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Doc. No.:
Title:
Austro Engine Work Instruction WI-MSB-E4-042 Rev.: 0 Type: Subject:
E4 Series Main bearing screws Page 1 of 18 Replacement
WORK INSTRUCTION WI-MSB-E4-042 Main bearing screws replacement Name / Position Date: Signature / Stamp:
Prepared:
Z. Grosu / ADE 02.02.2024 Checked/ Verified: HOMGENBESSER/ LDE 02.02.2024 Position: the jobholders position in the company signing the document e.g. LDE (Lead Design Engineer) or CVE Hardware (Compliance Verification Engineer responsible for Electronic Hardware) Prepared: preparation of this certification report under the CE responsibility Checked/Verified: checking and verification of the content of this certification report and checking that the defined requirements (e.g. CS-E) are met.
For details refer to: AE-VA-T-12-03 / Erstellen von Berichten zur Nachweisführung
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 2 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
TABLE OF CONTENT
0 General3
1 Power evaluation before replacement4
2 Main bearing screw replacement5
2.1 Parts5
2.2 Preliminary work5
2.2.1 Oil sump removal5
2.2.2 Oil repellent removal5
2.2.3 Oil pump drive removal6
2.3 Main bearing screw replacement9
2.4 Reassembly of the engine11
2.4.1 Oil pump installation11
2.4.2 Oil pump chain cover installation14
2.4.3 Oil repellent installation15
2.4.4 Oil sump installation15
2.4.5 Final procedures15
3 Power evaluation after screw replacement16
4 Tools and Consumable17
5 Shipping Info18
6 Remarks18
7 Referenced Documents18
8 Appendix18
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 3 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
0 General
This work instruction describes the procedure for replacing the six inner main bearing screws on E4 series engines without removing the bearing caps. Screws number 3 – 8 acc. to Fig. 1 are affected.
Fig. 1 affected main bearing screws
Screws number 1,2,9 and 10 must not be removed!
The replacement-screws with a higher tensile -strength can be identified by the imprint “12.9” on the screw head:
Fig. 2 comparison of the old (left) and the new (right) screw-head
1 2
3 4
5 6
7 8
9 10
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 4 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
1 Power evaluation before replacement
Before the disassembly of the engine , complete a power evaluation to obtain data for comparison purposes. The data collected before and after replacement will be compared to ensure correct operation of the engine after replacement.
Do the following steps in accordance with the Maintenance Manual, Doc. E4.08.04, Chapter 85-30-00
p.4A:
• Start cold engine, bring temperatures to normal operating conditions (>50°C Engine Oil Temp, >60°C Coolant Temp, >35°C Gearbox Oil Temp)
• Start recording with attached LiveView-Config (LiveView Config MSB-E4-039 file on the Diamond Partner Portal)
Avoid any kind of wind exposure during the self-test procedure. If wind cannot be avoided, note the wind conditions (direction, wind strength).
• Perform self-test
• Bring Power Lever to Max. Continuous Power (92%)
• Record 30s on ECU A, then 30s on ECU B
• Bring Power Lever to Idle and stop LiveView-Recording
• Collect and store the recorded data.
In case of unistalled engine or unistalled engine core, this step is not necessary.
As alternative:
- For engine core: perform the ground run with the old engine core installed and record the results.
- For new engine: after installation, perform the EECU download of the last 10 hrs (the power performance check is recorded).
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 5 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
2 Main bearing screw replacement
2.1 Parts
Replacement parts list:
Part Number Parts Description Qty E4A-05-000-003 Gasket for oil sump 1 E4A-10-100-202 Main bearing screw 6 DIN3771-16X3-ACM70 O-Ring 16x3 ACM 1 DIN 7603-C 14x18-CuFa Oil return line sealing ring (oil sump) 2 E4A-05-000-104 Sealing (T/C – oil return line) 1 OR_7.8X3.2-ACM70 O-Ring for oil return line 1 DIN7603-A12X16-AL Oil backflow line sealing rings 2 DIN7603-A14X20CU Oil drain plug sealing ring 1 E4A-04-000-003 T/C - Exhaust pipe sealing 1 2142110 Exhaust flange nut 4 NAS1758L8 Engine mount locking nut 1
Make sure the working area is clean. Use clean gloves.
Use appropriate plugs to cover all engine openings and protect them against ingress of dirt and moisture.
Following 3D-pictures pictures are only for reference. The actual engine can remain in the airframe.
2.2 Preliminary work
➢ Remove the upper and lower part of the engine cowling acc. to aircraft manufacturers manual.
➢ Remove the engine oil filter according to Maintenance Manual, Ch. 79. Visually examine the used Oil Filter for contamination and metal abrasion. If an abnormal condition is found (metal shavings exceeding 1.5 mm; concentr ation of particles; clogged filter), please contact Austro Engine for further instructions. Reinstall engine oil filter if no abnormalities could be found.
2.2.1 Oil sump removal ➢ Remove the oil sump acc. to the Maintenance Manual E4.08.04, section 79-10-00 Para. 3A.
Unlike specified in the Maintenance Manual, the engine can stay in the airframe . Therefore, tilt the engine within the remaining 3 engine mounts as far to the right as possible!
2.2.2 Oil repellent removal ➢ Remove oil repellent screws (7x M6; 2x M10 with washers) acc. to Fig. 3 ➢ Remove the oil repellent.
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 6 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
Fig. 3 oil repellent removal
2.2.3 Oil pump drive removal
➢ Loosen two screws [01] that attach the chain cover [02] to the oil pump and remove the chain cover.
Fig. 4 oil pump chain cover removal
02 01
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 7 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
➢ Remove three screws [03] that attach the oil pump to the crankcase.
Fig. 5 oil pump screw removal (1)
Fig. 6 oil pump screw removal (2)
03 03
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 8 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
Fig. 7 oil pump screw removal (3)
➢ Loosen the oil pump chain gear from the oil pump chain.
➢ Remove the oil pump.
➢ Examine the oil pump for blockage. Make sure that the pump gears move freely when turned by hand.
Fig. 8 oil pump removal
In case of a blocked, partially blocked, and/or damaged oil pump, please contact Austro Engine for further instructions.
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 9 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
2.3 Main bearing screws replacement
Only the screws of the inner three main bearings are replaced (Screws No. 3 – 8)!
The screws of the outer bearings (1,2,9 and 10) must not be loosened!
The bearing caps stay in place! Do not remove them from the engine!
The screws of the con-rods must not be loosened!
Following pictures are only for reference, parts may differ slightly.
➢ Loosen the six screws of the inner three main bearings. Leave the loosened screws hand-tight in place until the last of the six screws is loosened.
To rule out that the bearing caps will fall out of its place, only one screw per bearing cap is removed at a time.
➢ Apply engine oil thoroughly to the head contact surface and the thread of the new screws.
➢ First replace only the lower three screws, leaving the old upper three screws retaining the bearing caps (see Fig. 9).
Fig. 9 replacement of screws No. 4,6,8 ➢ Insert the new screws to the lower positions of the bearing shells and torque it to 10Nm.
4 6 8
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 10 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
➢ Now remove the upper three screws, insert the new ones and torque it to 10Nm (see Fig. 10)
Fig. 10 replacement of screws No. 3,5,7 ➢ Apply 55Nm to screws No 3 - 8 ➢ Tighten the screws another 90°. This may be done in max.3 directly consecutive steps (3x30°).
Start with the center bearing. It is recommended to use a rotation angle measurement device.
➢ Check the ease of movement of the crankshaft by slightly turning it back and forth on the flywheel gearing by hand.
In case something went wrong during final torquing procedure, repeat chapter 2.3 from the beginning to remove all previously installed screws and replace by new ones.
3 5 7
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 11 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
2.4 Reassembly of the engine
2.4.1 Oil pump installation
➢ Make sure that the circlips [04] (E4A-50-300-801) [05] (E4A-50-400-801) used to secure both plugs on the oil pump is in the correct position.
Fig. 11 circlips to check ➢ Install the new O-Ring between the oil pump and the crankshaft housing., make sure it is correctly fitted (see Fig. 12 and Fig. 13)
Fig. 12 Oil pump o-ring
04 05 O-Ring
Title:
Work Instruction Doc. No.:
WI-MSB-E4-042 Rev.: 0
Page 12 of 18 Type:
E4 Series Subject:
Main bearing screws Replacement
Fig. 13 Oil pump o-ring
➢ Apply some approved engine oil (refer to the MM) on the chain before installation.
➢ Install the oil pump chain onto the oil pump sprocket
Fig. 14 Oil pump chain installation
➢ Install the oil pump with O-Ring and three screws [04] (M7x27) on the crankcase. (see Fig. 15, Fig.
16 and Fig. 17) ➢ Apply Loctite 2701 or 278 on the thread and tighten with a torque of 14 Nm.
O-Ring