNS ARE INSTALLED AND VERIFY THAT THE CABIN DOOR LATCH IS OPEN.DO NOT STAND WITHIN THE ARC OF THE PROPELLER BLADES WHILE TURNINGTHE PROPELLER.x October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision CSub-SectionSectionChapterTABLE OF CONTENTSPage NumberGeneral InformationRevision History and Effective Page ListSafety AdvisoryTable of ContentsList of FiguresList of Tables01 00 0002 00 0004 00 0072 00 0304iiiixxixvxviiIntroductionAbout This ManualRelated PublicationsObtaining Service InformationAbbreviationsConsumable Materials List11113Description and OperationGeneral DescriptionContinued AirworthinessModel DesignationsEngine Components General DescriptionSpecificationsFeatures and Operating Mechanisms111333Airworthiness LimitationsMandatory Intervals and Procedures1Testing and Fault IsolationGeneral1Special ProceduresGeneralSpecial Tools and Equipment11xi October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision CSub-SectionSectionChapterTABLE OF CONTENTS (cont’d)72 00 050607Page NumberEngine RemovalGeneral1Engine DisassemblyGeneralDisassembly MaterialsParts for DiscardSpecial Tools and EquipmentGeneral Disassembly ProceduresDisassembly111122CleaningGeneralTools and MaterialsCleaning InstructionsDegreasingDecarbonizingScratch and Corrosion RemovalAccessory MountsFuel Injector and Primer NozzlesScreens and FiltersAccessoriesPreservation and Corrosion Prevention11112223334xii October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision CSub-SectionSectionChapterTABLE OF CONTENTS (cont’d)72 00 080910Page NumberInspection and CheckGeneralMaterials and ToolsGeneral Inspection ProceduresGeneral Non-Destructive TestingAccessory HousingCrankcase AssemblyCylinder HeadCylinder Head Dimensional InspectionsCylinder Barrel InspectionsCylinder Barrel Dimensional InspectionsCylinder Assembly InspectionPiston InspectionsPiston Dimensional InspectionsValve RockersPushrod InspectionValve Springs InspectionCrankshaftCrankshaft Counterbore Face InspectionCamshaft InspectionConnecting Rods Inspection112233666777711111113131414Engine AssemblyGeneralFits, Clearances and Torque ValuesMaterials Required for AssemblySpecial Tools and EquipmentEngine AssemblyEngine Accessory Assembly InstallationStorage After Assembly111124759Engine InstallationGeneral1xiii October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision CSub-SectionSectionChapterTABLE OF CONTENTS (cont’d)72 00 111213Page NumberPreservation and StorageGeneralTemporary StorageReturning an Engine to Service After Storage122RepairGeneralRepair ProceduresRepair 1 – Threaded Area Repair and Stud ReplacementRepair 2 – Nick and Scratch RepairRepair 3 – Crankshaft or Crankpin RepairRepair 4 – Painted PartsRepair 5 – Crankshaft Oil Seal SurfaceRepair 6 – Cylinder Interior SurfaceRepair 7 – Cylinder Head Cooling FinsRepair 8 – Valve, Valve Seat, and Valve GuideRepair 9 – Spark Plug Threaded InsertRepair 10 – Rocker Bushing ReplacementRepair 11 – Connecting Rod Bushing ial Tools and EquipmentEngine Installation and Testing ProceduresEngine preservation and Storage After Testing1114Appendix A Assembly In Process Quality InspectionsAppendix B Approved Assembly MaterialsAppendix C Table of Limitsxiv October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision 9.1272-00-09.1372-00-09.14PageEngine Model Number erLIST OF FIGURES0200001ReservedAccessory HousingCrankcase Bearing and Flange SurfacesCylinder AssemblyPiston AssemblyPiston Rings and LandsValve TrainCamshaft Assembly084589101215Crankcase Bearing Retention DowelCrankshaft Bearing and Oil Pressure Relief ValveCrankshaft AssemblyCrankshaft Thrust and Slinger ClearanceCrankcase Assembly and Front Prop. Gov. Gear AssemblyConnecting Rod and Piston AssemblyConnecting Rod InstallationCamshaft AssemblyMain Bearing Reference MarksMain Bearing InstallationCrankcase Attaching HardwareCrankcase Attaching Hardware (cont’d.)Sealant Compound and Silk Thread ApplicationCrankcase Halves Assembly0945678121314151617181920xv October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision CCylinder Related Parts and Spring AssemblyPiston Assembly to Connecting RodCylinder Assembly and Head Oil Drain LinePiston Assembly with Ring Compressor ToolCylinder Base Nuts Sequence of TighteningIdler Gear in CrankcaseIdler Gear in Crankcase (cont’d.)Accessory Drive Gear ArrangementAccessory HousingOil Pump AssemblyAccessory Housing Gasket TrimmingInner Cylinder Cooling BaffleOil Sump and Induction SystemOil Level GageInduction SystemIntake Tube AssemblyVacuum Pump DriveFuel PumpPropeller Governor AdapterPropeller Governor Oil LineOil Filter AssemblyFuel Priming SystemCarburetor InstallationFuel Injection Servo InstallationFuel Injection Manifold InstallationMagneto and Adapter InstallationStarter Ring Gear AlignmentAlternator .4Cylinder Interior Resurface CrosshatchCooling Fin Removal MaximumValve Seat DimensionsValve to Seat Fit Acceptable ChapterLIST OF FIGURES 051535455565960611216182324xvi October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision nsConsumable 00-03.972-00-03.10Special Tools and EquipmentAbnormal Operating ProceduresEngine Will Not StartRough IdlingEngine Not Able To Develop Full PowerRough Engine OperationLow Power & Engine Runs RoughLow Oil Pressure On Engine GageHigh Oil TemperatureExcessive Oil Consumption720003112223334472-00-05.1Equipment and Materials List05172-00-06.172-00-06.272-00-06.3Disassembly MaterialsDiscard PartsSpecial Tools and Equipment0611372-00-07.172-00-07.2Equipment Required for CleaningMaterials Required for Cleaning071172-00-08.172-00-08.2Inspection MaterialsSpecial Tools and Equipment081172-00-09.1Special Tools and Equipment09272-00-10.172-00-11.1Equipment and Materials ListStorage -12.472-00-12.572-00-12.6List of RepairsList of MaterialsList of EquipmentList of Repair CodesReservedConsumable Materials for Paint Procedures13223311TablePageChapterLIST OF TABLESxvii October 2014 Superior Air Parts Inc.RRGeneral Information

Overhaul ManualO-360 and IO-360 Series EnginesRevision CINTRODUCTIONAbout This ce Manual fulfills the contentrequirements of FAR 33.4 Appendix A33.3(a)”and has been found “Acceptable to the FederalAviation Administration (FAA)”. The purpose ofthis Overhaul Manual is to provide thenecessary instructions for major repair andreplacement of Superior VantageO-360 andIO-360 series engines. Maintenance informationmay be found in the Maintenance Manual,SVMM01.Series Engines. Superior Air Parts values yourinput regarding revisions and additionalinformation for our manuals. Please forwardyour comments and input to:Superior Air PartsAttn: Engineering Department621 South Royal Lane Suite 100Coppell, Texas 75019Related PublicationsThe following are related engine and accessorypublications.The information in this publication is based ondata available at the time of publication and isupdated, supplemented, and automaticallyamended by Service Bulletins and PublicationRevisions that are issued by Superior Air PartsInc.O & IO-360 Installation and Operation Manual,SVIOM01O & IO-360 Maintenance Manual, SVMM01Obtaining Service InformationAll Vantage Series Engine manuals and rparts.comThis manual is divided into separate sectionsrelating to the general and specific overhaulinstructions required for the engine. Thesegeneral and specific instructions are generallyorganizedandnumberedpertherecommendations of the General AviationManufacturers Association (GAMA). In this way,information may be located in a conventionalmanner to aid in both accuracy and timeliness.All Vantage Series Engine manuals and serviceinformation may be purchased by contacting:Superior Air Parts621 South Royal Lane, Suite 100Coppell, Texas 75019Page numbering is organized within eachsection. The section number (e.g., 72-00-01) isdisplayed in the right hand section of the footeron each page. The page number is displayed inthe center of the footer on each page.or call: 972-829-4600AbbreviationsA list of abbreviations used in this manual isshown in Table 01-00-00.1 below.Superior Air Parts has made clear and accurateinformation available for those who maintain,own and repair the Vantage O-360 and IO-3601 October 2014 Superior Air Parts Inc.01-00-00Introduction

Overhaul ManualO-360 and IO-360 Series EnginesRevision CTable 01-00-00.1 AbbreviationsAbbreviationAMSAssyBTC / PropPSIRPMSAETIRUNF DefinitionAerospace Material StandardAssemblyBefore Top Center / Before Top Dead CenterCylinder Head TemperatureDiameterFahrenheitFigureFoot-PoundsIn Accordance WithInside DiameterInch-PoundsPoundsNumberNational Pipe ThreadOutside DiameterOuncePart NumberPropellerPounds per Square InchRevolutions Per MinuteSociety of Automotive EngineersTotal Indicator ReadingUnified National FineDegree2 October 2014 Superior Air Parts Inc.01-00-00Introduction

Overhaul ManualO-360 and IO-360 Series EnginesRevision CConsumable Materials ListRefer to Table 01-00-00.2 below for consumablematerials used during repair of the Vantage O360 and IO-360 series engines.NOTE:Equivalent substitutes may be used.Table 01-00-00.2 Consumable MaterialsMaterialAcetone or Methyl Ethyl Ketone (MEK)Assembly Grease – Lubriplate No. 105Cleaning SolventTMCopper Based Anti-seize, Fel-Pro C5-ATMFuelubeIsopropyl alcoholTMLoctite 271, P/N 27183TMLoctite No. 2 Gasket Sealant P/N 30514Lubricating Oil, SAE 10Lubricating Oil, SAE 50Mineral Oil (MIL-L-6082), SAE 50 weightTMPermatex , P/N 27100TMPliobond #20Pre-Lube Mixture – approx. 15% pre-lubricantTM(STP brand or equivalent) plus 85% SAE 50straight weight mineral oilPreservative oil mix (MIL-C-6529, type 1 plusMIL-L-6082)TMRTV 102 Silicon SealantSafety Wire (0.032) Type 304 Stainless Steel,P/N MS20995 C32Safety Wire (0.041) Type 304 Stainless Steel,P/N MS20995 C41TMSilastic 140 SealantSilk thread, size 00 (100% Silk)TMSTP High Viscosity Oil TreatmentTitesealTM No. 2 Gasket and Joint CompoundP/N T2-01Phthalate resin-type enamel AMS3125C orequivalent MIL-E-7729 Randolph Black (#303)Toluene or equivalent AMS3180 (or equivalentFederal Spec TT-T-548)Zinc Chromate Primer3 October 2014 Superior Air Parts Inc.SourceCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableOhio Industrial LubricantsCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableLocally Prepared MixtureLocally Prepared MixtureGeneral ElectricCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially AvailableCommercially Available01-00-00Introduction

Overhaul ManualO-360 and IO-360 Series EnginesRevision CTHISPAGEINTENTIONALLYLEFTBLANK4 October 2014 Superior Air Parts Inc.01-00-00Introduction

Overhaul ManualO-360 and IO-360 Series EnginesRevision CDESCRIPTION AND OPERATIONGeneral DescriptionSuperior Vantage Engines are four-cylinder,horizontally opposed, air-cooled, direct drivepowerplants incorporating a wet sump, bottommounted induction, bottom exhaust with eithercarbureted or port injected fuel systems.Provisions exist for both front and rear mountedaccessories. All engine components will bereferenced as they are installed in the airframe.Therefore, the “front” of the engine is thepropeller end and the “rear” of the engine is theaccessory mounting drive area. The oil sump ison the “bottom” of the engine and the cylindershroud tubes are on the “top”. The terms “left”and “right” are defined as being viewed from therear of the engine looking toward the front.Cylinder numbering is from the front to the rearwith odd numbered cylinders on the right side ofthe engine. The direction of crankshaft rotationis clockwise as viewed from the rear of theengine looking forward unless otherwisespecified. Accessory drive rotation direction isdefined as viewed from the rear of the enginelooking forward.Continued AirworthinessVantage Engines discussed in this documentmust be installed and operated in accordancewith the limitations, conditions and operatingprocedures described in the Installation andOperation Manual (SVIOM01). They must alsobe maintained in accordance with this manualand the applicable Maintenance Manual(SVMM01). For RSA-5 Fuel Servo, refer toPrecision Airmotive Operation and ServiceManual (15-338E). For the carburetor, refer toMarvel-Schebler Carburetor Service Manual(MSACSM). Sky-Tec starters and Slickmagnetos must be returned to their mfr. forservice or overhaul. The engine’s time betweenoverhaul (TBO) period is currently defined as1500 hours. A TBO extension program is inprocess.Model DesignationsThe model number designation is defined in away that the digits of the model number caneasily identify the basic configuration of theengine as described in Figure 02-00-00.1.Figure 02-00-00.1 Engine Model Number Designation1 October 2014 Superior Air Parts Inc.02-00-00Description and Operation

Overhaul ManualO-360 and IO-360 Series EnginesRevision CFuel System TypeIO Denotes Port Fuel Injection System and “opposed cylinder” arrangement.O Denotes a carbureted system and “opposed cylinder” arrangement.Cylinder Type360 Parallel valve cylinder, 361 cubic inches.Model SuffixDenotes detail engine configuration1st Digit Crankshaft & Propeller TypeA Fixed-Pitch, Thin-wall front mainB Constant-Speed, Thin-wall front mainC Fixed-Pitch, Heavy-wall front mainD Constant-Speed, Heavy-wall front mainE Fixed-Pitch, Solid front main2nd Digit Crankcase & Engine Mount Type123456#1 Dynafocal Mount#2 Dynafocal MountConical Mount#1 Dynafocal Mount, Front Propeller Governor#2 Dynafocal Mount, Front Propeller GovernorConical Mount, Front Propeller Governor3rd Digit Accessory PackageIgnition SystemAUnison MagnetosFuel SystemCarbureted (O-360)Precision CarburetorFuel Injected (IO-360)Precision Fuel Injection4th Digit Power Rating: Piston Compression Ratio12Cylinder Type360CRHP7.2:11688.5:1180Engine Components General Description2 October 2014 Superior Air Parts Inc.02-00-00Description and Operation

Overhaul ManualO-360 and IO-360 Series EnginesRevision CFeatures and Operating MechanismsThe O-360 and IO-360 series engines are aircooled, four cylinder, horizontally opposed,direct drive engines.See Installation &Operation Manual (SVIOM01) for Manufacturer’sGeneral Specifications.Crankshaft - The crankshaft is made from highquality, aerospace grade steel. All bearingjournal surfaces are nitrided. There are 3 kindsof crankshafts: thin-wall, thick-wall, and solidfront mains which can be identified by looking atthe center of the front of the crankshaft or propoil cavity.The thin-wall and thick-wallcrankshafts are each available as fixed-pitch orconstant-speed. Fixed-pitch versions have aplug installed in the inner diameter of the frontmain, or prop oil, cavity which prevents escapeof oil out the front, since there isn’t a propgovernor or constant-speed prop for the oilpressure to act upon.The complete engine (and engine overhaul)includes the following components andassemblies (note that the fuel systemcomponents,

0. O-360 & IO-360 SERIES ENGINES OVERHAUL MANUAL 621 South Royal Lane, Suite 100 / Coppell, TX 75019 / 800-277-5168 www.superio