# Austro Engine Mandatory Service Bulletin MSB-E4-042: No revision named - Rights: © Austro Engine. Filed by the FAA in regulations.gov docket FAA-2024-0456; AD 2024-05-01 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Austro Engine Mandatory Service Bulletin MSB-E4-042](https://openairdocs.org/service-documents/austro-engine/msb-e4-042.md) - Title as filed: Austro Engine Work Instruction MSB-E4-042 - Pages: 18 - PDF: https://openairdocs.org/files/sha256/02/b1/02b1af339447f299a0c9d2eb871fff6c269550645accc61dea0aa126b73a6a53 - Page: https://openairdocs.org/service-documents/austro-engine/msb-e4-042/file/02b1af339447 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 (OCR) 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 ### Page 2 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 General ......................................................................................................................... 3 1 Power evaluation before replacement ......................................................................... 4 2 Main bearing screw replacement ................................................................................. 5 2.1 Parts ............................................................................................................................ 5 2.2 Preliminary work .......................................................................................................... 5 2.2.1 Oil sump removal .................................................................................................. 5 2.2.2 Oil repellent removal ............................................................................................. 5 2.2.3 Oil pump drive removal .......................................................................................... 6 2.3 Main bearing screw replacement ................................................................................... 9 2.4 Reassembly of the engine ........................................................................................... 11 2.4.1 Oil pump installation ............................................................................................ 11 2.4.2 Oil pump chain cover installation .......................................................................... 14 2.4.3 Oil repellent installation ....................................................................................... 15 2.4.4 Oil sump installation ............................................................................................ 15 2.4.5 Final procedures .................................................................................................. 15 3 Power evaluation after screw replacement ............................................................... 16 4 Tools and Consumable ................................................................................................ 17 5 Shipping Info .............................................................................................................. 18 6 Remarks ...................................................................................................................... 18 7 Referenced Documents .............................................................................................. 18 8 Appendix ..................................................................................................................... 18 ### Page 3 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 ### Page 4 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). ### Page 5 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. ### Page 6 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 ### Page 7 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 ### Page 8 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. 03 ### Page 9 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 ### Page 10 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 ### Page 11 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 ### Page 12 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 ### Page 13 Title: Work Instruction Doc. No.: WI-MSB-E4-042 Rev.: 0 Page 13 of 18 Type: E4 Series Subject: Main bearing screws Replacement Fig. 15 oil pump screw (1) Fig. 16 oil pump screw (2) 03 03 ### Page 14 Title: Work Instruction Doc. No.: WI-MSB-E4-042 Rev.: 0 Page 14 of 18 Type: E4 Series Subject: Main bearing screws Replacement Fig. 17 oil pump screw (3) 2.4.2 Oil pump chain cover installation ➢ Slide the chain cover [02] in place on the oil pump and tighten the screws [01] (ISO8102 -M6x20) (x2) with 12 Nm Fig. 18 oil pump chain cover installation 02 01 03 ### Page 15 Title: Work Instruction Doc. No.: WI-MSB-E4-042 Rev.: 0 Page 15 of 18 Type: E4 Series Subject: Main bearing screws Replacement 2.4.3 Oil repellent installation ➢ Place the oil repellent [06] on the crankcase by sliding it underneath the oil pump suction pipe acc. to Fig. 19 ➢ Tighten the screws with the following torques: 7x M6 [07] with 12 Nm and Loctite 243 applied on the thread; 2x M10 [08] and washer with 53 Nm and Loctite 243 applied on the thread. Fig. 19 oil repellent installation 2.4.4 Oil sump installation ➢ Install the oil sump acc. to the Maintenance Manual E4.08.04, section 79-10-00 Para. 3B. 2.4.5 Final procedures ➢ Fill up the engine oil according to Maintenance Manual, Ch. 79. ➢ Reinstall aircraft related parts acc. to aircraft manufacturers manual ➢ Fill up all operating fluids ➢ Conduct a ground run acc. to Chapter 3 08 06 07 07 ### Page 16 Title: Work Instruction Doc. No.: WI-MSB-E4-042 Rev.: 0 Page 16 of 18 Type: E4 Series Subject: Main bearing screws Replacement 3 Power evaluation after screw replacement After the main bearing screw replacement procedure as outlined i n Chapter 2 has been carried out, do the following power evaluation procedure: ➢ Start the engine and let it warm up with <20% power lever until all following conditions are reached: ➢ Engine oil temperature >50°C ➢ Coolant temperature >60°C ➢ Gearbox oil temperature >35°C ➢ Conduct engine power evaluation as described in Chapter 1. The data collected before and after replacement can be compared in case of different engine behaviour. For engine core: compare the data with the ground run performed with the old engine core. For new engine: compare the data with the previous download. ➢ Cool down the engine (approx. 2min idle) ➢ Shut down the engine ➢ Check entire engine installation for leaks and abnormalities. ### Page 17 Title: Work Instruction Doc. No.: WI-MSB-E4-042 Rev.: 0 Page 17 of 18 Type: E4 Series Subject: Main bearing screws Replacement 4 Tools and Consumable Consumable List Consumables Material definition Parts applicability Sealant MERCEDES BENZ A003989982010 Oil Sump Dow Corning 736 Heat Resistant/Sealant Service lid and fire sleeves No. 5970, alternative 5900 or 5910 Engine sealants Screw lock Loctite No. 243 Loctite No. 2701 or 278 Screw locks For applicability refer to the relevant chapters of this document. No. 542 Thread sealant Engine seala Grease Lubricant (acid-free lubrication) Released AE300 engine oils which are defined in the AE300 Operation Manual. O-ring and Rubber Gaskets Safety wire Suitable for flight purposes stainless safety wire. Wire thickness 0.81 mm For applicability refer to the relevant chapters of this manual Cleaning agent customary brake cleaner parts cleaning Refer also to the Maintenance Manual E4.08.04. ### Page 18 Title: Work Instruction Doc. No.: WI-MSB-E4-042 Rev.: 0 Page 18 of 18 Type: E4 Series Subject: Main bearing screws Replacement 5 Shipping Info Removed parts shall be quarantined for 6 month and eventually destroyed. 6 Remarks NOTE: ➢ All measures must be carried out by an authorized diamond service center. ➢ The accomplishment of the instructions shown must be confirmed in the respective engine log book. ➢ Replace the main bearing screws in accordance with MSB-E4-042 and mark the Service Bulletin as executed in the engine logbook and via Diamond Partners Portal; ➢ In case of doubt, please contact Austro Engine GmbH via the Diamond Partners Portal o If you are not a Diamond Partner / Service Centre, please contact a Diamond Authorized Service Centre near you. 7 Referenced Documents - Maintenance Manual, Doc. E4.08.04, latest revision - MSB-E4-042, latest revision 8 Appendix None --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.