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Austro Engine E4 Series Maintenance Manual

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Summary of Contents for Austro Engine E4 Series

  • Page 2 E4 Series Introduction Maintenance Manual Intentionally left blank Page 2 01 – Intro E4.08.04 01-Jul-2020 Rev. 29...
  • Page 3 E4 Series Introduction Maintenance Manual Maintenance Manual E4 Date: Wiener Neustadt, 01-Jul-2020 Author: Austro Engine GmbH Rudolf – Diesel – Straße - 11 2700 Wiener Neustadt Austria Document number: E4.08.04 Revision: 29 Page 3 01-Introduction E4.08.04 Rev. 29 01-Jul-2020...
  • Page 4 E4 Series Introduction Maintenance Manual Intentionally left blank Page 4 01-Introduction E4.08.04 01-Jul-2020 Rev. 29...
  • Page 5 E4 Series Introduction Maintenance Manual CHAPTER 01 INTRODUCTION Page 1 01 - Title E4.08.04 Rev. 29 01-Jul-2020...
  • Page 6 E4 Series Introduction Maintenance Manual Intentionally left blank Page 2 01 – Title E4.08.04 01-Jul-2020 Rev. 29...

  • Page 7: Table Of Contents

    E4 Series Introduction Maintenance Manual Table of Contents Chapter 01 01-00-00 Introduction ....................1 General ..........................1 Warning, Cautions and Notes ....................2 Manual Configuration ......................2 Chapter Configuration ..................... 3 Page Numbering System ....................3 Figures ........................... 3 Revisions ........................... 4 List of Revisions ......................
  • Page 8 E4 Series Introduction Maintenance Manual Intentionally left blank Page 2 01 - Contents E4.08.04 01-Jul-2020 Rev. 29...

  • Page 9: Introduction

    With the publication of the Maintenance Manual, Austro Engine GmbH ensures the correctness of the instructions. Austro Engine GmbH will inform about changes with Service Bulletins, Service Letters or manual amendments, as necessary.

  • Page 10: Warning, Cautions And Notes

    E4 Series Introduction Maintenance Manual 2. Warning, Cautions and Notes The following symbols and warning signs are used in this manual to point out important instructions. Obey the safety precautions and maintenance instructions when you do maintenance. A WARNING TELLS THE PERSON DOING THE MAINTENANCE THAT INJURY OR DEATH IS POSSIBLE IF THEY DO NOT STRICTLY OBEY THE INSTRUCTIONS.

  • Page 11: Chapter Configuration

    E4 Series Introduction Maintenance Manual A. Chapter Configuration The first page of each chapter shows the number of the chapter and the title. The second page shows the contents. Where applicable, each chapter contains the topics that follow: System Description and Operation Trouble-Shooting Maintenance Procedures.

  • Page 12: Revisions

    E4 Series Introduction Maintenance Manual 4. Revisions All revisions of this manual are recorded in chapter “List of Revisions“. All incorporated Temporary revisions must be recorded in chapter “List of incorporated Temporary Revisions”. The new or amended text is indicated by a vertical black line at the left hand side of the revised page, with the revision number and date appearing at the bottom of the page.

  • Page 13: List Of Revisions

    E4 Series Introduction Maintenance Manual A. List of Revisions Reason Chapter Page(s) Date of Approval Date of Signature Revision Approval Authority 07-May-2009 remarks DOA *) updated 2,4,5,6,7, Intro 10,11,12, 13,14 1,2,3,4 1,2,3,4,5, 1,2,3,4,5, 1,2,4,5 1,2,3,4,5, 6,7,8,9 Authority 1,2,3,4 09-Sep-2009 remarks...
  • Page 14 E4 Series Introduction Maintenance Manual Reason Chapter Page(s) Date of Approval Date of Signature Revision Approval 2,3,4 1-6,8 2-25 1,2,4, 6-9 1-3, 5, 7-17 1-5,7-9, 11,13,14 16-18, 20-22, 1-10 Last page Intro 2,5,6,7,8, 12-16 4,8,9 27-Jan-2011 MDC-E4-199 DOA *) Intro...
  • Page 15 E4 Series Introduction Maintenance Manual Reason Chapter Page(s) Date of Approval Date of Signature Revision Approval 2-39 4-11 Intro 2,5-8, 12-17 3-4,22-46 15-Nov-2011 MDC-E4-237 DOA *) 1,2,4 14-16,23 1-13 Intro 2, 5-9 13-21 1-2,4-46 1, 4-6 2-5,22,24 2-4,6-8 19-Jan-2012 MDC-E4-257...
  • Page 16 E4 Series Introduction Maintenance Manual Reason Chapter Page(s) Date of Approval Date of Signature Revision Approval Intro 2,6-9, 16-22 6-23 10-Jul-2012 MDC-E4-274 DOA *) 1-2,6 11-43 13,14 Intro 2,6-9 16-22 05-Sep-2012 MDC-E4-219 DOA *) 4,7-45 Intro 2, 6-9 03-Oct-2012 MDC-E4-283...
  • Page 17 E4 Series Introduction Maintenance Manual Reason Chapter Page(s) Date of Approval Date of Signature Revision Approval 5,9,10,12, Intro 2,7-22 23.Sep.20 06-Sep-2013 MDC-E4-275 2-10 EASA Intro 2,7-10 MDC-E4-318 20-26, DOA *) 19-Nov-2013 and MDC- 29-31, E4-238c 33,35,36, 38-40, 42-44 Intro 2,7-10,...
  • Page 18 E4 Series Introduction Maintenance Manual Reason Chapter Page(s) Date of Approval Date of Signature Revision Approval 4-68 7-72 DOA *) 14-Dec-2015 MDC-E4-359 EASA 23-Feb-2017 MDC-E4-384 EASA 04-Mar-2019 MDC-E4-478 EASA 01-Jul-2020 MDC-E4-604 *) The technical content of this document is approved under the authority of DOA ref.

  • Page 19: List Of Included Temporary Revisions

    E4 Series Introduction Maintenance Manual B. List of included Temporary Revisions Temporary Revision Incorporated with Title of Temporary Revision Number Manual Rev. MM-TR-MDC-E4-309b Oil baffle panel installation Injector cover with maintenance lid & MM-TR-MDC-E4-314b change of breather hose oil separator...
  • Page 20 E4 Series Introduction Maintenance Manual Temporary Revision Incorporated with Title of Temporary Revision Number Manual Rev. MM-TR-MDC-E4-422a Waste Gate Steuerstange ausfallsichere Verbindung MM-TR-MDC-E4-422b Waste Gate Conrod Fail-Safe Bridge MM-TR-MDC-E4-422c Waste Gate Conrod Fail-Safe Bridge MM-TR-MDC-E4-425 Harness Repair MM-TR-MDC-E4-439 Electrical Harness...

  • Page 21: List Of Service Bulletins Included As Maintenance Procedures

    E4 Series Introduction Maintenance Manual Temporary Revision Incorporated with Title of Temporary Revision Number Manual Rev. MM-TR-MDC-E4-582 Restrictor and BPS Adaption MM-TR-MDC-E4-594 Oil Return Line MM-TR-MDC-E4-594a Oil Return Line MM-TR-MDC-E4-594b Oil Return Line MM-TR-MDC-E4-636 Engine Harness MM-TR-RDC-E4-038 Engine Harness alternator connector repair kits...

  • Page 22: Abbreviations

    E4 Series Introduction Maintenance Manual 5. Abbreviations A. General Austro Engine BATT Battery Computer Aided Design Controller Area Network Counterclockwise Certification Specification DOHC Double Overhead Camshaft EASA European Union Aviation Safety Agency EECS Electronic Engine Control System EECU Electronic Engine Control Unit...

  • Page 23: Engine Harness

    E4 Series Introduction Maintenance Manual B. Engine Harness Boost Pressure Actuator BPS1 Boost Pressure Sensor 1 BPS2 Boost Pressure Sensor 2 CAS 1 Camshaft Sensor 1 CAS 2 Camshaft Sensor 2 Connector Type CRS 1 Crankshaft Sensor 1 CRS 2...

  • Page 24: Conversion Factors

    E4 Series Introduction Maintenance Manual 6. Conversion Factors A. Conversion Table of Given Torque Values Newton Meter (Nm) Pound-force inch (lbf in) Page 16 01-Introduction E4.08.04 01-Jul-2020 Rev. 29...

  • Page 25: Conversion Table Of Given Pressure Values

    E4 Series Introduction Maintenance Manual B. Conversion Table of Given Pressure Values Pressure Pressure Pressure [bar] [psi] [lbf/ft²] 1044 2089 3133 4177 5221 6266 7310 8354 9398 10443 11487 12531 13576 14620 15664 16708 17753 18797 19841 10,0 20885 C. Engine Power Conversions 1 Metric horsepower [hp(M)] ≙...

  • Page 26: Consumable List

    Turbocharger, between Sicherungslack (tamper proof Torque Seal compressor and bearing sealant), housing Color Blue Please contact the Austro Engine GmbH customer support under service@austroengine.at +43 (0) 2622 23000 2525 in case of material availability. Page 18 01-Introduction E4.08.04 01-Jul-2020 Rev. 29...

  • Page 27: General Description Of The Engine

    E4 Series Introduction Maintenance Manual 01-10-00 General Description of the Engine Type Designation: TC-Designation: Models: (Sales Name AE300) (Sales Name AE330) For detailed information about available configurations, refer to MSB E4-002 in its latest revision. If not otherwise stated, this manual is applicable to all available configurations.
  • Page 28 E4 Series Introduction Maintenance Manual Characteristics: max. Manifold pressure (Model E4): 2660 mbar max. Manifold pressure (Model E4P): 2750 mbar max. Fuel pressure: 1600 bar Firing order: 1:3:4:2 The EECU is the Electrical Engine Control Unit which is used to control the engine actuators (e.g.
  • Page 29 E4 Series Introduction Maintenance Manual Additional: The following components are not part of the Type Design of the E4 engine series. These parts are provided by the airframe manufacturer.  Governor  Fuel pumps  Fuel Filter Housing  Fuel Filter ...
  • Page 30 E4 Series Introduction Maintenance Manual Engine Front View: Common Rail Pressure Coolant Thermostat Control Valve Engine Oil Filter Housing Wastegate Controller Intake Manifold Turbocharger Gearbox Oil Fill Plug Fuel Gearbox Overpressure Relief Value Temperature Sensor Fuel Pressure V-Ribbed Belt Sensor...
  • Page 31 E4 Series Introduction Maintenance Manual Engine Top View: Injector Cover Turbocharger Coolant Thermostat Pressure Control Valve Wastegate Controller Fuel Pressure Sensor Rail Pressure Sensor Boost Pressure Actuator Fuel Metering Unit One of 4 Glow Plugs Fuel High Pressure Pump Boost Pressure Sensor Starter Intake Air Temp.
  • Page 32 E4 Series Introduction Maintenance Manual Engine Left Side View: Rail Pressure Control Valve Coolant Thermostat Fuel Pressure Sensor Injector Cover Turbocharger Fuel Metering Unit High Pressure Pump Propeller Shaft Wastegate Controller Gearbox Oil Fill Plug Starter Boost Pressure Actuator Gearbox Temp.
  • Page 33 E4 Series Introduction Maintenance Manual Engine Right Side View: Turbocharger Injector Cover Wastegate Controller High Pressure Pump Boost Pressure Actuator Connector Exhaust Manifold Air Filter for Boost Pressure Actuator Oil Pressure Line for Boost Pressure the Turbocharger Actuator Crankshaft Sensor #1...
  • Page 34 E4 Series Introduction Maintenance Manual Engine Top View with removed Injector Cover: Fuel Return Line Plug Camshaft Sensor #2 Camshaft Sensor #1 Camshaft High Pressure Pump Fuel Injector #2 Fuel Injector #4 Sensor #2 Fuel Injector #1 Fuel Injector #3...
  • Page 35 E4 Series Transport and Maintenance Manual Packaging CHAPTER 02 TRANSPORT AND PACKAGING Page 1 02 - Title E4.08.04 Rev.29 01-Jul-2020...
  • Page 36 E4 Series Transport and Maintenance Manual Packaging Intentionally left blank Page 2 02 - Title E4.08.04 01-Jul-2020 Rev.29...
  • Page 37 E4 Series Transport and Maintenance Manual Packaging Table of Contents Chapter 02 02-00-00 Transport and Packaging................. 1 General ..........................1 Packaging .......................... 1 Transport ........................... 5 Protective Covers ....................... 6 Storage and Preservation ....................7 Storage of a received engine ................... 7 Preservation of an installed engine ..................
  • Page 38 E4 Series Transport and Maintenance Manual Packaging Intentionally left blank Page 2 02 – Content E4.08.04 01-Jul-2020 Rev.29...

  • Page 39: Transport And Packaging

    E4 Series Transport and Maintenance Manual Packaging 02-00-00 Transport and Packaging 1. General This chapter contains information about packaging and transport of the engine attached to the corresponding mountings. 2. Packaging Detail Steps/Work Items Key Items/References If not specified differently, ship the Put the engine in a wooden box.
  • Page 40 E4 Series Transport and Maintenance Manual Packaging Fig. 02 - 2 Fig. 02 - 3 Page 2 02 – Transport and Packaging E4.08.04 01-Jul-2020 Rev.29...
  • Page 41 E4 Series Transport and Maintenance Manual Packaging Fig. 02 - 4 Fig. 02 - 5 Page 3 02 – Transport and Packaging E4.08.04 Rev.29 01-Jul-2020...
  • Page 42 E4 Series Transport and Maintenance Manual Packaging Fig. 02 - 6 Page 4 02 – Transport and Packaging E4.08.04 01-Jul-2020 Rev.29...

  • Page 43: Transport

    E4 Series Transport and Maintenance Manual Packaging 3. Transport Detail Steps/Work Items Key Items/References Use a correct lifting device for the weight of the engine. Lift the engine with the transport eyelets. Refer to Fig. 02 - 7 and Fig. 02 - 8.

  • Page 44: Protective Covers

    To prevent the engine from corrosion, store Corrosion protective package is and transport the engine and in an available at Austro Engine GmbH. appropriate package. Remove all protective covers and mountings before the engine operation. To prevent engine contamination during the installation process, remove the covers step by step when installing the lines and hoses.

  • Page 45: Storage And Preservation

    A. Storage of a received engine The storage time limit after initial preservation of the engine ex works is 36 months (see the shipping documents, e.g. engine log). If this period is exceeded, contact Austro Engine GmbH for further instructions.
  • Page 46 E4 Series Transport and Maintenance Manual Packaging  Engine Start and Warm Up according to Section 5.1.2 and 5.1.3 from the E4 Operation Manual E4.01.01 or Section 4.1.2 and 4.1.3 from the E4P Operation Manual E4.01.02. Non-compliance with Section 3.5.6.3 from the E4 Operation Manual E4.01.01 or Section 2.5.6.3 from the E4P Operation Manual E4.01.02 is acceptable during ground run only...

  • Page 47: Engine Depreservation

    Store the engine either installed or uninstalled in a dry, protected place. Refer to Paragraph C - Engine depreservation. Engine preservation over 6 months Contact Austro Engine GmbH for further instructions. C. Engine depreservation  Remove all covers from the engine compartment openings.

  • Page 48: Engine Storage

    E4 Series Transport and Maintenance Manual Packaging D. Engine storage This procedure applies for an installed engine intended to be uninstalled and stored.  Perform the engine preservation up to 6 months. Refer to Paragraph B - Preservation of an installed engine.

  • Page 49: Return Parts Shipping Instructions

    Transport and Maintenance Manual Packaging 6. Return Parts Shipping Instructions If it is necessary to return parts to Austro Engine GmbH, obey the following instructions: Detail Steps/Work Items Key Items/References Clean the part, especially the oil contaminated parts (e.g. Governor).
  • Page 50 E4 Series Transport and Maintenance Manual Packaging Intentionally left blank Page 12 02 – Transport and Packaging E4.08.04 01-Jul-2020 Rev.29...
  • Page 51 E4 Series Engine Maintenance Manual Installation CHAPTER 03 ENGINE INSTALLATION Page 1 03 - Title E4.08.04 Rev.29 01-Jul-2020...
  • Page 52 E4 Series Engine Maintenance Manual Installation Intentionally left blank Page 2 03 - Title E4.08.04 01-Jul-2020 Rev.29...
  • Page 53 E4 Series Engine Maintenance Manual Installation 03-00-00 Engine Installation For detailed engine installation instructions, refer to the Installation Manual E4.02.01 for the E4 engine series or the applicable Aircraft Maintenance Manual. Page 1 03 – Engine Installation E4.08.04 Rev.29 06-Dec-2019...
  • Page 54 E4 Series Engine Maintenance Manual Installation Intentionally left blank Page 2 03 – Engine Installation E4.08.04 01-Jul-2020 Rev.29...
  • Page 55 E4 Series Airworthiness Maintenance Manual Limitation CHAPTER 04 AIRWORTHINESS LIMITATION Page 1 04 - Title E4.08.04 Rev.29 01-Jul-2020...
  • Page 56 E4 Series Airworthiness Maintenance Manual Limitation Intentionally left blank Page 2 04 - Title E4.08.04 01-Jul-2020 Rev.29...
  • Page 57 E4 Series Airworthiness Maintenance Manual Limitation 04-00-00 Airworthiness Limitation EASA Approval Statement: This Airworthiness Limitation Section is approved by European Aviation Safety Agency (EASA) in accordance with the applicable certification procedures and the type certification basis. Any changes must be documented and approved by the local airworthiness agency.
  • Page 58 E4 Series Airworthiness Maintenance Manual Limitation Intentionally left blank Page 2 04 – Airworthiness Limitation E4.08.04 01-Jul-2020 Rev.29...
  • Page 59 Time Limits and E4 Series Maintenance Maintenance Manual Check CHAPTER 05 TIME LIMITS AND MAINTENANCE CHECK Page 1 05 - Title E4.08.04 Rev. 29 20-Jul-2020...
  • Page 60 Time Limits and E4 Series Maintenance Maintenance Manual Check Intentionally left blank Page 2 05 – Title E4.08.04 20-Jul-2020 Rev. 29...
  • Page 61 Time Limits and E4 Series Maintenance Maintenance Manual Check Table of Contents Chapter 05 05-00-00 Time Limits and Maintenance Check ............... 1 General ..........................1 Words for special meanings ....................2 Claimable Exceed of Maintenance Actions ................4 05-10-00 Component Time Limits and Maintenance Requirements ....... 5 Component Time Limits ......................
  • Page 62 Time Limits and E4 Series Maintenance Maintenance Manual Check Intentionally left blank Page 2 05 - Contents E4.08.04 20-Feb-2020 Rev. 29...

  • Page 63: Time Limits And Maintenance Check

    Time Limits and E4 Series Maintenance Maintenance Manual Check 05-00-00 Time Limits and Maintenance Check 1. General This chapter describes how to do the maintenance of the E4 engine correctly. Refer to Chapter 04 and 05 to find out when to do maintenance and inspections.

  • Page 64: Words For Special Meanings

    Time Limits and E4 Series Maintenance Maintenance Manual Check 2. Words for special meanings In this Maintenance Manual the words that follow have special meanings: Adjust To put a specified position or condition. For example, adjust the clearance to 1 mm.
  • Page 65 Time Limits and E4 Series Maintenance Maintenance Manual Check Record (1) Technical name for something that shows what was done. For example, write the result of the test in the engine record. (2) The act of making a record. For example, record the result of the test in the Engine Maintenance Log.

  • Page 66: Claimable Exceed Of Maintenance Actions

    Time Limits and E4 Series Maintenance Maintenance Manual Check 3. Claimable Exceed of Maintenance Actions Maintenance actions based on operating hours Operating Hours Intervals Claimable Exceed of the Basic Interval up to and including 100 operating hours ± 10 % between 101 and 1000 operating hours ±...

  • Page 67: Component Time Limits And Maintenance Requirements

    Time Limits and E4 Series Maintenance Maintenance Manual Check 05-10-00 Component Time Limits and Maintenance Requirements Component time limits and maintenance requirements must be followed to keep the engine into airworthy and good technical condition. Components not explicitly listed in this section have the same Time before Overhaul as the engine.

  • Page 68: Component Time Limits

    Time Limits and E4 Series Maintenance Maintenance Manual Check 1. Component Time Limits The following table lists life limited components, which must be replaced at a specific time. Component Time Limit Reference High Pressure pump 600 h 73-10-03 Circlip of the Wastegate Controller...

  • Page 69: Component Maintenance Requirements

    Time Limits and E4 Series Maintenance Maintenance Manual Check 2. Component Maintenance Requirements The following table list require specific maintenance checks at the given times. For Model E4 Activities/Services 300 h 600 h 900 h 1000 h 1500 h Chapter...

  • Page 70: Engine Time Between Overhaul

    Only a certified mechanic or otherwise authorized person under consideration of the applicable national requirements may overhaul the engine. The overhaul trained by Austro Engine GmbH must be done with the instructions given in the overhaul manual of Austro Engine GmbH.

  • Page 71: Scheduled Maintenance Checks

    E4 Series Maintenance Maintenance Manual Check 05-20-00 Scheduled Maintenance Checks This section describes the scheduled maintenance checks for the E4 Series. The scheduled annual inspection consists of the 100 hours inspection program. Activities/Service Interval 100 h 300 h General Send the following data to Austro Engine GmbH: Serial Number of the Engine(s) –...
  • Page 72 Time Limits and E4 Series Maintenance Maintenance Manual Check Activities/Service Interval 100 h 300 h Drain the Gearbox Oil according to Section 85-10-00. Examine the Gearbox Oil according to Section 85-10-00. Collect a sample of used Gearbox Oil using the oil container provided with the 300 h Service Kit.
  • Page 73 Time Limits and E4 Series Maintenance Maintenance Manual Check Activities/Service Interval 100 h 300 h COOLING SYSTEM Visually examine the Cooling System. Look especially for signs of wear and leakage. – Make sure that the connections are tight fitted and the hoses –...
  • Page 74 Time Limits and E4 Series Maintenance Maintenance Manual Check Activities/Service Interval 100 h 300 h Install the Injector Cover according to Section 85-10-00 Paragraph 3.B. EXHAUST SYSTEM Visually examine the Wastegate Controller for: Deformations at the connection rod A deformed mounting eyelet at the rod eye of the waste gate Mechanical fractures/dents/chafing marks/cracks (affecting the functionality).
  • Page 75 Time Limits and E4 Series Maintenance Maintenance Manual Check Activities/Service Interval 100 h 300 h Complete an engine ground run according to Section 71-00-01. Examine the oil system for leakage. If leaks are found, examine the root cause and do the repair –...

  • Page 76: Unscheduled Maintenance Checks

    Check 05-50-00 Unscheduled Maintenance Checks 1. Performance Deterioration Analyse EECU data using the AE 300 Wizard to find the root cause. Austro Engine GmbH may assist for this analysis on request. Send the following data: Engine log Data log (min. 3 hrs.).

  • Page 77: High Engine Oil Consumption Inspection

    Time Limits and E4 Series Maintenance Maintenance Manual Check 6. High Engine Oil Consumption Inspection 1. Examine the engine for oil leakage. 2. Examine the compression. 3. Analyse EECU data using the AE 300 Wizard to find the root cause.
  • Page 78 Time Limits and E4 Series Maintenance Maintenance Manual Check Intentionally left blank Page 208 05-Maintenance Check E4.08.04 20-Jul-2020 Rev. 29...
  • Page 79 E4 Series Servicing Maintenance Manual CHAPTER 12 SERVICING Page 1 12 - Title E4.08.04 Rev.29 01-Jul-2020...
  • Page 80 E4 Series Servicing Maintenance Manual Intentionally left blank Page 2 12 - Title E4.08.04 01-Jul-2020 Rev.29...
  • Page 81 E4 Series Servicing Maintenance Manual Table of Contents Chapter 12 12-00-00 Servicing ...................... 201 12-10-00 Engine Oil Servicing ..................201 Complete a check of the Oil level .................. 201 Do a check of the Gearbox Oil level ................202 Engine Coolant Servicing ....................202...

  • Page 82: Servicing

    E4 Series Servicing Maintenance Manual Intentionally left blank Page 2 12 – Content E4.08.04 01-Jul-2020 Rev.29...

  • Page 83: Engine Oil Servicing

    E4 Series Servicing Maintenance Manual 12-00-00 Servicing This chapter contains information on the engine servicing. 12-10-00 Engine Oil Servicing A. Complete a check of the Oil level Detail Steps/Work Items Key Items/References Remove the oil dipstick. Refer to Fig. 12 - 1.

  • Page 84: Do A Check Of The Gearbox Oil Level

    E4 Series Servicing Maintenance Manual B. Do a check of the Gearbox Oil level Detail Steps/Work Items Key Items/References Do a check of the gearbox oil quantity. Refer to Fig. 12 - 3. For details acc. to the Prop Regulation System, refer to the applicable Aircraft Maintenance Manual.
  • Page 85 E4 Series Electrical Power Maintenance Manual CHAPTER 24 ELECTRICAL POWER Page 1 24 - Title E4.08.04 Rev.29 01-Jul-2020...
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  • Page 87 E4 Series Electrical Power Maintenance Manual Table of Contents Chapter 24 24-00-00 Electrical Power ....................1 Electrical System Description ....................1 Electrical System Installation ....................2 Alternator ........................2 Alternator-Regulator Adjustment E4A-91-200-000 ..............3 Paralleling for twin engine system E4A-91-200-000 .............. 3 Troubleshooting Information ...................
  • Page 88 E4 Series Electrical Power Maintenance Manual Install the Brush Holder ....................232 Functional Check ......................236 Mark the inspected Alternator E4A-91-400-000 .............. 240 24-60-00 Alternator-Regulator E4A-91-100-000 ............241 General ........................... 241 Adjust the voltage regulation E4A-91-100-000 ..............242 Adjust the alternator balancing E4A-91-100-000 (only for twin-engine applications) .... 242 Replace Alternator-Regulator E4A-91-100-000 ..............

  • Page 89: Electrical Power

    E4 Series Electrical Power Maintenance Manual 24-00-00 Electrical Power 1. Electrical System Description The Electrical System consists of the following major components: Starter (refer to Chapter 80) – Generator – GPC – Glow Plug Control Unit (refer to Chapter 80) –...

  • Page 90: Electrical System Installation

    E4 Series Electrical Power Maintenance Manual 2. Electrical System Installation Make sure that all of the electrical system and wiring harness have protection against chafing at hot parts or sharp edges. The main aircraft battery supplies electrical power to the electrical system.

  • Page 91: Alternator-Regulator Adjustment E4A-91-200-000

    E4 Series Electrical Power Maintenance Manual 3. Alternator-Regulator Adjustment E4A-91-200-000 There is no regulator adjustment (e.g. by potentiometer) required to set a stable voltage adjustment. 4. Paralleling for twin engine system E4A-91-200-000 A current-regulator is implemented, which enables the adjustment of the load balancing in twin- engine applications with high accuracy and fault-tolerance against single faults at the load-balancing adjustment structure.
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  • Page 93: Troubleshooting Information

    E4 Series Electrical Power Maintenance Manual Troubleshooting Information 1. General The table below lists the possible defects of the alternator system. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
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  • Page 95: Alternator E4A-91-000-000

    E4 Series Electrical Power Maintenance Manual 24-30-00 Alternator E4A-91-000-000 1. General This section contains the procedures how to remove/install and examine Alternator E4A-91-000-000. Fig. 24 - 3 Alternator E4A-91-000-000 2. Maintenance Procedures A. Remove the Alternator Detail Steps/Work Items Key Items/References Disconnect the battery.

  • Page 96: Install The Alternator

    E4 Series Electrical Power Maintenance Manual B. Install the Alternator Detail Steps/Work Items Key Items/References Install the alternator on the alternator bracket. Refer to Fig. 24 - 5. Torque 20 Nm Install the alternator bracket on the engine Connect the excitation line marked with Make sure that the connector is locked.
  • Page 97 E4 Series Electrical Power Maintenance Manual Bolts Alternator Bracket Bolts Alternator Fig. 24 - 5 Detailed view with removed alternator Page 203 24-30-00 E4.08.04 Rev. 29 01-Jul-2020...

  • Page 98: Acceptance Criteria For Alternator Bench Tests

    E4 Series Electrical Power Maintenance Manual 3. Acceptance criteria for alternator bench tests For alternator tests on an alternator test bench, the following acceptance criteria apply: Alternator [RPM] Voltage [V] Load Current [A] Hold time of load Currents [s] 9700 (+/-50) 28 (+/- 0.5)

  • Page 99: Visually Examine The Alternator Housing And Pulley

    E4 Series Electrical Power Maintenance Manual Fig. 24 - 6 Alternator backside ASSY brush holder E4A-91-300-000 Fig. 24 - 7 Alternator with removed plastic cover C. Visually examine the Alternator Housing and Pulley Detail Steps/Work Items Key Items/References Examine the alternator housing for:...

  • Page 100: Examine The Contact Ring And Brushes

    E4 Series Electrical Power Maintenance Manual Detail Steps/Work Items Key Items/References Accelerate the pulley by hand also The rotor shall turn without delay. – clockwise. Pulley Fig. 24 - 8 Pulley D. Examine the Contact Ring and Brushes Detail Steps/Work Items Key Items/References Examine the contact ring.

  • Page 101: Disassemble The Brush Holder Assembly E4A-91-300-000

    E4 Series Electrical Power Maintenance Manual Contact ring Fig. 24 - 9 Contact ring E. Disassemble the Brush Holder assembly E4A-91-300-000 Detail Steps/Work Items Key Items/References Push the upper carbon brush with a small screwdriver and hold them in the end Refer to Fig.
  • Page 102 E4 Series Electrical Power Maintenance Manual Brush Holder Cover Rib Upper Brush Lower Brush Cover Fig. 24 - 10 Brush holder Push Direction Thin Metal Sheet Cover Rib Fig. 24 - 11 Brush holder Page 208 24-30-00 E4.08.04 01-Jul-2020 Rev.29...
  • Page 103 E4 Series Electrical Power Maintenance Manual Push Direction Cover Fig. 24 - 12 Brush holder The picture below shows the released carbon brushes and the demounted cover. Carbon Brush Cover Fig. 24 - 13 Brush holder with cover Page 209 24-30-00 E4.08.04...

  • Page 104: Measure The Length Of Carbon Brushes

    E4 Series Electrical Power Maintenance Manual F. Measure the Length of Carbon Brushes Carbon brush Brush Holder Fig. 24 - 14 Brush length Detail Steps/Work Items Key Items/References Refer to Fig. 24 - 14. Measure the length of both carbon minimum length 7 mm brushes with a caliber gauge.
  • Page 105 E4 Series Electrical Power Maintenance Manual Thin Metal Sheet Push Direction Upper Brush Position Lower Brush Position Cover Fig. 24 - 15 Brush holder End Position Cover Cover Rib Fig. 24 - 16 ASSY Brush holder E4A-91-300-000 with brushes pushed back in mounting position...

  • Page 106: Install The Brush Holder

    E4 Series Electrical Power Maintenance Manual Backside of Cover Backside of ASSY Brush Holder Fig. 24 - 17 Brush holder and cover H. Install the Brush Holder Detail Steps/Work Items Key Items/References Assemble the brush holder with screws Refer to Fig. 24 - 20.
  • Page 107 E4 Series Electrical Power Maintenance Manual Fig. 24 - 18 Brush holder assembly mounted onto the alternator (brushes are not released) - incorrect Push Direction Fig. 24 - 19 Cover at end position (brushes are released) - correct Page 213 24-30-00 E4.08.04...
  • Page 108 E4 Series Electrical Power Maintenance Manual Fig. 24 - 20 Alternator with brush holder assembly fixed Fig. 24 - 21 Cover at end position Page 214 24-30-00 E4.08.04 01-Jul-2020 Rev.29...

  • Page 109: Functional Check

    E4 Series Electrical Power Maintenance Manual Functional Check After assembly, do the functional test of the alternator. Test Case 1: a. Measure the resistance of the excitation winding. Detail Steps/Work Items Key Items/References Connect one terminal of the multimeter to Refer to Fig.
  • Page 110 E4 Series Electrical Power Maintenance Manual Test Case 2: Detail Steps/Work Items Key Items/References Use a calibrated digital multimeter with Adjustment digital multimeter: proper function. - Diode Check Measuring points: - B+ - Alternator housing. Disconnect all terminals. Connect + terminal of the digital multimeter to the B+ terminal of the alternator.
  • Page 111 E4 Series Electrical Power Maintenance Manual Fig. 24 - 23 Page 217 24-30-00 E4.08.04 Rev. 29 01-Jul-2020...
  • Page 112 E4 Series Electrical Power Maintenance Manual Test Case 3: Detail Steps/Work Items Key Items/References Use a calibrated digital multimeter with Adjustment digital multimeter: proper function. - Diode Check Measuring points: - B+ - Alternator housing. Disconnect all terminals. Connect - terminal of the digital multimeter to the B+ terminal of the alternator.
  • Page 113 E4 Series Electrical Power Maintenance Manual Fig. 24 - 24 Page 219 24-30-00 E4.08.04 Rev. 29 01-Jul-2020...
  • Page 114 E4 Series Electrical Power Maintenance Manual Mark the inspected Alternator E4A-91-000-000 For each check of the ASSY brush holder E4A-91-300-000, engrave an X (cross) on the bottom of the alternator. Fig. 24 - 25 shows the dimension of the marking.
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  • Page 116: Alternator E4A-91-400-000

    E4 Series Electrical Power Maintenance Manual 24-31-00 Alternator E4A-91-400-000 1. General This section contains the procedures how to remove/install and examine Alternator E4A-91-400-000. Fig. 24 - 27 Alternator E4A-91-400-000 2. Maintenance Procedures A. Remove the Alternator Detail Steps/Work Items Key Items/References Disconnect the battery.

  • Page 117: Install The Alternator

    E4 Series Electrical Power Maintenance Manual B. Install the Alternator Detail Steps/Work Items Key Items/References Carefully install the alternator on the Refer to Fig. 24 - 28. alternator bracket. Torque 20 Nm Install the alternator bracket on the engine. Connect the excitation line marked with The fastening torque for the lock nut is “GEN”...
  • Page 118 E4 Series Electrical Power Maintenance Manual Bolts Alternator Bracket Bolts Alternator Fig. 24 - 28 Detailed view with removed alternator Page 224 24-31-00 E4.08.04 01-Jul-2020 Rev. 29...
  • Page 119 E4 Series Electrical Power Maintenance Manual Lock nut Dust Seal Black plastic cover Fig. 24 - 29 Fig. 24 - 30 White dust seal Fig. 24 - 31 Fig. 24 - 32 Alternator backside with covers Page 225 24-31-00 E4.08.04 Rev.0...

  • Page 120: Acceptance Criteria For Alternator Bench Tests

    E4 Series Electrical Power Maintenance Manual 3. Acceptance criteria for alternator bench tests For alternator tests on an alternator test bench, the following acceptance criteria apply: Alternator [RPM] Voltage [V] Load Current [A] Hold time of load Currents [s] 9700 (+/-50) 28 (+/- 0,5) >0<5...
  • Page 121 E4 Series Electrical Power Maintenance Manual Plastic cover Fig. 24 - 33 Alternator back side G & G2 – Fig. 24 - 34 Alternator back side G & G2 – torx screws hexagon nuts Brush Holder Assembly E4A-91-410-000 Fig. 24 - 35...
  • Page 122 E4 Series Electrical Power Maintenance Manual Remove Direction of Brush Holder Assembly Fig. 24 - 36 Alternator with removed plastic cover Page 228 24-31-00 E4.08.04 01-Jul-2020 Rev. 29...

  • Page 123: Visually Examine The Alternator Housing And Pulley

    E4 Series Electrical Power Maintenance Manual C. Visually examine the Alternator Housing and Pulley Detail Steps/Work Items Key Items/References Examine the alternator housing for: If you find damages on the housing which can cause incorrect operation, cooling, or Mechanical damages (cracks, –...

  • Page 124: Examine The Contact Ring And Brushes

    E4 Series Electrical Power Maintenance Manual D. Examine the Contact Ring and Brushes Detail Steps/Work Items Key Items/References Examine the contact ring. Refer to Fig. 24 - 38. Measure the grooving on the contact ring. Grooving (<0.5 mm) caused by abrasion of carbon brushes are permitted.

  • Page 125: Examine The Assy Brush Holder E4A-91-410-000

    E4 Series Electrical Power Maintenance Manual E. Examine the ASSY Brush Holder E4A-91-410-000 Detail Steps/Work Items Key Items/References Do not use a steel brush for cleaning to prevent any damage. Clean the brush holder and the brush rip Fig. 24 - 39 shows the released carbon with a soft brush.

  • Page 126: Install The Brush Holder

    E4 Series Electrical Power Maintenance Manual Carbon brush Brush Holder Fig. 24 - 40 Brush length G. Install the Brush Holder Detail Steps/Work Items Key Items/References Carefully put the Brush Holder Assembly Make sure that the guide rail of E4A-91-410-000 onto the alternator.
  • Page 127 E4 Series Electrical Power Maintenance Manual Install the black plastic cover of W, L, and B+ terminals. Guide rail Guide rail Fig. 24 - 41 Alternator with Brush Holder Page 233 24-31-00 E4.08.04 Rev.0 01-Jul-2020...
  • Page 128 E4 Series Electrical Power Maintenance Manual Push direction of Brush Holder Assembly Guide rail Push direction of carbon brush Fig. 24 - 42 Alternator with Brush Holder ASSY Fig. 24 - 43 Correct installation of Brush Holder ASSY Page 234 24-31-00 E4.08.04...
  • Page 129 E4 Series Electrical Power Maintenance Manual Brush Holder ASSY E4A-91-410-000 Fig. 24 - 44 Alternator with removed plastic cover Fig. 24 - 45 Alternator backside Page 235 24-31-00 E4.08.04 Rev.0 01-Jul-2020...

  • Page 130: Functional Check

    E4 Series Electrical Power Maintenance Manual H. Functional Check After assembly, do the functional test of the alternator. Test Case 1: a. Measure the resistance of the excitation winding. Detail Steps/Work Items Key Items/References Connect one terminal of the multimeter to Refer to Fig.
  • Page 131 E4 Series Electrical Power Maintenance Manual Excitation Winding Fig. 24 - 46 Alternator E4A-91-400-000 Page 237 24-31-00 E4.08.04 Rev.0 01-Jul-2020...
  • Page 132 E4 Series Electrical Power Maintenance Manual Test Case 2: Detail Steps/Work Items Key Items/References Use a calibrated digital multimeter with Adjustment digital multimeter: proper function. - Diode check Measuring points: - B+ - Alternator housing. Disconnect all terminals. Connect + terminal of the digital...
  • Page 133 E4 Series Electrical Power Maintenance Manual Test Case 3: Detail Steps/Work Items Key Items/References Use a calibrated digital multimeter with Adjustment digital multimeter: proper function. - Diode check Measuring points: - B+ - Alternator housing. Disconnect all terminals. Connect - terminal of the digital...
  • Page 134 E4 Series Electrical Power Maintenance Manual Mark the inspected Alternator E4A-91-400-000 For each check of the Brush Holder Assembly E4A-91-410-000, engrave an X (cross) on the bottom of the alternator. Fig. 24 - 49 shows dimension of the marking. ~10 mm ~10 mm Fig.

  • Page 135: Alternator-Regulator E4A-91-100-000

    E4 Series Electrical Power Maintenance Manual 24-60-00 Alternator-Regulator E4A-91-100-000 1. General This section contains the procedures how to adjust Alternator-Regulator. Fig. 24 - 51 Page 241 24-60-00 E4.08.04 Rev. 29 01-Jul-2020...

  • Page 136: Adjust The Voltage Regulation E4A-91-100-000

    E4 Series Electrical Power Maintenance Manual 2. Adjust the voltage regulation E4A-91-100-000 Detail Steps/Work Items Key Items/References Make sure that the engines are at full operation coolant temperatures. Set one engine at the cruising speed. Adjust the voltage on the operating system Replace the screw set.
  • Page 137 E4 Series Standard Maintenance Manual Procedures CHAPTER 70 STANDARD PROCEDURES Page 1 70 - Title E4.08.04 Rev.29 01-Jul-2020...
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  • Page 139 E4 Series Standard Maintenance Manual Procedures Table of Contents Chapter 70 70-00-00 Standard Procedures ..................1 General ..........................1 Safetying methods ......................1 Standard Torque Values ....................1 Troubleshooting Information ................... 101 General ........................... 101 70-10-00 Safety wiring ....................201 General ...........................
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  • Page 141: Standard Procedures

    E4 Series Standard Maintenance Manual Procedures 70-00-00 Standard Procedures 1. General This chapter contains standard procedures and data about the fasteners used for the E4 engine. A. Safetying methods (1) Safety wiring Safety wiring is a method of locking together two or more units so that any tendency of one to loosen is counteracted by the tightening of the wire.
  • Page 142 E4 Series Standard Maintenance Manual Procedures Inch Thread Torque (Nm) Torque (lbf.ft) 5/16 7/16 ½ 9/16 Table 1 Standard Torque Values for Bolts and Nuts Taper Thread Torque (Nm) Torque (lbf.ft) 1/16 - 27 NPT 1/8 - 27 NPT 1/4 - 18 NPT 3/8 - 18 NPT 12.3...

  • Page 143: Troubleshooting Information

    E4 Series Standard Maintenance Manual Procedures Troubleshooting Information 1. General The table below lists the possible defects of the engine fasteners. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
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  • Page 145: Safety Wiring

    E4 Series Standard Maintenance Manual Procedures 70-10-00 Safety wiring 1. General This section contains the standard procedure for the safety wiring. 2. Special Tools Number Description Dimensions Safety wire pliers Wire cutters (dykes) Needle nose pliers Jigs 3. Basic rules...

  • Page 146: Safety Wiring Methods

    E4 Series Standard Maintenance Manual Procedures 4. Safety wiring methods Fig. 70 - 1 Safety wiring methods Nuts, bolts, and screws are safety wired with the single wire or double twist method. The safety wiring method is related to the installation.

  • Page 147: Single Wire Locking

    E4 Series Standard Maintenance Manual Procedures A. Single wire locking Detail Steps/Work Items Key Items/References Do not use a lock-wire longer than 60 cm for single wire locking three or more parts as a group! Put the wire through each part, one after other, in the direction that will prevent the part Refer to Fig.

  • Page 148: Double Wire Locking

    E4 Series Standard Maintenance Manual Procedures B. Double wire locking There are two methods for double safety wiring: By hand With pliers. (a) Double wire locking by hand Detail Steps/Work Items Key Items/References Pull the wire through the first bolt.
  • Page 149 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 3 Fig. 70 - 4 Double wire locking by hand Page 205 70 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 150 E4 Series Standard Maintenance Manual Procedures (b) Double wire locking with pliers Detail Steps/Work Items Key Items/References Torque the bolts and carefully align the bolt holes. Insert the wire through the hole in the first Select sufficient size of wire.
  • Page 151 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 5 Double-twist lock-wire installation Fig. 70 - 6 Lock-wire Page 207 70 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 152 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 7 Safety wire pliers Page 208 70 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...

  • Page 153: Examples Of Safety Wiring

    E4 Series Standard Maintenance Manual Procedures C. Examples of Safety Wiring Fig. 70 - 8 Safety wiring examples Page 209 70 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 154 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 9 Safety wiring examples Page 210 70 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...
  • Page 155 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 10 Safety wiring examples Page 211 70 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 156 E4 Series Standard Maintenance Manual Procedures Examples for wire locking on tensioning clamps: Fig. 70 - 11 Double-twist method with holes in clamp screw and housing Fig. 70 - 12 Single wire method (no locking holes are available) Page 212 70 - Maintenance Procedures E4.08.04...

  • Page 157: Torque Procedure

    E4 Series Standard Maintenance Manual Procedures 70-20-00 Torque procedure Detail Steps/Work Items Key Items/References Do not apply more than the maximum permitted torque value! Overstressing the threaded areas can cause failure of the bolt or nut. If the torque is not specified, use the standard torques.
  • Page 158 E4 Series Standard Maintenance Manual Procedures Detail Steps/Work Items Key Items/References Do not exceed the maximum recommended torque! If you apply torque to the heads or cap screws, apply the recommended torque plus friction drag torque. If you use special adapters, adjust the final...
  • Page 159 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 13 Torque wrench with different adapters Page 215 70 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 160 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 14 Torque wrench with different adapters Page 216 70 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...

  • Page 161: Installation Of Helical Threaded Inserts

    E4 Series Standard Maintenance Manual Procedures 70-30-00 Installation of helical threaded inserts 1. General This section contains instructions how to install helical threaded inserts (e.g. HELICOIL LN 9039, LN 9499, and NASM 21209). The helical threaded inserts are used to repair damaged or worn threads.
  • Page 162 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 17 Installation drawing for threaded inserts = Nominal thread diameter = Thread pitch = Holding thread outside diameter = Core hole thread diameter = Minimum depth of core hole = Thread depth = Maximum screw-in depth with tang not broken off = Distance of thread insert from the separating surface.
  • Page 163 E4 Series Standard Maintenance Manual Procedures Nominal Pitch Fully cut thread Screw-in length for Core Drill Outside thread useable thread depth screw if driven tang is hole Ø Ø Ø nominal length of not removed insert min. min. max. max.

  • Page 164: Special Tools

    E4 Series Standard Maintenance Manual Procedures Nominal Pitch Fully cut thread Screw-in length for Core Drill Outside thread useable thread depth screw if driven tang is hole Ø Ø Ø nominal length of not removed insert min. 1.5 d 6.55 ¼”-28...
  • Page 165 E4 Series Standard Maintenance Manual Procedures Detail Steps/Work Items Key Items/References Turn the thread clockwise onto the insertion mandrel until the spindle yoke engages the Refer to Fig. 70 - 18. tang. Attach the large–sized components with clamps in an applicable holding device (e.g.
  • Page 166 E4 Series Standard Maintenance Manual Procedures Fig. 70 - 19 Insertion depth (for inserts in through holes and pocket holes) Fig. 70 - 20 Tang removal Page 222 70 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...

  • Page 167: Examine The Threaded Insert For Correct Installation

    E4 Series Standard Maintenance Manual Procedures 4. Examine the threaded insert for correct installation Detail Steps/Work Items Key Items/References Do a check of the insertion properties. For threaded inserts per LN 9039 (non– locking): It must be possible to install the threaded Use the fastener or an internal limit insert without a tool.

  • Page 168: Safety The Rotating Threaded Inserts

    E4 Series Standard Maintenance Manual Procedures 6. Safety the rotating threaded inserts Detail Steps/Work Items Key Items/References Do the procedure only if specified in Paragraph 4. Refer to Paragraph 5 for the removal Remove the threaded inserts. instructions. Clean the new threaded insert and the thread with organic solvents.
  • Page 169 E4 Series Power Plant Maintenance Manual CHAPTER 71 POWER PLANT Page 1 71 - Title E4.08.04 Rev. 29 01-Jul-2020...
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  • Page 171 E4 Series Power Plant Maintenance Manual Table of Contents Chapter 71 71-00-00 Power Plant ..................... 1 General ..........................1 Description ........................1 Electrical Harness ......................1 Engine Harness Routing Overview ................... 5 Engine Harness Routing General Instructions ..............11 Troubleshooting Information ................... 101 General ...........................
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  • Page 173: Power Plant

    E4 Series Power Plant Maintenance Manual 71-00-00 Power Plant 1. General This chapter contains information about the power plant components. 2. Description The engine power plant consists of the engine harness. A. Electrical Harness The engine electrical cables, plugs, sockets, and connectors connect the power plant system and are bent together to make the power plant installation and removal easier.
  • Page 174 E4 Series Power Plant Maintenance Manual INJ 4 GP 4 CAS 1 INJ 3 GP 3 INJ 2 GP 2 GBTS INJ 1 CAS 2 GP 1 CRS 1 CTS_GPC BPS2 IAT 2 IAT 1 BPS1 CRS 2 Connection Cockpit Connection EECU Fig.
  • Page 175 E4 Series Power Plant Maintenance Manual Wiring Harness E4A-90-000-000 Plug Connectors Description Wiring Description long version German description Abbr. diagram B1/1 Fuel Pressure Sensor Kraftstoffdrucksensor B4/6 Rail Pressure Sensor Raildrucksensor Oil Combinant Sensor Temperature Kombinierter Ölsensor Temperatur B5/1 Boost Pressure Sensor 1...
  • Page 176 E4 Series Power Plant Maintenance Manual Wiring Description long version German description Abbr. diagram Fuel Metering Unit Zumesseinheit X) Do a sensor check every 300 h, only if the Injector cover is removed. Page 4 71 – System Description E4.08.04 01-Jul-2020 Rev.

  • Page 177: Engine Harness Routing Overview

    E4 Series Power Plant Maintenance Manual B. Engine Harness Routing Overview The primary attachment point of the engine harness is on the cylinder head. The wiring harness is attached with a rubberized metal clamp on the drive belt side and cylinder head. The wiring harness is installed on the engine with additional rubberized metal clamps and cable ties.
  • Page 178 E4 Series Power Plant Maintenance Manual Fig. 71 - 2 Engine Harness Page 6 71 – System Description E4.08.04 01-Jul-2020 Rev. 29...
  • Page 179 E4 Series Power Plant Maintenance Manual Wiring Harness E4A-95-000-000 and E4B-95-000-000 Plug Connectors Description Wiring Description long version German description diagram Fuel Pressure Sensor Kraftstoffdrucksensor Rail Pressure Sensor Raildrucksensor Oil Combinant Sensor Kombinierter Ölsensor Temperature/ Oil Level Temperatur/ Ölstand BPS1...
  • Page 180 E4 Series Power Plant Maintenance Manual Wiring Description long version German description diagram INJ 4 Fuel Injector 4 Kraftstoff Injektor 4 Fuel Metering Unit Zumesseinheit X) Do a sensor check every 300 h, only if the Injector cover is removed.
  • Page 181 E4 Series Power Plant Maintenance Manual Fig. 71 - 3 Block diagram E4A-95-000-000 Page 9 71 - System Description E4.08.04 Rev. 29 01-Jul-2020...
  • Page 182 E4 Series Power Plant Maintenance Manual Fig. 71 - 4 Block Diagram E4B-95-000-000 Page 10 71 – System Description E4.08.04 01-Jul-2020 Rev. 29...

  • Page 183: Engine Harness Routing General Instructions

    E4 Series Power Plant Maintenance Manual C. Engine Harness Routing General Instructions Detail Steps/Work Items Key Items/References Before you install the harness on the engine block, read Paragraph A and B. The herein described installation of the engine harness only describes the installation without any customer/aircraft manufacturer installation (e.g.
  • Page 184 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Add protection to the wires and cables attached This will prevent wires and cables to assemblies where movement occurs deterioration. (rotating parts), if necessary. The wiring must: Make the maintenance easier...

  • Page 185: Troubleshooting Information

    E4 Series Power Plant Maintenance Manual Troubleshooting Information 1. General The table below lists the possible defects of the power plant. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
  • Page 186 E4 Series Power Plant Maintenance Manual Intentionally left blank Page 102 71 – Troubleshooting E4.08.04 01-Jul-2020 Rev. 29...

  • Page 187: Engine Ground Run

    Only authorized personnel is permitted to do the engine ground run. Incorrect engine maintenance can cause failure to the engine during operation. For warranty reason, only approved parts from the Austro Engine GmbH must be used. Page 201 71 -Maintenance Procedures E4.08.04...

  • Page 188: Engine Ground Run Instructions

    E4 Series Power Plant Maintenance Manual 2. Engine Ground Run Instructions Detail Steps/Work Items Key Items/References Start the engine. Refer to the applicable Aircraft Flight Run the engine until it is at the operating Manual (AFM). temperature. Refer to the applicable Aircraft Flight Do the EECU self-test.
  • Page 189 E4 Series Power Plant Maintenance Manual For any maintenance procedure on the camshaft sensor, complete the following procedure before the Engine Ground Test Run: Switch ECU-Voter to ECU_A Crank the engine Check engine Engine start‘s mechanical / electrical System Turn off engine...

  • Page 190: Electrical Harness

    E4 Series Power Plant Maintenance Manual 71-50-00 Electrical Harness 1. General This section contains information on maintenance procedures for the engine harness that connects the power plant system. 2. Maintenance Procedures Special Tools Number Description Dimensions Crimper Gauge Insertion/Extraction tool A.
  • Page 191 E4 Series Power Plant Maintenance Manual Burning marks Chafing marks Fig. 71 - 5 Roundit inspection Page 205 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 192 E4 Series Power Plant Maintenance Manual Chafing Marks Damaged Shielding / Single Wires Fig. 71 - 6 Cable inspection Page 206 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 193: Examine The Sensors / Actuators

    E4 Series Power Plant Maintenance Manual B. Examine the Sensors / Actuators Detail Steps/Work Items Key Items/References Use a repair kit if permitted, Examine the sensors for loosened, chafed, or differently, replace the engine harness. damaged connectors. Refer to Paragraph F.

  • Page 194: Install The Engine Wiring Harness For E4A-90-000-000

    E4 Series Power Plant Maintenance Manual C. Install the engine wiring harness for E4A-90-000-000 Material and safety elements for the engine wiring harness installation Part number Description Torque Tool specification (Nm) E4A-90-000-000 Engine wiring harness E4A-90-000-801 Hex-head screw with tooth lock M6x10...
  • Page 195 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Torque 10 Nm. Tighten the screw [06] on the oil filter housing and attach the clamp [09]. Refer to Fig. 71 - 7. Torque 12 Nm. Tighten the screw on the cylinder head cover and attach the clamp [12].
  • Page 196 E4 Series Power Plant Maintenance Manual Clamp [09] Screw [06] Fig. 71 - 7 Harness attachment on oil filter housing Clamp [12] Fig. 71 - 8 Harness attachment on cylinder head Page 210 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 197 E4 Series Power Plant Maintenance Manual Clamp [03] Fig. 71 - 9 Glow plug wire attachment on the thermostat Clamp [03] Fig. 71 - 10 Wire attachment on the thermostat Page 211 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 198 E4 Series Power Plant Maintenance Manual Fig. 71 - 11 Cable strap with edge clip on the air intake manifold Screw [07] Clamp [11] Fig. 71 - 12 Harness attachment on the engine block Page 212 71 - Maintenance Procedures E4.08.04...
  • Page 199 E4 Series Power Plant Maintenance Manual Fig. 71 - 13 Harness routing high pressure pump Fig. 71 - 14 Harness branch routed below the injector cover Page 213 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 200 E4 Series Power Plant Maintenance Manual Fig. 71 - 15 Harness branch routed below the injector cover Clamp [11] Fig. 71 - 16 Harness attachment on the belt holder Page 214 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 201 E4 Series Power Plant Maintenance Manual Fig. 71 - 17 Clamp [05] Fig. 71 - 18 Page 215 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 202 E4 Series Power Plant Maintenance Manual Clamp [04] Fig. 71 - 19 Harness installation at the oil level sensor Page 216 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 203 E4 Series Power Plant Maintenance Manual Clamp [04] Screw [02] Fig. 71 - 20 Harness attachment on the gearbox Clamp [05] Fig. 71 - 21 Installation on oil filter housing Page 217 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 204 E4 Series Power Plant Maintenance Manual Fig. 71 - 22 Alternator Fig. 71 - 23 Page 218 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 205 E4 Series Power Plant Maintenance Manual Fig. 71 - 24 Glow Plug Control (GPC) Fig. 71 - 25 Crankshaft sensor (CRS 1) Page 219 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 206 E4 Series Power Plant Maintenance Manual Fig. 71 - 26 Crankshaft sensor (CRS 2) Page 220 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 207 E4 Series Power Plant Maintenance Manual Fig. 71 - 27 Mechanical protection (Mesh tube) Fig. 71 - 28 Mechanical protection (Mesh tube) Page 221 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 208 E4 Series Power Plant Maintenance Manual Fig. 71 - 29 Mechanical protection (Mesh tube) Page 222 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 209 E4 Series Power Plant Maintenance Manual Fig. 71 - 30 Injector harness routing Page 223 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 210 E4 Series Power Plant Maintenance Manual clearance Fig. 71 - 31 CORRECT BPA wire installation Fig. 71 - 32 INCORRECT BPA wire installation Page 224 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 211 E4 Series Power Plant Maintenance Manual Fig. 71 - 33 Attachment point of the shielding cable Fig. 71 - 34 Attachment point in the aircraft Page 225 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 212 E4 Series Power Plant Maintenance Manual Fig. 71 - 35 Attachment point in the aircraft Fig. 71 - 36 Attachment points in the aircraft Page 226 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 213: Install The Engine Wiring Harness E4A-95-000-000 And E4B-95-000-000

    E4 Series Power Plant Maintenance Manual D. Install the engine wiring harness E4A-95-000-000 and E4B-95-000-000 Material and safety elements for the E4A/E4B engine wiring harness installation Torque in Part Number Description E4A(B)-95-000-000 Assy – Engine Harness DIN3016-W1-DM28-20 Clamp 28 DIN3016-W1-DM 22x15...
  • Page 214 To identify the part number of engine harness E4A(B)-95-000-000 and its production revision (e.g.: 010, AA.1), refer to Fig. 71 - 37 and Fig. 71 - 38 (red marked area, near EECU connectors). Fig. 71 - 37 Batch Number Austro Engine Part Number Revision Date of production Fig. 71 - 38...
  • Page 215 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Unless specified differently, the installation instructions are the same for all versions of E4 engine wire harness E4A-95-000-000 and E4B-95-000-000. Attach the harness with the main clamp on Refer to Fig. 71 - 39.
  • Page 216 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References For CAS2 installed on the belt drive side of the engine with engine harness revision AC.1 or lower, refer to Paragraph a). For CAS2 installed on the belt drive side of the engine with engine harness revision AD.1 or higher, refer to Paragraph b).
  • Page 217 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References use the screw of BPS1 (torque 5 Nm) to connect the combined pigtails of IAT1 & BPS1 and use the screw of BPS2 (torque 5 Nm) to connect the combined pigtails of BPS2 &...
  • Page 218 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Tighten the blade terminal [13] together with the mounting screw of the lifting eyelet. Torque 12 Nm. Refer to Fig. 71 - 60, if not already installed. Connect the double flat terminal of FMU to the blade terminal mounted to the lifting.
  • Page 219 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Use two edge clips [07]. Attach the branch of GBTS and W11/2 on the (42) GPC holder. Refer to Fig. 71 - 70. Torque 10 Nm. Connect the pigtails of GBTS and W11/2 (43) terminal to the GPC holder screw.
  • Page 220 E4 Series Power Plant Maintenance Manual Engine Head Fin Main Clamp (Position A ) Fig. 71 - 39 Main clamp installation Page 234 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 221 E4 Series Power Plant Maintenance Manual Lifting Eyelet Pigtail RPS Main clamp (Position A) [02] Fig. 71 - 40 Shared harness branches Page 235 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 222 E4 Series Power Plant Maintenance Manual Fig. 71 - 41 Harness installation Position A and Position B Cable tie [05] Fig. 71 - 42 BPA branch installation Page 236 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 223 E4 Series Power Plant Maintenance Manual Fig. 71 - 43 Harness installation near cylinder head Page 237 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 224 E4 Series Power Plant Maintenance Manual Fig. 71 - 44 Harness installation near cylinder head Page 238 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 225 E4 Series Power Plant Maintenance Manual CAS 1 Cable tie [05] Fig. 71 - 45 Injectors harness installation Cable tie [05] CAS1 CAS 2 Fig. 71 - 46 Injectors harness installation (E4A(B)-95-000-000 rev. AD.1 or higher, and CAS2 is installed under the injector cover)
  • Page 226 E4 Series Power Plant Maintenance Manual Rail Cable tie[05] Fig. 71 - 47 Harness branch installation on high pressure rail Pigtails BPS2 & IAT 2 Pigtails BPS1 & IAT1 Pigtails BPS2 & IAT 2 Pigtails BPS1 & IAT 2 Fig. 71 - 49 Pigtail connection for E4B- Fig.
  • Page 227 E4 Series Power Plant Maintenance Manual Cable tie [05] Fig. 71 - 50 Page 241 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 228 E4 Series Power Plant Maintenance Manual Glow Plug Branch Fig. 71 - 51 Glow plugs branch installation Glow Plug Branch Fig. 71 - 52 Glow plugs branch installation Page 242 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 229 E4 Series Power Plant Maintenance Manual Harness parallel Fig. 71 - 53 Gearbox side harness installation Page 243 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 230 E4 Series Power Plant Maintenance Manual EGR Cover Clamp [03] Fig. 71 - 54 Harness installation on the EGR cover Fig. 71 - 55 Harness installation in the area below the intake manifold Page 244 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.
  • Page 231 E4 Series Power Plant Maintenance Manual Cable tie [05] Fig. 71 - 56 Coolant temperature branch attachment Fig. 71 - 57 FTS and PCV pigtails connection Page 245 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 232 E4 Series Power Plant Maintenance Manual Position of mounting screw for ring terminal or blade terminal Lifting eyelet High Pressure Pump Gearbox Fig. 71 - 58 Page 246 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 233 E4 Series Power Plant Maintenance Manual Fig. 71 - 59 FMU and CTS pigtails connection Page 247 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 234 E4 Series Power Plant Maintenance Manual Blade Terminal [13] Mounting Screw Fig. 71 - 60 Page 248 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 235 E4 Series Power Plant Maintenance Manual Pigtail FMU Fig. 71 - 61 CTS Pigtail Fig. 71 - 62 Page 249 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 236 E4 Series Power Plant Maintenance Manual Netting Cable Tie Tape Fig. 71 - 63 FPS and FPS cable shielding Pigtail FPS Branch FPS Fig. 71 - 64 FPS pigtail connection Page 250 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 237 E4 Series Power Plant Maintenance Manual Edge clip [08] Fig. 71 - 65 CRS1 branch attachment EGR Cover Pigtail CRS1 CRS1 Fig. 71 - 66 CRS1 pigtail connection Page 251 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 238 E4 Series Power Plant Maintenance Manual GPC_CTS Clamp [03] Starter GBTS Oil filter housing Cable Tie [05] CRS2 Fig. 71 - 67 Harness routing on the engine block (Prop. Governor not installed) Page 252 71 - Maintenance Procedures E4.08.04 01-Jul-2020...
  • Page 239 E4 Series Power Plant Maintenance Manual Heat exchanger Pigtail OPS Clamp [03] Cable tie [05] Fig. 71 - 68 OPS pigtail connection Clamp [04] Pigtail GEN Pigtail MOK W11/1 Oil sump Screw [09] Fig. 71 - 69 GEN and MOK pigtails connection...
  • Page 240 E4 Series Power Plant Maintenance Manual GBTS Edge clips [07] Fig. 71 - 70 GBTS branch installation GBTS Pigtail GPC Holder W11/2 Fig. 71 - 71 GBTS pigtail connection Page 254 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 241 E4 Series Power Plant Maintenance Manual Branch CRS2 Edge clip [08] Fig. 71 - 72 Branch CRS2 installation Branch CRS2 Edge clip [07] GPC Holder Fig. 71 - 73 CRS2 branch installation Page 255 71 -Maintenance Procedures E4.08.04 Rev. 29...
  • Page 242 E4 Series Power Plant Maintenance Manual Branch CRS2 Pigtail CRS2 CRS2 Edge clip [06] Fig. 71 - 74 CRS2 pigtail connection Governor Fig. 71 - 75 Governor connection Page 256 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 243 E4 Series Power Plant Maintenance Manual Fig. 71 - 76 Engine harness Page 257 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 244 E4 Series Power Plant Maintenance Manual a) CAS2 installed on the belt drive side of the engine with engine harness revision AC.1 or lower If the CAS2 sensor is installed as shown in Fig. 71 - 77 and the engine harness is E4A(B)-95-000- 000 revision AC.1 or lower, do the instructions in this section.
  • Page 245 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Only the cable tie is permitted for connector adapter (of BPA filter) attachment. Do not tighten the BPA hose with too much force! Attach the BPA branch on the connector Use a cable tie [05] housing.
  • Page 246 E4 Series Power Plant Maintenance Manual Edge clip No.[06] 2x Cable tie No.[05] Fig. 71 - 79 CAS 2 and BPA branch installation Page 260 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 247 E4 Series Power Plant Maintenance Manual b) CAS2 installed on the belt drive side of the engine with engine harness revision AD.1 or higher If the CAS2 sensor is installed as shown in Fig. 71 - 80 and the engine harness is E4A(B)-95-000- 000 revision AD.1 or higher, do the instructions in this paragraph.
  • Page 248 E4 Series Power Plant Maintenance Manual Refer to Fig. 71 - 81 for an overview of the wiring harness installation described in this paragraph min 25 mm distance Pigtail BPA CAS 2 Branch Pigtail CAS 2 BPA Branch Fig. 71 - 81...
  • Page 249 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Only the cable tie is permitted for connector adapter (of BPA filter) attachment. Do not tighten the BPA hose with too much force! Attach the BPA filter. Use a cable tie No.[05] Blade Terminal [11] and washer for BPA Fig.
  • Page 250 E4 Series Power Plant Maintenance Manual Pigtail BPA Pigtail CAS2 Fig. 71 - 83 Fig. 71 - 84 Page 264 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 251 E4 Series Power Plant Maintenance Manual Cable Tie Fig. 71 - 85 Page 265 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 252 E4 Series Power Plant Maintenance Manual Edge clip No.[06] Cable tie No.[05] Fig. 71 - 86 CAS2 and BPA branch installation Page 266 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 253 E4 Series Power Plant Maintenance Manual c) CAS2 installed under the injector cover with engine harness revision AD.1 and higher If the CAS2 sensor is installed as shown in Fig. 71 - 87 and the engine harness is E4A(B)-95-000- 000 revision AD.1 and higher, do the instructions in this section.
  • Page 254 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Connect the CAS2 branch to sensor. Refer to Fig. 71 - 87 and Fig. 71 - 88. Connect the pigtail of CAS2 to the blade terminal installed with CAS1.
  • Page 255 E4 Series Power Plant Maintenance Manual CAS 1 CAS 2 Fig. 71 - 88 CAS2 installed under the injector cover CAS 1 Screw CAS1 with installed blade terminal Pigtail CAS 2 Pigtail CAS 1 Fig. 71 - 89 Page 269 71 -Maintenance Procedures E4.08.04...
  • Page 256 E4 Series Power Plant Maintenance Manual BPA blade terminal [11] Fig. 71 - 90 BPA blade terminal installation Pigtail BPA Fig. 71 - 91 Page 270 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 257 E4 Series Power Plant Maintenance Manual Edge clip No.[06] Cable tie No.[05] Fig. 71 - 92 CAS2 and BPA branch installation Page 271 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 258 E4 Series Power Plant Maintenance Manual E. Remove the engine wiring harness Detail Steps/Work Items Key Items/References Disconnect the power source. Refer to Section 85-10-00 Paragraph Remove the Injector Cover. 3.A. Remove all clamps. Remove the cable tie from the edge clip and (10) the starter motor.
  • Page 259 E4 Series Power Plant Maintenance Manual Locked Connectors Unlocked Connectors Fig. 71 - 93 Page 273 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 260 E4 Series Power Plant Maintenance Manual F. Repair the engine wiring harness E4A(B)-95-000-000 The following harness repair procedures for connectors replacement can be done only once for each connector. If a connector was damaged, without any damage to the cable, it is possible to replace only the connector housing.
  • Page 261 E4 Series Power Plant Maintenance Manual Repair a sensor cable branch This section contains general instructions to repair a defective connector / cable branch with a repair kit. The following description is a standard. The figures are only an example of the basic procedure.
  • Page 262 E4 Series Power Plant Maintenance Manual Part number Description Cutter knife Hot Air Gun AD-1377 by TE Connectivity Crimp tool for Inline crimp Ohmmeter Recommended Crimp tool for ring terminal 58433-3 by TE Connectivity (TE Connectivity) Recommended DIE Set for crimp tool (TE...
  • Page 263 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References The direction of the pigtail must be opposite the connector housing (single Apply heat on the solder sleeve. wires). Refer to Fig. 71 - 98. The length of the repair must not be Cut the repair kit to the necessary length.
  • Page 264 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Apply a self-vulcanizing tape on the area (18) where the engine harness roundit and the Refer to Fig. 71 - 105. repair kit roundit meet. To prevent chafing, you can attach cable ties PLT1M-M30 and PLT4S-M30 on the Roundit and the repaired cable branch.
  • Page 265 E4 Series Power Plant Maintenance Manual Cut Off Position Solder sleeve Pigtail Fig. 71 - 94 Cable branch cut off position Page 279 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 266 E4 Series Power Plant Maintenance Manual Pigtails Shared ring terminal Shared ring terminal Fig. 71 - 95 Shared ring terminal Page 280 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 267 E4 Series Power Plant Maintenance Manual 50 mm (+5) White Isolation Shield Braid Fig. 71 - 96 White isolation cut Shielding Braid folded back Fig. 71 - 97 Shielding braid folded back Page 281 71 -Maintenance Procedures E4.08.04 Rev. 29...
  • Page 268 E4 Series Power Plant Maintenance Manual Solder Sleeve Pigtail direction Fig. 71 - 98 Solder sleeve installation 5mm (+/-1) Fig. 71 - 99 Wire isolation cut Page 282 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 269 E4 Series Power Plant Maintenance Manual Isolation sleeve Splice crimp Fig. 71 - 100 In-line crimp Isolation sleeve Fig. 71 - 101 Isolation sleeve installation Page 283 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 270 E4 Series Power Plant Maintenance Manual Splice crimp Crimp tool Fig. 71 - 102 Wire crimping Page 284 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 271 E4 Series Power Plant Maintenance Manual E4A-95-R15-000 Connector Connector CAS1 ECUA CAS1 ECUA CAS1 ECUA CAS2 ECUB CAS2 ECUB CAS2 ECUB E4A-95-R13-000 Connector Connector IAT1 ECUA IAT1 ECUA IAT2 ECUB IAT2 ECUB E4A-95-R14-000 Connector Connector ECUA ECUA ECUA FPS (for Harness revision ECUA AB.1 and higher)
  • Page 272 E4 Series Power Plant Maintenance Manual BPS1 ECUA BPS1 ECUA BPS1 ECUA BPS2 ECUB BPS2 ECUB BPS2 ECUB E4A-95-R19-000 Connector Connector CRS1 ECUA CRS1 ECUA CRS2 ECUB CRS2 ECUB E4A-95-R20-000 Connector Connector ECUPWR ECUPWR E4A-95-R21-000 Connector Connector INJ1 ECUPWR INJ1...
  • Page 273 E4 Series Power Plant Maintenance Manual Isolation sleeve with covered splice crimp Hot air gun Fig. 71 - 103 Splice crimps sealing Roundit repair kit Roundit engine harness Cable tie Pigtail Fig. 71 - 104 Roundit application Page 287 71 -Maintenance Procedures E4.08.04...
  • Page 274 E4 Series Power Plant Maintenance Manual Tape Fig. 71 - 105 Tape application E4A-95-100-000 Fig. 71 - 106 Shielding application Page 288 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 275 E4 Series Power Plant Maintenance Manual Netting Cable tie Tape Fig. 71 - 107 Netting application Page 289 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 276 E4 Series Power Plant Maintenance Manual Blue isolation Shared ring terminal Fig. 71 - 108 Shared ring terminal isolation Page 290 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 277 E4 Series Power Plant Maintenance Manual G. Replace the sensors connectors for E4A-90-000-000 a) Replace the connector to “Intake Air Temperature” sensors Pos. Partnumber Description Qty. E4A-90-R16-000 Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco) D-436-36 crimp...
  • Page 278 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Solder Sleeve Remove approx. 10 mm (± 2 mm) of the insulation with shielding of the remaining wire. Put the solder sleeve over the cable of the remaining engine harness.
  • Page 279 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Move the solder sleeve (see Step (3)) over the wire of the remaining harness and the shielding (see Step (5). White/black wire Solder Sleeve The red marking of the solder sleeve must be over the shielding.
  • Page 280 E4 Series Power Plant Maintenance Manual b) Replace the connector to Fuel Pressure Sensor (FPS) Pos. Partnumber Description Qty. E4A-90-R18-000 Assy Repair Kit Cable E4A-95-100-000 Assy Shielding Fuel Pressure Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-36 crimp Detail Steps/Work Items...
  • Page 281 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References 50 mm (±5) Remove the black and white cable insulation. 10 mm (+5 mm) Remove the shielding. Solder Sleeve Put the solder sleeve over the engine harness cable and above the shielding.
  • Page 282 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References 5 mm (±1) Remove the isolation at the end of each single wire of the engine harness and the repair kit cable E4A-90-R18- 000. Put the isolation sleeve of the inline...
  • Page 283 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Put the Roundit over the repair kit cable and the engine wiring harness. Roundit Decrease the length of the Roundit, if necessary. Make sure that the pigtail comes out Pigtail of the Roundit.
  • Page 284 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Remove the black and white cable insulation. 50 mm (+5 mm) Remove the shielding. 10 mm (+5 mm) Put the solder sleeve over the wiring harness cable, above the shielding.
  • Page 285 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Put the isolation sleeve of the inline Isolation sleeves Crimps crimp over the single wire of the engine harness. Put the splice crimp at the end of each single wire of the repair kit cable E4A- 90-R17-000.
  • Page 286 E4 Series Power Plant Maintenance Manual d) Replace the connector for Alternator E4A-91-400-000 Pos. Partnumber Description Qty. E4A-90-R21-000- Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-37 crimp Detail Steps/Work Items Key Items/References Remove the black backsheel.
  • Page 287 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Put the blue isolation of the inline crimp (Part Number D-436-37) over the single wire of the repair kit cable. Put the splice crimp at the end of the single wire of the repair kit cable.
  • Page 288 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References long enough to be a cover for the inline crimp and the black expando. Do a check of the connection Connector Connector between pins. X1/2 G2/GEN Use a Multimeter.
  • Page 289 E4 Series Power Plant Maintenance Manual e) Replace the connector for Alternator E4A-91-000-000 Pos. Partnumber Description Qty. E4A-90-R22-000-000 Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-37 crimp Detail Steps/Work Items Key Items/References Solder Sleeve Cut off the damaged part of the solder sleeve at the engine harness.
  • Page 290 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References 50 mm (+5) Remove the white cable insulation down to the shielding of the cable. 10 mm (+5) Put the solder sleeve over the cable of the remaining engine harness.
  • Page 291 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Put the isolation sleeve of the inline crimp D-436-37 directly over the splice crimp. Isolation sleeve Apply heat to the inline crimp isolation sleeve until it seals the inline crimp barrel and the single wires.
  • Page 292 E4 Series Power Plant Maintenance Manual f) Replace the connector for the Fuel Metering Unit (FMU) Pos. Partnumber Description Qty. E4A-90-R23-000 ZB-Repair_kit_Connector_FMU Cutter Hot Air Gun Crimp Tool for TE (Tyco) D-436-36 crimp Multimeter Detail Steps/Work Items Key Items/References Cut off the damaged FMU connector from the engine harness.
  • Page 293 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References 50 mm (+5) Remove approx. 50 mm of black isolation from the remaining harness. 50 mm (+5) Remove the white cable isolation down to the cable shielding. 10 mm (+5)
  • Page 294 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Remove the remaining shielding. Remove the single wire insulation 5 mm (+/-1) for the two wires. Requirements for crimping tool For crimp D-436-37 by Tyco (TE Connectivity): Manufacturer Manufacturer Mil.
  • Page 295 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References Put the blue isolation sleeve of the inline crimp D-436-37 directly over the splice crimp. (10) Apply heat to the inline crimp Isolation sleeve isolation sleeve until it seals the inline crimp barrel and the single wires.
  • Page 296 E4 Series Power Plant Maintenance Manual g) Replace the connector housing GPC for Engine Harness E4A(B)-95-000-000 This section contains the instructions to replace the GPC connector. Connector Repair Kit Comment E4A-95-R17-000 Repair kit Pos. Part number Description Provided by: Qty.
  • Page 297 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References If only the locking of the GPC is damaged, it is possible to replace the GPC connector housing. If the crimps or cables dedicated to GPC are damaged, replace the engine harness.
  • Page 298 E4 Series Power Plant Maintenance Manual Detail Steps/Work Items Key Items/References (16) Move the wedge lock to its locked position. Squeeze in the locking latches to release (17) Refer to Fig. 71 - 113. them. Move the wedge lock into the housing until (18) Refer to Fig.
  • Page 299 E4 Series Power Plant Maintenance Manual Label Tape Fig. 71 - 109 GPC connector Fig. 71 - 110 Contact removal Page 313 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 300 E4 Series Power Plant Maintenance Manual E4A-95-R17-000 Connect Connector X1/1 X1/1 X1/1 X1/1 X1/1 X1/1 X1/1 X1/1 Ring W11/1 Terminal CTS_GPC CTS_GPC Table 71 - 5 Fig. 71 - 111 Contact insertion Page 314 71 - Maintenance Procedures E4.08.04 01-Jul-2020...
  • Page 301 E4 Series Power Plant Maintenance Manual Fig. 71 - 112 Fig. 71 - 113 Fig. 71 - 114 Page 315 71 -Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 302 E4 Series Power Plant Maintenance Manual Cable tie Label Fig. 71 - 115 Single wires attachment Roundit Tape Fig. 71 - 116 Tape application Page 316 71 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 303 E4 Series Engine Fuel Maintenance Manual System CHAPTER 73 ENGINE FUEL SYSTEM Page 1 73 - Title E4.08.04 Rev.29 01-Jul-2020...
  • Page 304 E4 Series Engine Fuel Maintenance Manual System Intentionally left blank Page 2 73 - Title E4.08.04 01-Jul-2020 Rev.29...
  • Page 305 E4 Series Engine Fuel Maintenance Manual System Table of Contents Chapter 73 73-00-00 Engine Fuel and Control .................. 1 General ..........................1 System Description ......................1 Troubleshooting Information ................... 101 General ........................... 101 73-10-00 Engine Fuel Supply ..................201 General ........................... 201 Special Tools ........................
  • Page 306 E4 Series Engine Fuel Maintenance Manual System Intentionally left blank Page 2 73 - Content E4.08.04 01-Jul-2020 Rev.29...

  • Page 307: Engine Fuel And Control

    E4 Series Engine Fuel Maintenance Manual System 73-00-00 Engine Fuel and Control 1. General This chapter contains information and maintenance procedures about the engine fuel system. For approved fuels refer to the Operation Manual and the Airplane Flight Manual. 2. System Description The E4 engine has a common rail fuel injection system.
  • Page 308 E4 Series Engine Fuel Maintenance Manual System Components of the airframe fuel system For installation and maintenance instructions refer to the applicable Aircraft Maintenance Manual.  Feed pump  Fuel feed line  Fuel filter  Fuel return line ...
  • Page 309 E4 Series Engine Fuel Maintenance Manual System Fig. 73 - 2 Example for acceptable fuel supply system For a fuel system description of the complete fuel system refer to the applicable Aircraft Maintenance Manual. Page 3 73-System Description E4.08.04 Rev. 29...
  • Page 310 E4 Series Engine Fuel Maintenance Manual System Intentionally left blank Page 4 73- System Description E4.08.04 01-Jul-2020 Rev. 29...

  • Page 311: Troubleshooting Information

    E4 Series Engine Fuel Maintenance Manual System Troubleshooting Information 1. General The table below lists the possible defects of the engine fuel system. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
  • Page 312 E4 Series Engine Fuel Maintenance Manual System Intentionally left blank Page 102 73 - Troubleshooting E4.08.04 01-Jul-2020 Rev.29...

  • Page 313: Engine Fuel Supply

    E4 Series Engine Fuel Maintenance Manual System 73-10-00 Engine Fuel Supply 1. General This section contains maintenance procedures for the part of the fuel system used to supply the engine. Always make sure that the high-pressure components are clean when you disconnect them.

  • Page 314: Install The Injectors

    E4 Series Engine Fuel Maintenance Manual System Detail Steps/Work Items Key Items/References Remove the screws that attach the clamping shoe of the Refer to Fig. 73 - 8 and Fig. injector. 73 - 9. If necessary, use the Carefully remove the injectors.
  • Page 315 E4 Series Engine Fuel Maintenance Manual System Detail Steps/Work Items Key Items/References Always use a torque angle gauge to turn the torque-to-yield bolt! Over-torque can cause engine failure! Level 1: 7 Nm Torque the clamping shoes. Level 2: 90º Level 3: 90º...
  • Page 316 E4 Series Engine Fuel Maintenance Manual System flare nuts x 4 fuel line fuel rail Circlip x 4 flare nuts x 4 return line Fig. 73 - 3 Injectors installation ball Fig. 73 - 4 Cylinder head ball Page 204 73 - Maintenance Procedures E4.08.04...
  • Page 317 E4 Series Engine Fuel Maintenance Manual System grease Fig. 73 - 5 Page 205 73 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 318 E4 Series Engine Fuel Maintenance Manual System Fig. 73 - 7 New clamping shoe Fig. 73 - 6 Original clamping shoe clamping shoe screw gasket ring Fig. 73 - 8 Page 206 73 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...
  • Page 319 E4 Series Engine Fuel Maintenance Manual System clamping shoe screw injector Fig. 73 - 9 Page 207 73 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...

  • Page 320: Fuel Return Line

    E4 Series Engine Fuel Maintenance Manual System 73-10-02 Fuel Return line A. Remove the Fuel Return Line Detail Steps/Work Items Key Items/References Refer to Section 85-10-00 Paragraph Remove the injector cover. 3.A. Remove the circlip from the injectors. Refer to Fig. 73 - 14.
  • Page 321 E4 Series Engine Fuel Maintenance Manual System Detail Steps/Work Items Key Items/References Refer to Section 85-10-00 Paragraph (10) Install the injector cover. 3.B. (11) Do an engine ground run. Refer to Section 71-00-01. (12) Examine the fuel system for leakage.
  • Page 322 E4 Series Engine Fuel Maintenance Manual System banjo clamp bolt return line fitting Sealing rings Fig. 73 - 11 Page 210 73 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...
  • Page 323 E4 Series Engine Fuel Maintenance Manual System circlip Fig. 73 - 14 Fig. 73 - 12 fitting return line lock-wire anjo bolt clamps x 4 Fig. 73 - 13 Page 211 73 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...

  • Page 324: High Pressure Pump (Hpp)

    E4 Series Engine Fuel Maintenance Manual System 73-10-03 High Pressure Pump (HPP) A. Remove the High Pressure Pump (HPP) Detail Steps/Work Items Key Items/References When you loosen or tighten hose connections fitted with a twin nipple, always hold the twin nipple firmly.
  • Page 325 E4 Series Engine Fuel Maintenance Manual System fuel supply line screw 3x Fig. 73 - 15 lock wire banjo bolt banjo bolt flare nut fuel return line Fig. 73 - 16 Page 213 73 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
  • Page 326 E4 Series Engine Fuel Maintenance Manual System rubber gasket Fig. 73 - 17 Page 214 73 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...

  • Page 327: Install The High Pressure Pump (Hpp)

    E4 Series Engine Fuel Maintenance Manual System B. Install the High Pressure Pump (HPP) Detail Steps/Work Items Key Items/References Lightly lubricate the rubber gasket with engine oil. Fill the pump with fuel (if not already filled). Put the HPP into the rear housing.

  • Page 328: Remove The Spur Gear From High Pressure Pump

    E4 Series Engine Fuel Maintenance Manual System C. Remove the spur gear from High Pressure Pump Detail Steps/Work Items Key Items/References Use the counter torque wrench Remove the hexagon nut from the drive shaft. AE300T-012-1 or AEP-00379-000. Remove the spur gear from the drive shaft.

  • Page 329: Install The Spur Gear From High Pressure Pump

    E4 Series Engine Fuel Maintenance Manual System Fig. 73 - 19 D. Install the spur gear from High Pressure Pump Detail Steps/Work Items Key Items/References Put the spur gear onto the drive shaft of the Refer to Fig. 73 - 18.

  • Page 330: Engine Fuel Control

    E4 Series Engine Fuel Maintenance Manual System 73-20-00 Engine Fuel Control 1. General This section contains maintenance procedures for the fuel control system. 73-20-01 Low Fuel Pressure Sensor (FPS) A. Remove the Fuel Pressure Sensor Detail Steps/Work Items Key Items/References Disconnect the cable plug connection (FPS).

  • Page 331: Fuel Rail

    E4 Series Engine Fuel Maintenance Manual System 73-20-02 Fuel rail A. Remove the fuel rail Detail Steps/Work Items Key Items/References Remove the connectors (RPS), (PCV). Refer to Fig. 73 - 20. Refer to Section 85-10-00 Remove the injector cover. Paragraph 3.A.
  • Page 332 E4 Series Engine Fuel Maintenance Manual System flare nuts fuel rail screw screw flare nuts Fig. 73 - 20 Fuel rail installation Page 220 73 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev.29...
  • Page 333 E4 Series Engine Control Maintenance Manual System CHAPTER 76 ENGINE CONTROL SYSTEM Page 1 76 - Title E4.08.04 Rev.29 01-Jul-2020...
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  • Page 335 E4 Series Engine Control Maintenance Manual System Table of Contents Chapter 76 76-00-00 Engine Control System ..................1 General ..........................1 System Description/Operation ..................... 1 Engine Electronic Control Unit (EECU) ................1 Troubleshooting Information ................... 101 General ........................... 101 76-10-00 Engine Control .....................
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  • Page 337: Engine Control System

    E4 Series Engine Control Maintenance Manual System 76-00-00 Engine Control System 1. General This chapter contains information how to remove/install and examine the engine control system components. 2. System Description/Operation A. Engine Electronic Control Unit (EECU) The EECU is a 28V supplied device which consists of two equivalent parts: ECU A and ECU B.
  • Page 338 E4 Series Engine Control Maintenance Manual System Actuators  Injectors  Boost Pressure Actuator  Rail Pressure Control Valve  Fuel Metering Unit  Pre-Supply (electrical) Fuel Pump  Governor Set Point Actuator  Caution Lamps EECU Functions Sensors ECU A...
  • Page 339 E4 Series Engine Control Maintenance Manual System EECU Power Supply ECU A ECU A Sensors ECU A Relay Shared Sensors Voter Actuators Matrix Sensors ECU B ECU B Power Supply ECU B 3way Cockpit Engine Switch Power Indications / Sensor A...
  • Page 340 E4 Series Engine Control Maintenance Manual System  ECU Switch Over Reported Failures can lead to an automatic switch over An internal logic (Voter) selects the ECU to be active  The Pilot can overrule the decision of the EECU ...
  • Page 341 E4 Series Engine Control Maintenance Manual System Engine Speed and Power Control The necessary propeller speed set point is calculated depending on the power lever sensor position. The current engine speed is used to calculate the deviation of the actual propeller speed from the set point.
  • Page 342 E4 Series Engine Control Maintenance Manual System Fig. 76 - 3 EECU and Governor Page 6 76 – System Description E4.08.04 01-Jul-2020 Rev.29...
  • Page 343 E4 Series Engine Control Maintenance Manual System Technical Data of the Electrical System Components: EECU: The EECU is the Electrical Engine Control Unit which is used to control the engine actuators (e.g. fuel injectors) according to the engine sensor information.
  • Page 344 E4 Series Engine Control Maintenance Manual System Display and Diagnostic Interface: The Display and diagnostic interface is a High Speed CAN Bus (with 500k Baud) which is used to transmit all information to a display/indication panel. A BUS termination is required at the physical end of the BUS.
  • Page 345 E4 Series Engine Control Maintenance Manual System Propeller Self-Test (Automatic Run-Up Test) Description: The propeller governor self-test has been designed to emulate the manual run-up test performed by the pilot of an aircraft equipped with a conventional (mechanical) propeller control lever. With the single power lever installation of the AE300 engine, the self-test button must be pressed during the automatic run up.
  • Page 346 E4 Series Engine Control Maintenance Manual System Governor Interface: This EECU is able to operate the electric motor which changes the governor-set point. According to power lever position the EECU controls the related propeller speed. As long as the actual propeller speed is different to the predefined propeller set point curve, the EECU provides a signal to drive the electric motor which is part of the governor.
  • Page 347 E4 Series Engine Control Maintenance Manual System The governor must have two mechanical stops which can be detected by the EECU through sensing pins. If one of these stops is reached, the electric motor will not be actuated into the direction of the detected stop, only movement into direction of the opposite stop is possible.
  • Page 348 E4 Series Engine Control Maintenance Manual System Activation of the self-test via the Self-test push-button is only be possible if the VOTER Switch is in AUTO Position (logical AND relation). During the whole Self-test the push-button must remain pressed. (For particular installation refer to the applicable Aircraft Maintenance Manual) Fig.

  • Page 349: Troubleshooting Information

    Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column. Trouble Possible Cause Repair An unscheduled maintenance is necessary. Latched caution indication Austro Engine GmbH has to be informed. Page 101 76-Troubleshooting E4.08.04 Rev. 29 01-Jul-2020...
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  • Page 351: Engine Control

    The AE300-Wizard uses a Flash Container (FCT), which includes the Software file to update the EECU. The FCT is available on the Austro Engine Homepage / Client Area. Obey the diagram below for the Software Update procedure by use of references to the A300 Wizard.
  • Page 352 E4 Series Engine Control Maintenance Manual System EECU SW to be updated Engine Log Flash Container Update EECU with new SW AE300 Wizard Load Flash Container (downloaded from into Wizard Software AE-Homepage) Acc. „AE300 SW Update Check-Sheet“ Flash Log Flash Autosave...
  • Page 353 E4 Series Engine Control Maintenance Manual System Detail Steps/Work Items Key Items/References - Update process successful. - If RED MESSAGE BOX shows, obey Make sure the GREEN MESSAGE BOX shows. the steps explained in the AE300 User Guide section “Detailed Steps of the Software Update Process”.

  • Page 354: Examine The Eecu Fault Log

    E4 Series Engine Control Maintenance Manual System B. Examine the EECU Fault Log Detail Steps/Work Items Key Items/References If this failure shows on one of the ECUs (ECU A or ECU B) with the error type “NPL: RTC-oscillator has stopped, time/date 00:00:00 2000- 01-01 substituted”, replace the EECU...

  • Page 355: Glow Plug Control

    E4 Series Engine Control Maintenance Manual System 3. Glow Plug Control (GPC) A. Remove the Glow Plug Control Detail Steps/Work Items Key Items/References Remove the GPC connector. Remove the four screws from the GPC. Refer to Fig. 76 - 10.

  • Page 356: Crankshaft Sensor

    E4 Series Engine Control Maintenance Manual System 4. Crankshaft Sensor A. Remove the Crankshaft Sensor Detail Steps/Work Items Key Items/References Disconnect the electrical lines CRS1 or CRS2. Remove the screw that from the crankshaft Refer to Fig. 76 - 11.
  • Page 357 E4 Series Engine Control Maintenance Manual System 5. Camshaft Sensor CAS 1 A. Remove the Camshaft Sensor CAS 1 Detail Steps/Work Items Key Items/References Refer to Section 85-10-00 Paragraph Remove the injector cover. 3.A. Pull down the electrical connector CAS1.

  • Page 358: Camshaft Sensor Cas 2

    E4 Series Engine Control Maintenance Manual System CAS1 Locking screw Fig. 76 - 12 Camshaft Sensor CAS1 6. Camshaft Sensor CAS2 A. Remove the Camshaft Sensor CAS2 Detail Steps/Work Items Key Items/References Pull down the electrical connector CAS2. Remove the locking screw from the sensor.
  • Page 359 E4 Series Engine Control Maintenance Manual System CAS2 Locking screw Fig. 76 - 13 CAS2 installed on the belt drive side of the engine CAS1 CAS2 Locking screw Fig. 76 - 14 CAS2 installed under the injector cover Page 209 76 - Maintenance Procedures E4.08.04...
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  • Page 361 E4 Series Engine Maintenance Manual Indicating CHAPTER 77 ENGINE INDICATING Page 1 77 - Title E4.08.04 Rev.29 01-Jul-2020...
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  • Page 363 E4 Series Engine Maintenance Manual Indicating Table of Contents Chapter 77 77-00-00 Engine Indicating .................... 1 General ..........................1 System Description/Operation ..................... 1 Troubleshooting Information ................... 101 General ........................... 101 Page 1 77 - Content E4.08.04 Rev.29 01-Jul-2020...
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  • Page 365: Engine Indicating

    One applicable engine display system consists of a Main Engine Display (MED) and a Secondary Engine Display (SED) device, which is offered by Austro Engine (part no. MED: A1A-10-100-000; part no. SED: A1A-10-200-000). This system is proven to display the relevant engine parameters in consistence with the engine operation limitations as described in the Operation Manual.
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  • Page 367: Troubleshooting Information

    E4 Series Engine Maintenance Manual Indicating Troubleshooting Information 1. General The table below lists the possible defects of the engine control system. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
  • Page 368 E4 Series Engine Maintenance Manual Indicating Intentionally left blank Page 102 77 - Troubleshooting E4.08.04 01-Jul-2020 Rev.29...
  • Page 369 E4 Series Engine Exhaust Maintenance Manual System CHAPTER 78 ENGINE EXHAUST SYSTEM Page 1 78 - Title E4.08.04 Rev.29 01-Jul-2020...
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  • Page 371 E4 Series Engine Exhaust Maintenance Manual System Table of Contents Chapter 78 78-00-00 Engine Exhaust System ................... 1 General ..........................1 System Description/Operation ..................... 1 Troubleshooting Information ................... 101 General ........................... 101 78-10-00 Engine Exhaust .................... 201 General ........................... 201 Exhaust Manifold ......................
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  • Page 373: Engine Exhaust System

    E4 Series Engine Exhaust Maintenance Manual System 78-00-00 Engine Exhaust System 1. General This chapter contains information how to remove/install and examine the engine exhaust system components. For more information on the intake/exhaust system, refer to Chapter 81. 2. System Description/Operation The exhaust system is necessary to release the exhaust gas in a safe and proper way into the environment.
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  • Page 375: Troubleshooting Information

    E4 Series Engine Exhaust Maintenance Manual System Troubleshooting Information 1. General The table below lists the possible defects of the engine exhaust system. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
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  • Page 377: Engine Exhaust

    E4 Series Engine Exhaust Maintenance Manual System 78-10-00 Engine Exhaust 1. General This section contains the maintenance procedures for the engine exhaust system. 2. Exhaust Manifold A. Remove the Exhaust Manifold Detail Steps/Work Items Key Items/References Remove the exhaust pipe from the turbocharger.

  • Page 378: Install The Exhaust Manifold

    E4 Series Engine Exhaust Maintenance Manual System B. Install the Exhaust Manifold Detail Steps/Work Items Key Items/References Attach the turbocharger with new gasket to the Refer to Fig. 78 - 3. exhaust manifold. Install the four screws that attach the exhaust Use new nuts.
  • Page 379 E4 Series Engine Exhaust Maintenance Manual System Clip Wategate Clip Wastegate controller controller Banjo bolt Pick-up hose Pick-up hose Grub screw Fig. 78 - 1: Discontinued hose routing Fig. 78 - 2: Latest version with grub with banjo connection screw Turbocharger Fill with approx.
  • Page 380 E4 Series Engine Exhaust Maintenance Manual System Screw Gasket Exhaust Manifold Gasket Fig. 78 - 5 Spherical washers Conical washers Gasket Screw Fig. 78 - 6 Explosion for turbocharger installation on the exhaust manifold Page 204 78 - Maintenance Procedures E4.08.04...

  • Page 381: Exhaust Manifold Gasket Exchange

    E4 Series Engine Exhaust Maintenance Manual System 3. Exhaust manifold Gasket Exchange For removal/installation instructions, refer to Paragraph 2. Page 205 78 - Maintenance Procedures E4.08.04 Rev.29 01-Jul-2020...
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  • Page 383 E4 Series Engine Oil Maintenance Manual System CHAPTER 79 ENGINE OIL SYSTEM Page 1 79 - Title E4.08.04 Rev. 29 01-Jul-2020...
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  • Page 385 E4 Series Engine Oil Maintenance Manual System Table of Contents Chapter 79 79-00-00 Engine Oil System .................... 1 General ..........................1 System Description/Operation ..................... 1 Troubleshooting Information ................... 101 General ........................... 101 79-10-00 Oil Storage ....................201 General ........................... 201 Special Tools ........................
  • Page 386 E4 Series Engine Oil Maintenance Manual System 79-30-00 Oil System Sensors ..................235 General ........................... 235 Oil Level Sensor ......................235 Remove the Oil Level Sensor ..................235 Install the Oil Level Sensor ................... 235 Oil Pressure Sensor ......................237 Remove the Oil Pressure Sensor ...................

  • Page 387: Engine Oil System

    For the approved engine oils refer to the Operation Manual applicable to the engine model. Only engine oils specified in the Operation Manual are approved by Austro Engine GmbH for operation. If other types of oil are used, this will lead to rejection of warranty claims by Austro Engine GmbH.
  • Page 388 E4 Series Engine Oil Maintenance Manual System Fig. 79 - 1 Lubrication System Page 2 79 – System Description E4.08.04 01-Jul-2020 Rev. 29...

  • Page 389: Troubleshooting Information

    E4 Series Engine Oil Maintenance Manual System Troubleshooting Information 1. General The table below includes the possible defects of the lubrication system. If you have the trouble listed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
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  • Page 391: Oil Storage

    E4 Series Engine Oil Maintenance Manual System 79-10-00 Oil Storage 1. General This section contains the maintenance procedures for the part of the oil system that stores the oil. 2. Special Tools Number Description Dimensions Wrench Oil Filter Wrench Oil Drain Pan...

  • Page 392: Install The Oil Sump

    E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References Remove the screws that attach the oil sump (10) to the crankcase. Refer to Fig. 79 - 2. (11) Carefully remove the oil sump. B. Install the Oil Sump...
  • Page 393 E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References Refer to Fig. 79 - 4. (14) Install the oil sump. Torque: 1 step 6 Nm step 13 Nm Refer to Section 79-20-00 Paragraph (15) Install the oil filter housing drain line.
  • Page 394 E4 Series Engine Oil Maintenance Manual System Screw Gasket Washer 6x Sealing ring Screw plug Oil baffle panel Oil sump Screw 14x Screw LU position sensor Screw Screw Screw Screw Oil dipstick LU oil level Washer 2x Screw Screw sensor Fig.
  • Page 395 E4 Series Engine Oil Maintenance Manual System Fig. 79 - 3 Application of additional sealing material Fig. 79 - 4 Tightening Sequence Page 205 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 396: Oil Supply

    E4 Series Engine Oil Maintenance Manual System 79-20-00 Oil Supply 1. General This section contains maintenance procedures for the oil supply system. 2. Oil Filter Housing Remove the Oil Filter Housing Detail Steps/Work Items Key Items/References Disconnect the oil pressure sensor from the engine harness.

  • Page 397: Install The Oil Filter

    E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References Refer to Section 79-30-00 Paragraph Torque 18 Nm. Install the fitting on the housing drain line with a new sealing ring. Refer to Fig. 79 - 6. Refer to Section 79-20-00 Paragraph Install the oil filter housing drain line.
  • Page 398 E4 Series Engine Oil Maintenance Manual System Oil pressure sensor screw Stud bolt fitting clamp screw Housing drain line Fig. 79 - 6 Oil filter housing installation Page 208 79-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 399 E4 Series Engine Oil Maintenance Manual System 3. Oil Filter A. Remove the Oil Filter Detail Steps/Work Items Key Items/References Remove the oil filter cover. Remove the oil filter from the oil filter cover. Remove the O-Rings from the oil filter cover.

  • Page 400: Oil Filter Housing Drain Line

    E4 Series Engine Oil Maintenance Manual System Filter cover Oil filter Fig. 79 - 8 Oil filter installation 4. Oil Filter Housing Drain Line A. Remove the Oil Filter Housing Drain Line Detail Steps/Work Items Key Items/References Open the sleeve nut of the drain line on the upper end (oil filter housing).

  • Page 401: Install The Oil Filter Housing Drain Line

    E4 Series Engine Oil Maintenance Manual System B. Install the Oil Filter Housing Drain Line Detail Steps/Work Items Key Items/References Install new gasket rings on the banjo bolt at the oil sump. Connect the lower end of the drain line to the banjo bolt at the oil sump.
  • Page 402 E4 Series Engine Oil Maintenance Manual System Sleeve nut Banjo Filter housing drain line Lock-wire bolt Sleeve Oil sump Fig. 79 - 9 Oil filter housing drain line installation Page 212 79-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 403: Engine Oil

    E4 Series Engine Oil Maintenance Manual System 5. Engine Oil If a quick drain valve is installed as part of the power plant installation, refer to the Airplane Maintenance Manual for the procedures to drain and refill the engine oil.
  • Page 404 E4 Series Engine Oil Maintenance Manual System Drain plug Lock-wire Fig. 79 - 10 Oil sump Page 214 79-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 405: Oil Separator

    E4 Series Engine Oil Maintenance Manual System 6. Oil Separator A. Remove the Oil Separator Detail Steps/Work Items Key Items/References Refer to Section 85-10-00 Remove the injector cover. Paragraph 3.A. Remove the screws that attach the oil separator Refer to Fig. 79 - 13.

  • Page 406: Remove The Oil Separator By-Pass Valve

    E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References Make sure that the O-Rings at the oil pipe are in (12) Refer to Fig. 79 - 12. the correct position. Do not use Loctite on thread with grease!
  • Page 407 E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References Clean the working area. Do an engine ground run. Refer to Section 71-00-01. Examine the oil system for leakage. Fig. 79 - 11 Oil separator hose installation Hose 1...

  • Page 408: Oil Separator Return Line

    E4 Series Engine Oil Maintenance Manual System Hose 2 Injector cover screws Injector cover Oil pipe Fig. 79 - 13 Oil separator installation 7. Oil Separator Return Line A. Remove the Oil Separator Return Line Detail Steps/Work Items Key Items/References Remove the lock-wire from the banjo bolt on the Refer to Fig.
  • Page 409 E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References Push the oil line in the injector cover. Refer to Fig. 79 - 17. Tighten the screw. Tighten the banjo bolt at the camshaft sensor Torque 15 Nm.
  • Page 410 E4 Series Engine Oil Maintenance Manual System Banjo bolt camshaft sensor housing Lock-wire Fig. 79 - 15 Oil separator return line installation Banjo bolt Oil line Fig. 79 - 16 Modified oil separator return line Page 220 79-Maintenance Procedures E4.08.04 01-Jul-2020 Rev.
  • Page 411 E4 Series Engine Oil Maintenance Manual System Fig. 79 - 17 Oil line installation Page 221 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 412: Turbocharger Oil Supply Line

    E4 Series Engine Oil Maintenance Manual System 8. Turbocharger Oil Supply Line A. Remove the Turbocharger Oil Supply Line Detail Steps/Work Items Key Items/References Remove the lock-wire from the banjo bolt at the turbocharger. Refer to Fig. 79 - 19.
  • Page 413 E4 Series Engine Oil Maintenance Manual System Turbocharger oil supply line screw screw clamp Fig. 79 - 18 Turbocharger Oil supply Page 223 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 414 E4 Series Engine Oil Maintenance Manual System Banjo bolt Lock-wire Fig. 79 - 19 Banjo bolt on turbocharger Page 224 79-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 415 E4 Series Engine Oil Maintenance Manual System Banjo bolt Sealing rings Turbocharger oil supply line Screw O-Ring Screw Clamp Fig. 79 - 20 Turbocharger oil supply line sealing rings installation Page 225 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 416: Turbocharger Oil Return Line

    E4 Series Engine Oil Maintenance Manual System 9. Turbocharger Oil Return Line A. Remove the Turbocharger Oil Return Line Detail Steps/Work Items Key Items/References Refer to Section 79-20-00 Drain the engine oil. Paragraph 5.A. Remove the lock-wire at the banjo bolt at the oil sump.
  • Page 417 E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References (10) Tighten the banjo bolt at the oil sump. Torque 50 Nm. Secure the banjo bolt at the oil sump with lock- (11) Refer to Fig. 79 - 22.
  • Page 418 E4 Series Engine Oil Maintenance Manual System gasket Banjo bolt / adapter assembly Refer to Paragraph C and D. Screws O-Ring clamp oil return line Screw Sealing rings Banjo bolt Fig. 79 - 21 Oil return line gasket installation Page 228 79-Maintenance Procedures E4.08.04...
  • Page 419 E4 Series Engine Oil Maintenance Manual System screws adapter Return line screw clamp Lock-wire Banjo bolt Fig. 79 - 22 Turbocharger Oil return line Page 229 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 420: Remove And Disassemble The Banjo Bolt/Adapter Assembly

    E4 Series Engine Oil Maintenance Manual System C. Remove and disassemble the banjo bolt/adapter assembly Detail Steps/Work Items Key Items/References For the Cylinder Head Version 2 (Refer to Section 85-30-00 Paragraph 4 for description), do the steps (1) to (3).
  • Page 421 E4 Series Engine Oil Maintenance Manual System Detail Steps/Work Items Key Items/References One more sealing ring Tighten the banjo bolt into the connection fitting. Install lock-wire between the banjo bolt and the Refer to the standard procedures. connection fitting. Apply rubber grease on the new O-Rings.
  • Page 422 E4 Series Engine Oil Maintenance Manual System Sealing ring Banjo fitting Banjo adapter Fig. 79 - 23 Fig. 79 - 24 Banjo bolt Connection fitting Banjo bolt Sealing rings Lock-wire Connection fitting Banjo fitting O-Rings Fig. 79 - 26 Fig. 79 - 25...
  • Page 423 E4 Series Engine Oil Maintenance Manual System (a) Install the connector assembly Detail Steps/Work Items Key Items/References To install the connector, the oil pipe must be disassembled. Therefore, before the connector installation do the instructions in Paragraph 9.A – Remove the Turbocharger Oil Return Line...

  • Page 424: Oil System Sensors

    E4 Series Engine Oil Maintenance Manual System 79-30-00 Oil System Sensors 1. General This section contains the maintenance procedures for the part of the oil system that shows the quantity and the pressure of the oil. 2. Oil Level Sensor A.
  • Page 425 E4 Series Engine Oil Maintenance Manual System Connector Screw with washer Clamp Oil Level Sensor Screw with washer Fig. 79 - 30 Oil level sensor Page 235 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 426: Oil Pressure Sensor

    E4 Series Engine Oil Maintenance Manual System 3. Oil Pressure Sensor A. Remove the Oil Pressure Sensor Detail Steps/Work Items Key Items/References Disconnect the electrical connector (OPS). Refer to Fig. 79 - 31. Remove the oil pressure sensor. Open and remove the oil filter.
  • Page 427 E4 Series Engine Oil Maintenance Manual System Oil pressure sensor Sealing ring Connector Fig. 79 - 31 Oil pressure sensor Page 237 79-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
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  • Page 429 E4 Series Starting Maintenance Manual CHAPTER 80 STARTING Page 1 80 - Title E4.08.08 Rev. 29 01-Jul-2020...
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  • Page 431 E4 Series Starting Maintenance Manual Table of Contents Chapter 80 80-00-00 Starting ......................1 General ..........................1 System Description ......................1 Electrical Starter ......................1 Glow Plug Control Unit ....................1 Troubleshooting Information ................... 101 General ........................... 101 80-10-00 Cranking ...................... 201 General ...........................

  • Page 432: Starting

    E4 Series Starting Maintenance Manual Intentionally left blank Page 2 80 - Contents E4.08.04 01-Jul-2020 Rev. 29...

  • Page 433: General

    E4 Series Starting Maintenance Manual 80-00-00 Starting 1. General This chapter contains information about the engine starting system and its components. For the operating instructions, refer to the Operation Manual. 2. System Description The engine starting system contains the following components:...
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  • Page 435: Troubleshooting Information

    Defective glow plug plug for: Caution lamp active for GPC any kind of physical (if installed) damage broken parts If you find broken parts, contact Austro Engine GmbH. Defective water temperature Replace the water temperature sensor sensor. Page 101 80 -Troubleshooting E4.08.04 Rev.
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  • Page 437: Cranking

    E4 Series Starting Maintenance Manual 80-10-00 Cranking 1. General This section contains the procedures how to remove, install, and examine the starter. Starter Remove the Starter Detail Steps/Work Items Key Items/References Disconnect the battery as follows: The negative pole Refer to the applicable Aircraft The positive pole.

  • Page 438: Install The Starter

    E4 Series Starting Maintenance Manual B. Install the Starter Detail Steps/Work Items Key Items/References Carefully put the starter to the crankcase housing. Refer to Fig. 80 - 1. Be careful with the ring gear! Put the GPC-bracket in the correct position.
  • Page 439 E4 Series Starting Maintenance Manual Tie rap GPC bracket Screw Spacer bush Fig. 80 - 1 Starter installation Screw Fig. 80 - 2 Starter installation Page 203 80 - Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 440: Glow System

    E4 Series Starting Maintenance Manual 3. Glow System A. Examine the Glow Plug Control Unit (GPC) Detail Steps/Work Items Key Items/References Examine the GPC (new version) for: Incorrect sealing Unequal clearance between housing Refer to Fig. 80 - 3 and Fig. 80 - 4.

  • Page 441: Remove The Glow Plugs

    E4 Series Starting Maintenance Manual B. Remove the Glow Plugs Detail Steps/Work Items Key Items/References Carefully remove the cable connectors Refer to Fig. 80 - 6. (GP1/GP2/GP3/GP4) from the cylinder head. Remove the glow plugs. C. Install the Glow Plugs...
  • Page 442 E4 Series Starting Maintenance Manual Connector Fig. 80 - 6 Glow Plugs installation Page 206 80 - Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 443 E4 Series Turbocharging Maintenance Manual CHAPTER 81 TURBOCHARGING Page 1 81 - Title E4.08.04 Rev. 29 01-Jul-2020...
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  • Page 445 E4 Series Turbocharging Maintenance Manual Table of Contents Chapter 81 81-00-00 System Description ..................1 General ..........................1 Charged Air System ......................1 Turbocharger ......................... 2 Components of the aircraft ....................4 Part of the engine ......................4 Troubleshooting Information ................... 101 General ...........................
  • Page 446 E4 Series Turbocharging Maintenance Manual Intentionally left blank Page 2 81 - Contents E4.08.04 01-Jul-2020 Rev. 29...

  • Page 447: System Description

    E4 Series Turbocharging Maintenance Manual Turbocharging 81-00-00 System Description 1. General This chapter contains information about the turbocharger system and procedures how to remove/install, examine, and adjust the Turbocharger system. 2. Charged Air System The charged air system recovers energy from the exhaust gas in order to increase intake air pressure and engine performance using a turbocharger.
  • Page 448 E4 Series Turbocharging Maintenance Manual The air filter prevents that foreign objects and particles enter the engine. The alternate intake valve provides sufficient air supply if the air filter becomes clogged. The turbocharger compresses the intake air and makes the air hot.
  • Page 449 E4 Series Turbocharging Maintenance Manual Fig. 81 - 2 Turbocharger Operation Fig. 81 - 3 Turbocharger Page 3 81 - System Description E4.08.04 Rev. 29 01-Jul-2020...

  • Page 450: Components Of The Aircraft

    E4 Series Turbocharging Maintenance Manual Fig. 81 - 4 Turbocharger Torque Seal B. Components of the aircraft For installation and maintenance details refer to the applicable Aircraft Maintenance Manual.  Air filter  Intercooler  Hoses  Alternate Air intake if required C.

  • Page 451: Troubleshooting Information

    E4 Series Turbocharging Maintenance Manual Troubleshooting Information 1. General The table below lists the possible defects of the turbocharger system. If you have the trouble detailed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
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  • Page 453: General

    E4 Series Turbocharging Maintenance Manual 81-20-00 Turbocharger 1. General This section contains the procedures how to remove/install, and examine the turbocharger and its components. 2. Special Tools Number Description Dimensions Pressure device Fig. 81 - 5 Air pressure device Page 201 81- Maintenance Procedures E4.08.04...

  • Page 454: Remove The Turbocharger

    E4 Series Turbocharging Maintenance Manual 3. Turbocharger A. Remove the turbocharger Detail Steps/Work Items Key Items/References Remove the exhaust pipe from the turbocharger. Remove the charged air tubing from the Refer to the Aircraft Maintenance turbocharger. Manual. Disconnect the clamps and remove the air intake hose from the turbocharger.
  • Page 455 E4 Series Turbocharging Maintenance Manual Turbocharger Screws Exhaust manifold Fig. 81 - 6 Turbocharger installation Exhaust manifold Screws Fig. 81 - 7 Turbocharger installation Page 203 81- Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 456: Boost Pressure Actuator (Bpa)

    E4 Series Turbocharging Maintenance Manual 4. Boost Pressure Actuator (BPA) A. Remove the BPA Detail Steps/Work Items Key Items/References Remove the electrical connector BPA. Remove the clamps from the hose to the BPA. Remove the hoses. Refer to Fig. 81 - 9.
  • Page 457 E4 Series Turbocharging Maintenance Manual Detail Steps/Work Items Key Items/References Do an engine ground run. Refer to Section 71-00-01. Cylinder head cover Screws Bracket Fig. 81 - 8 BPA Configuration 1 Page 205 81- Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 458 E4 Series Turbocharging Maintenance Manual Screw Restrictor Restrictor Clamp Clamp el. connector “BPA” Clamp Spacer Clamp Fig. 81 - 9 Latest BPA installation version Page 206 81- Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 459 E4 Series Turbocharging Maintenance Manual Fig. 81 - 10 Installation direction of the restrictor Set screw Fig. 81 - 11 Set screw installation Page 207 81- Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 460: Wastegate Controller

    E4 Series Turbocharging Maintenance Manual 5. Wastegate Controller A. Remove the Wastegate Controller Detail Steps/Work Items Key Items/References Refer to Section 05-20-00 Examine the turbocharger torque seal for distortion. item 45-49. Remove the clamp from the air hose to the wastegate Refer to Fig.
  • Page 461 E4 Series Turbocharging Maintenance Manual Hose Clamp Wastegate controller Screw Wastegate pin Spring loaded circlip Fig. 81 - 12 Turbocharger engine configuration “-A” Fig. 81 - 13 Wastegate connection rod precautions Page 209 81- Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 462: Install And Adjust The Wastegate Controller

    E4 Series Turbocharging Maintenance Manual B. Install and adjust the Wastegate Controller Detail Steps/Work Items Key Items/References Remove the clamp from the air hose to the Refer to Fig. 81 - 12. wastegate, if installed. Discard the clamp! Disconnect the air hose from the port of the Refer to Fig.
  • Page 463 E4 Series Turbocharging Maintenance Manual Detail Steps/Work Items Key Items/References (10) Release the pressure at the air pressure device. Do not exceed the maximum permitted air pressure of 2.5 bar (relative)! (11) Slowly pressurize the wastegate controller. Use the air pressure device.
  • Page 464 E4 Series Turbocharging Maintenance Manual Detail Steps/Work Items Key Items/References Make sure that the installation position applies to Refer to Fig. 81 - 15, Fig. 81 - (24) the engine configuration. 16 and Fig. 81 - 17. When you apply Loctite, there must be no grease on the thread!
  • Page 465 E4 Series Turbocharging Maintenance Manual Wastegate Wastegate controller controller Screw Screw Circlip Circlip Fig. 81 - 15 Turbocharger engine Fig. 81 - 16 Turbocharger engine configuration “-A” configuration “-B” Clamp Wastegate controller Connection rod Screw Circlip Circlip Hose Rod eye Fig.

  • Page 466: Examine The Wastegate Controller Adjustment

    E4 Series Turbocharging Maintenance Manual parallelism Fig. 81 - 19 Parallelism between rod eye and wastegate mechanism of turbocharger C. Examine the Wastegate Controller adjustment Detail Steps/Work Items Key Items/References Remove the clamp on the air hose to the wastegate.
  • Page 467 E4 Series Turbocharging Maintenance Manual Detail Steps/Work Items Key Items/References Remove the clamp and disconnect the hose of the air pressure device. Connect the air hose to the wastegate controller again Refer to Fig. 81 - 20. and attach a new clamp.

  • Page 468: Install The Wastegate Controller Conrod Fail-Safe Bridge

    E4 Series Turbocharging Maintenance Manual D. Install the Wastegate Controller Conrod Fail-Safe Bridge There are two procedures to secure the bolts on the Wastegate Controller to prevent rotation: By use of lock-wire – By use of Nord-Lock washers under the head of the bolts.
  • Page 469 E4 Series Turbocharging Maintenance Manual Fig. 81 - 21 Wastegate Conrod Fail-Safe Bridge torque seal Fig. 81 - 22 Torques seal Page 217 81- Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 470 E4 Series Turbocharging Maintenance Manual Wire locking Fig. 81 - 23 Wire locking Page 218 81- Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 471 E4 Series Reciprocating Maintenance Manual Engine CHAPTER 85 RECIPROCATING ENGINE Page 1 85 - Title E4.08.04 Rev. 29 01-Jul-2020...
  • Page 472 E4 Series Reciprocating Maintenance Manual Engine Intentionally left blank Page 2 85 – Title E4.08.04 01-Jul-2020 Rev. 29...
  • Page 473 E4 Series Reciprocating Maintenance Manual Engine Table of Contents Chapter 85 85-00-00 Reciprocating Engine..................1 General ..........................1 System Description/Operation ..................... 1 Governor ........................7 Troubleshooting Information ................... 101 General ........................... 101 85-10-00 Reciprocating Engine - Front Section ............201 General ...........................
  • Page 474 E4 Series Reciprocating Maintenance Manual Engine Remove the Crankshaft Cover ..................260 Install the Crankshaft Cover ..................261 85-30-00 Reciprocating Engine - Cylinder Section ............. 263 Intake Air System ......................263 Remove the Intake Air Manifold ..................263 Install the Intake Air Manifold ..................264 Boost Pressure Sensor (BPS) ....................
  • Page 475 E4 Series Reciprocating Maintenance Manual Engine Install the Belt Tensioner – Roller ................. 313 Timing Chain ........................314 Timing Chain Check ..................... 314 Prepare for timing chain check ................314 Timing Chain Measuring Tool (TCMT) ..............315 Complete a check of the timing chain..............316 Results of the timing chain check ...............
  • Page 476 E4 Series Reciprocating Maintenance Manual Engine Gearbox .......................... 207 Remove the Gearbox ....................207 Install the Gearbox ...................... 208 Remove the optional Gearbox Oil Cooler ............... 213 Install the optional Gearbox Oil Cooler ................213 Remove and examine the magnetic drain plug .............. 215 Install the magnetic drain pug ..................
  • Page 477 E4 Series Reciprocating Maintenance Manual Engine Remove the cylinder head cover ................ 278 Remove the Camshaft Sensor Housing for CAS 2 ..........279 Remove the rear cylinder head cover ..............281 Remove the front cylinder head cover ..............282 Remove the chain tensioner .................. 283 Remove the chain gear ..................
  • Page 478 E4 Series Reciprocating Maintenance Manual Engine Install the Coolant Temperature Sensor ................ 337 Water Pump ........................338 Remove the Water Pump ..................... 338 Install the Water Pump ....................338 Remove the Water Pump Bearing Housing Assembly ............. 339 Install the Water Pump Bearing Housing Assembly ............340 Heat Exchanger .......................

  • Page 479: Reciprocating Engine

    E4 Series Reciprocating Maintenance Manual Engine 85-00-00 Reciprocating Engine 1. General This chapter contains information how to remove/install and examine the reciprocating engine components. 2. System Description/Operation Gearbox The E4 engine has a gearbox installed to decrease RPM from the 3880 RPM maximum of the engine to 2300 RPM at the propeller.
  • Page 480 E4 Series Reciprocating Maintenance Manual Engine Two-Mass Flywheel A torsion vibration damper is installed between gearbox and crankshaft. It has two elements: a mass that is resistant to acceleration of the vibration an energy dissipating element that absorbs the vibrations.
  • Page 481 E4 Series Reciprocating Maintenance Manual Engine Crankcase The crankcase of the E4 engine is a single piece, squeeze casted part. Based on this design (cast iron), no separate cylinder liners are necessary. The cast iron design of the crankcase has good failsafe running functions and a decreased noise emission. The design of the E4 engine is an inline, liquid cooled engine, and the crankcase includes the cylinders as well as the coolant passages.
  • Page 482 E4 Series Reciprocating Maintenance Manual Engine Coolant System The internal engine cooling circuit has the following components: a coolant pump operated by the V-Ribbed belt the integrated coolant/oil heat exchanger coolant ducts within crankcase cylinder head intake manifold, where the coolant temperature sensors are located the coolant thermostat.
  • Page 483 E4 Series Reciprocating Maintenance Manual Engine Standard Cooling Circuit Example for permitted cooling circuit: (For particular installation refer to the applicable Aircraft Maintenance Manual) Expansion Tank (incl. Overpressure and low pressure valve) Part of certified engine Fig. 85 - 3...
  • Page 484 E4 Series Reciprocating Maintenance Manual Engine Cooling Circuit with optional Gearbox Oil Cooler: A Gearbox Oil-Water Heat Exchanger (HEX), installed directly at the rear side of the gearbox, is integrated in the coolant circuit, in addition to the standard cooling circuit (refer to Fig.

  • Page 485: Governor

    E4 Series Reciprocating Maintenance Manual Engine A. Governor An electrically controlled hydro mechanical governor is installed. The governor is not part of the engine. Approved governors for installation: MT-propeller P-877-16 MT-Propeller P-853-16 The EECU provides a signal for the governor to adjust the required rpm set point (refer to Fig.01-18)
  • Page 486 E4 Series Reciprocating Maintenance Manual Engine Governor Functional Description: The propeller speed is conventionally controlled and kept by a mechanical propeller governor, but the set point of the governor is adjusted by an electric motor controlled by the EECU. This electric motor substitutes the conventionally used Bowden cable and if e.g. the connection to the set point actuator fails, the set point remains unchanged and the governor controls the propeller speed to the last set-point.

  • Page 487: Troubleshooting Information

    E4 Series Reciprocating Maintenance Manual Engine Troubleshooting Information 1. General The table below includes the possible defects of the reciprocating engine. If you have the trouble listed in the Trouble column, read across to the Possible Cause column. Then do the repair in the Repair column.
  • Page 488 E4 Series Reciprocating Maintenance Manual Engine Intentionally left blank Page 102 85 – Troubleshooting E4.08.04 01-Jul-2020 Rev. 29...

  • Page 489: Reciprocating Engine - Front Section

    E4 Series Reciprocating Maintenance Manual Engine 85-10-00 Reciprocating Engine - Front Section 1. General This section contains the maintenance procedures for the reciprocating engine front section. 2. Special Tools Number Description Dimensions Spring band clamp pliers Flywheel Locking Tool Soft faced hammer Lever bar (slotted) Approx.

  • Page 490: Install The Injector Cover

    E4 Series Reciprocating Maintenance Manual Engine B. Install the Injector Cover Detail Steps/Work Items Key Items/References If the injector cover has no maintenance lid installed, refer to MSB-E4-008/2 or higher revisions. Refer to Fig. 85 - 10. Use a dry and clean rag only.
  • Page 491 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Refer to the applicable Aircraft (14) Attach the breather line to the injector cover. Maintenance Manual. Refer to Section 79-20-00 Paragraph (15) Install the oil separator return line. 7.B.
  • Page 492 E4 Series Reciprocating Maintenance Manual Engine Screw Screw Injector Cover Breather Line Screw Fig. 85 - 8 Injector Cover with maintenance lid Page 204 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 493 E4 Series Reciprocating Maintenance Manual Engine Oil separator hose Hose connection Hose clamp Fig. 85 - 9 Oil separator hose routing (for injector cover installation with maintenance lid) Oil separator hose Hose connection Fig. 85 - 10 Oil separator hose connection Fig.
  • Page 494 E4 Series Reciprocating Maintenance Manual Engine Hose clamp Injector plug Fig. 85 - 12 Hose clamp attachment Fig. 85 - 13 Injector plug Clamp Injector plug Fig. 85 - 15 Injector cover installation Fig. 85 - 14 Oil separator hose installation Fig.

  • Page 495: Gearbox

    E4 Series Reciprocating Maintenance Manual Engine 4. Gearbox A. Remove the Gearbox Detail Steps/Work Items Key Items/References Put a container with minimum 3 liters below the gearbox drain plug. Open the gearbox filler plug. Refer to Fig. 85 - 21.

  • Page 496: Install The Gearbox

    E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Use a support for the gearbox or lift the (18) gearbox with slings on the prop shaft. Refer to Fig. 85 - 20. Four different types of screws are used.
  • Page 497 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Remove the engine front lifting eyelet. Refer to Section 80-10-00 Paragraph Install the starter on the engine. 2.B. Refer to the applicable Aircraft Connect the pressure line to the governor, if Maintenance Manual.
  • Page 498 E4 Series Reciprocating Maintenance Manual Engine Drain plug Engine mount Fig. 85 - 17 Magnetic drain plug Engine mount Lock-wire Drain plug Fig. 85 - 19 Front right engine mount Fig. 85 - 18 Front left engine mount Screw Fig. 85 - 20 Gearbox drain plug...
  • Page 499 E4 Series Reciprocating Maintenance Manual Engine Filler plug el. connector Governor „GOV“ Gearbox Gearbox temperature sensor (GBTS) Pressure line Fig. 85 - 21 GBTS installation on the gearbox Page 211 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 500 E4 Series Reciprocating Maintenance Manual Engine Oil cooler Hose clamp Connecting hose Spring band clamp Coolant temperature sensor Hose connector Engine mount Engine Gearbox mount Fig. 85 - 22 Gearbox with optional Oil Cooler “-A” engine configuration Hose clamp Oil cooler...

  • Page 501: Remove The Optional Gearbox Oil Cooler

    E4 Series Reciprocating Maintenance Manual Engine C. Remove the optional Gearbox Oil Cooler Detail Steps/Work Items Key Items/References Remove the gearbox. Refer to paragraph A. Remove the screws and washers from the gearbox oil cooler. Refer to Fig. 85 - 24.
  • Page 502 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Use only new clamps. Put the second hose clamp on the (13) connecting hose as near as possible to the Refer to Fig. 85 - 22 and Fig. 85 - clamp installed before.

  • Page 503: Remove And Examine The Magnetic Drain Plug

    Drain the gearbox oil through the included The filter is included in the scheduled filter for bigger pieces and non-magnetic maintenance kit of Austro Engine. material. Put the magnetic drain plug into a solvent of oil contamination removal momentarily for a better debris inspection.

  • Page 504: Install The Magnetic Drain Pug

    E4 Series Reciprocating Maintenance Manual Engine F. Install the magnetic drain pug Detail Steps/Work Items Key Items/References Examine the gaskets for wear. If worn, use a new gasket. Lubricate the gasket with acid free lubricant. Torque 12 Nm. Install the magnetic drain plug.
  • Page 505 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 28 Magnetic drain plug inspection Page 217 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 506: Remove The Gearbox Oil Filter

    E4 Series Reciprocating Maintenance Manual Engine G. Remove the Gearbox Oil Filter Detail Steps/Work Items Key Items/References For a gearbox rev.79 to rev.90 installed on a “-B” or “-C” engine, the gearbox temperature sensor (GBTS) is installed instead of the plug screw.

  • Page 507: Install The Gearbox Oil Filter

    E4 Series Reciprocating Maintenance Manual Engine H. Install the Gearbox Oil Filter Detail Steps/Work Items Key Items/References For a gearbox rev. 70 to rev. 90 installed on a “-B” or “-C” engine, install the gearbox temperature sensor (GBTS) instead of the plug screw. Refer to Paragraph J.

  • Page 508: Remove The Gearbox Temperature Sensor

    E4 Series Reciprocating Maintenance Manual Engine Remove the Gearbox Temperature Sensor Detail Steps/Work Items Key Items/References Disconnect the electrical connector GBTS. Refer to Fig. 85 - 35. Remove the temperature sensor. Discard the sealing ring. Install the Gearbox Temperature Sensor...
  • Page 509 E4 Series Reciprocating Maintenance Manual Engine Temperature el. connector GBTS sensor Sealing ring Fig. 85 - 35 GBTS installation on gearbox rev. 65 or lower, or rev. 100 and higher Page 221 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 510: Gearbox Oil

    E4 Series Reciprocating Maintenance Manual Engine K. Gearbox Oil General gearbox oil information Oil type: Shell Spirax GSX 75W-80 Oil volume: 2.3 l Refer to Section 12-10-00 for gearbox oil level check instructions. (a) Drain the gearbox oil Refer to Paragraph E Step (2) to (5) for gearbox oil drain instructions.

  • Page 511: Two-Mass-Flywheel

    E4 Series Reciprocating Maintenance Manual Engine 5. Two-Mass-Flywheel Install only a hub and a two-mass flywheel approved for your engine configuration. If the hub and the two-mass flywheel are marked with serial numbers, the serial numbers must agree. If the hub or the two-mass flywheel is unserviceable, always replace the two components.

  • Page 512: Install The Two-Mass Flywheel

    E4 Series Reciprocating Maintenance Manual Engine B. Install the Two-Mass Flywheel Detail Steps/Work Items Key Items/References Put the two-mass flywheel in place on the engine crankshaft. Make sure the aligning pin is installed on the crankshaft. Use the flywheel locking tool.
  • Page 513 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References secondary and primary mass at the centering bore #2 and tap with a soft face hammer onto the hub at the elongated centering hole. Refer to Fig. 85 - 43.
  • Page 514 E4 Series Reciprocating Maintenance Manual Engine Screw Screw Fig. 85 - 39 Two-mass flywheel installation Centering pin #2 Centering pin #1 Fig. 85 - 40 Hub installation Gently tapping with soft faced hammer Page 226 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 515 E4 Series Reciprocating Maintenance Manual Engine Centering pin #2 Centering pin #1 Slotted lever bar approx. 8 mm thick Fig. 85 - 41 Hub alignment (Step 1) Slotted lever bar Fig. 85 - 42 Hub alignment (Step 2) Page 227 85-Maintenance Procedures E4.08.04...
  • Page 516 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 43 Hub alignment (Step 3) Screw Fig. 85 - 44 Hub installation Page 228 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 517: Examine The Hub

    E4 Series Reciprocating Maintenance Manual Engine C. Examine the Hub Detail Steps/Work Items Key Items/References No clearance is permitted between the two flanges. Before you remove the hub, make sure there If you see a clearance, replace the is no clearance between the flange of the two-mass flywheel and the hub.
  • Page 518 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 46 Engraving position Page 230 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 519: Examine The Two-Mass Flywheel

    E4 Series Reciprocating Maintenance Manual Engine D. Examine the Two-Mass Flywheel Overview The flywheel structure consists of two discs (masses):  Primary mass (E4A-73-300-201) – the bigger disc with the starter ring and pick up ring.  Secondary mass (E4A-73-300-202) – the smaller disc.
  • Page 520 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 48 Two-Mass Flywheel (back side) Page 232 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 521: Replace The Two-Mass Flywheel

    E4 Series Reciprocating Maintenance Manual Engine Starter ring Pick-up ring Fig. 85 - 49 Starter ring and Pick-up ring (with clearance) at the outer contour of the primary mass (a) Visual Inspection Detail Steps/Work Items Key Items/References Do the visual inspection before you clean the two-mass flywheel.
  • Page 522 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Measure the height mean value of the rivet The height of the rivet heads left heads. must not be less than 1.4 mm. Therefore, measure at minimum four of the eight rivet heads.
  • Page 523 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References The bearing friction ring is in the correct position when the inner diameter of the ring has approx. the same clearance to the outer diameter of the notch in the primary mass.
  • Page 524 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References If the balancing weights are missing Make sure that the balancing weights are not (you can see the weld points without loose or missing. the balancing weights), replace the two-mass flywheel.
  • Page 525 E4 Series Reciprocating Maintenance Manual Engine min. 1,5mm Wear due to interference requires additional measurement. Fig. 85 - 51 Wear of the inner rivet head Fig. 85 - 52 Measurement of the worn rivet head Page 237 85-Maintenance Procedures E4.08.04 Rev.
  • Page 526 E4 Series Reciprocating Maintenance Manual Engine Secondary mass Clearance Primary mass Fig. 85 - 53 Clearance between the primary and secondary mass Fig. 85 - 54 Dent at the cover of the spring-cage (not permitted) Page 238 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev.
  • Page 527 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 55 Large signs of grease leakage on the primary mass Centering pins Fig. 85 - 56 Two-mass flywheel top view Page 239 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 528 E4 Series Reciprocating Maintenance Manual Engine between 3 and 6 mm Fig. 85 - 57 Centering pins Correct position of the ring Fig. 85 - 58 Bearing friction ring position check Page 240 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 529 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 59 Damaged friction ring >0,5*t Fig. 85 - 60 Friction ring width Page 241 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 530 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 61 Pick-up ring tooth bend bending Fig. 85 - 62 Pick-up ring tooth bend Page 242 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 531 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 63 Pick-up ring tooth bend Fig. 85 - 64 Starter ring inspection Page 243 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 532 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 65 Balancing weight inspection Page 244 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 533 E4 Series Reciprocating Maintenance Manual Engine (b) Mechanical Inspection Detail Steps/Work Items Key Items/References Use the special testing rig AEP-0061 to do the Refer to Chapter 92. mechanical function inspection. Assemble the two-mass flywheel. Attach the two-mass flywheel with its primary Refer to Fig.
  • Page 534 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Use a torque wrench to apply the torque values specified in the Table 85-1 at the angle measuring gauge. To complete the mechanical inspection do the following steps: ...
  • Page 535 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 66 Tolerance limits diagram Page 247 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 536 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 67 Flywheel attachment adapter Fig. 85 - 68 Two-mass flywheel testing rig Page 248 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 537: Replace The Two-Mass Flywheel

    E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 69 Degree measuring gauge E. Replace the Two-Mass Flywheel Detail Steps/Work Items Key Items/References If you do not find any damage during the visual and mechanical inspection, the two- mass flywheel is serviceable on an E4 engine.

  • Page 538: Clean The Two-Mass Flywheel

    E4 Series Reciprocating Maintenance Manual Engine F. Clean the Two-Mass Flywheel Detail Steps/Work Items Key Items/References Clean the two-mass flywheel after the visual inspection is completed! Make sure that the cleaning agent or grease-dissolving materials do not get to the inner of the two-mass flywheel.
  • Page 539 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 70 Connecting Flange Engine Side Fig. 85 - 71 Connecting Flange Gearbox Side Page 251 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 540: Mark The Two-Mass Flywheel After Inspection

    E4 Series Reciprocating Maintenance Manual Engine G. Mark the Two-Mass Flywheel after inspection Detail Steps/Work Items Key Items/References Do not hit the part to prevent damage to the two-mass flywheel. Refer to Fig. 85 - 72. If you do not find any damage during the...

  • Page 541: Assembly The Two-Mass Flywheel

    E4 Series Reciprocating Maintenance Manual Engine H. Assembly the Two-Mass Flywheel Detail Steps/Work Items Key Items/References Install the two-mass flywheel. Refer to Paragraph 5.B. Pack and Ship the Two-Mass Flywheel Detail Steps/Work Items Key Items/References Put the overhauled two-mass flywheel in a Refer to Fig.

  • Page 542: Engine Carrier Mounting Gearbox

    E4 Series Reciprocating Maintenance Manual Engine 6. Engine carrier mounting gearbox A. Repair the damaged threads For repair, use a corrosion protective thread insert M8. Minimum material requirements for threaded insert: stainless steel A2 Part description: HELICOIL ® Plus from company BÖLLHOFF Item No.: 4130 008 0016...
  • Page 543 E4 Series Reciprocating Maintenance Manual Engine a. Engine carrier mounting RH side The installation of a threaded insert for a damaged thread is only permitted for the threads shown in the following figure. POS.2 POS.1 POS.4 POS.3 Fig. 85 - 75...
  • Page 544 E4 Series Reciprocating Maintenance Manual Engine b. Engine carrier mounting LH side The installation of a threaded insert for a damaged thread is only permitted for the threads shown in the following figure. POS.6 POS.5 POS.8 POS.7 Fig. 85 - 77 Gearbox engine carrier mounting LH side Sna pshot of E4A-70-000-000 AA.1 - 28.02.2017 13:50:16...

  • Page 545: Gearbox Shaft Seal

    E4 Series Reciprocating Maintenance Manual Engine 7. Gearbox Shaft Seal A. Remove the Gearbox Shaft Seal Detail Steps/Work Items Key Items/References Do not make scratches on the sealing surface of the gearbox housing and shaft! Remove the Gearbox. Refer to Paragraph 4.A.

  • Page 546: Install The Gearbox Shaft Seal

    E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 83 Hook tool B. Install the Gearbox Shaft Seal Detail Steps/Work Items Key Items/References Do not make scratches on the sealing surface of the gearbox housing and shaft! Use tool AEP-00132 to move the shaft...
  • Page 547 E4 Series Reciprocating Maintenance Manual Engine Shaft Seal AEP-00132 Fig. 85 - 84 Fig. 85 - 85 Retaining ring Shaft Seal Fig. 85 - 86 Shaft Seal installation position Page 259 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 548: Reciprocating Engine - Power Section

    E4 Series Reciprocating Maintenance Manual Engine 85-20-00 Reciprocating Engine - Power Section 1. Crankshaft Cover For removal and installation of the crankshaft cover, remove the engine from the aircraft. A. Remove the Crankshaft Cover Detail Steps/Work Items Key Items/References Refer to the applicable Aircraft Drain the coolant.

  • Page 549: Install The Crankshaft Cover

    Clean the sealing surface for oil sump. Apply engine sealing material at the joints. Refer to Fig. 85 - 89. The recommended engine sealing material is available at Austro Engine GmbH. Refer to the consumable list. Use a new oil sump gasket.
  • Page 550 E4 Series Reciprocating Maintenance Manual Engine Sleeve Fig. 85 - 87 Crankshaft cover and Fig. 85 - 88 Crankshaft cover with mounting sleeve mounting sleeve Crankshaft Cover Joint Joint Screw Fig. 85 - 89 Crankshaft cover installation Page 262 85-Maintenance Procedures E4.08.04...

  • Page 551: Reciprocating Engine - Cylinder Section

    E4 Series Reciprocating Maintenance Manual Engine 85-30-00 Reciprocating Engine - Cylinder Section 1. Intake Air System A. Remove the Intake Air Manifold Detail Steps/Work Items Key Items/References Refer to the applicable Aircraft Remove the intake hoses. Maintenance Manual. Put a container below the engine coolant drain.

  • Page 552: Install The Intake Air Manifold

    E4 Series Reciprocating Maintenance Manual Engine B. Install the Intake Air Manifold Detail Steps/Work Items Key Items/References Install a new gasket. Refer to Fig. 85 - 90. Put the intake air manifold in position above the cylinder head sealing area.
  • Page 553 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Refer to Fig. 85 - 93. Refer to the applicable Aircraft (14) Install the air intake hoses. Maintenance Manual. If the optional gearbox oil cooler is installed. (15) Install the gearbox.
  • Page 554 E4 Series Reciprocating Maintenance Manual Engine For engine configuration with new sensors (AEP-00286-901), use the parts with position numbers with “a” or other letters. Refer to Fig. 85 - 91. Hose connection O-Ring Sealing ring Fig. 85 - 91 Intake Air Inlet E4-A (if optional Gearbox Oil Cooler installed) Fig.
  • Page 555 E4 Series Reciprocating Maintenance Manual Engine Hose connection Collar screw Sealing ring O-Ring Spacer Intake Air Manifold Pressure sensor (BPS) Screw Temp. Sensor (CTS) Sealing ring Sealing ring Temp. Sensor (IAT) Plug screw Sealing ring Gasket Screw Screw Coolant thermostat Fig.
  • Page 556 E4 Series Reciprocating Maintenance Manual Engine For engine configuration with new sensors (AEP-00286-901), use the parts with position numbers with “a” or other letters. Refer to the Fig. 85 - 94. Hose connection O-Ring Sealing ring Fig. 85 - 94 Intake Air Version “-A”...
  • Page 557 E4 Series Reciprocating Maintenance Manual Engine O-Ring Intake Air Manifold Hose connection Sealing ring Spacer Temp. Pressure Sensor (CTS) sensor (BPS) Screw Sealing ring Sealing ring Temp. Screw Sensor (IAT) Sealing ring Gasket Screw Coolant Collar screw thermostat Fig. 85 - 95...
  • Page 558 E4 Series Reciprocating Maintenance Manual Engine For engine configuration with new sensors (AEP-00286-901), use the parts with position numbers with “a” or other letters. Refer to Fig. 85 - 96. Fig. 85 - 96 Intake Air Inlet E4-B Fig. 85 - 97...

  • Page 559: Boost Pressure Sensor (Bps)

    E4 Series Reciprocating Maintenance Manual Engine 2. Boost Pressure Sensor (BPS) A. Remove the BPS Detail Steps/Work Items Key Items/References Disconnect the electrical connectors BPS1 and BPS2. Remove the screws that attach the BPS on Refer to Fig. 85 - 90.
  • Page 560 E4 Series Reciprocating Maintenance Manual Engine If new sensors (AEP-00286-901) are installed, do the following steps: Detail Steps/Work Items Key Items/References Torque 15 Nm. Tighten the Boost Pressure Sensor [04a] with a new sealing ring [04b] on the spacer [04c].

  • Page 561: Intake Air Temperature Sensor (Iat)

    E4 Series Reciprocating Maintenance Manual Engine 3. Intake Air Temperature Sensor (IAT) A. Remove the IAT sensor Detail Steps/Work Items Key Items/References Disconnect the electrical connectors IAT1 and IAT2. Refer to Fig. 85 - 90. Remove the IAT sensors. B. Install the IAT sensor...

  • Page 562: Cylinder Head

    E4 Series Reciprocating Maintenance Manual Engine 4. Cylinder Head There are two cylinder head versions available:  Version 1: the old cylinder head with Part No E4A-12-100-000 and E4A-12-300-000  Version 2: the new cylinder head with Part No E4A-12-500-000 which can be identified by the marking I, II, III, IV on the cylinder head cover.

  • Page 563: Remove The Cylinder Head

    E4 Series Reciprocating Maintenance Manual Engine A. Remove the Cylinder Head Before the cylinder head replacement, complete a power analysis and collect the data. To make sure that the engine operates correctly, compare the collected data before and after the cylinder head replacement.
  • Page 564 E4 Series Reciprocating Maintenance Manual Engine Parts that are used again for the cylinder head installation:  Camshaft position sensors CAS 1 and CAS 2  Camshaft sensor housing for CAS 2, only if old camshafts are used  Exhaust manifold ...

  • Page 565: (A) Remove The Parts Attached To The Cylinder Head

    E4 Series Reciprocating Maintenance Manual Engine (a) Remove the parts attached to the cylinder head Detail Steps/Work Items Key Items/References Remove the injector cover. Refer to Paragraph 3.A. Remove the oil return line from the oil Refer to Section 79-20-00 Paragraph separator.

  • Page 566: (B) Remove The Cylinder Head Cover

    E4 Series Reciprocating Maintenance Manual Engine (b) Remove the cylinder head cover Detail Steps/Work Items Key Items/References Remove the screw [01] from the cylinder head Refer to Fig. 85 - 98. cover. Remove the camshaft position sensor CAS 1 Refer to Section 76-10-00 Paragraph from the cylinder head cover.

  • Page 567: (C) Remove The Camshaft Sensor Housing For Cas 2

    E4 Series Reciprocating Maintenance Manual Engine (c) Remove the Camshaft Sensor Housing for CAS 2 Detail Steps/Work Items Key Items/References Refer to Section 76-10-00 Paragraph Remove the camshaft position sensor CAS 2. 6.A. For CAS 2 is installed under the injector cover, refer to Fig. 85 - 100.
  • Page 568 E4 Series Reciprocating Maintenance Manual Engine CAS 1 CAS 2 Fig. 85 - 100 CAS 2 installed under the injector cover Page 280 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 569: (D) Remove The Rear Cylinder Head Cover

    E4 Series Reciprocating Maintenance Manual Engine (d) Remove the rear cylinder head cover Detail Steps/Work Items Key Items/References Remove the screws that attach the rear cylinder head cover. Refer to Fig. 85 - 101. Remove the rear cylinder head cover and the O-Ring.

  • Page 570: (E) Remove The Front Cylinder Head Cover

    E4 Series Reciprocating Maintenance Manual Engine (e) Remove the front cylinder head cover Detail Steps/Work Items Key Items/References Remove the 5 screws from the cylinder head cover. Refer to Fig. 85 - 102. Remove the front cylinder head cover and the O- Ring.

  • Page 571: (F) Remove The Chain Tensioner

    E4 Series Reciprocating Maintenance Manual Engine (f) Remove the chain tensioner Detail Steps/Work Items Key Items/References Remove the chain tensioner with the sealing ring Refer to Fig. 85 - 103. from the cylinder head. Sealing ring Chain tensioner Fig. 85 - 103 Chain tensioner...

  • Page 572: (H) Remove The Camshafts

    E4 Series Reciprocating Maintenance Manual Engine (h) Remove the camshafts Detail Steps/Work Items Key Items/References Remove the 7 screws from the camshaft bearings. Remove the camshaft bearing covers and the Refer to Fig. 85 - 105. bracket. Carefully remove the camshafts.

  • Page 573: (I) Remove The Egr (Exhaust Gas Recirculation) Closing Cover Top

    E4 Series Reciprocating Maintenance Manual Engine (i) Remove the EGR (Exhaust Gas Recirculation) closing cover top Detail Steps/Work Items Key Items/References Remove the 2 screws from the EGR cover. Refer to Fig. 85 - 106. Lift the EGR cover. EGR cover Screw Fig.

  • Page 574: (K) Remove The Cylinder Head Sub-Assembly From The Crankcase

    E4 Series Reciprocating Maintenance Manual Engine (k) Remove the cylinder head sub-assembly from the crankcase Detail Steps/Work Items Key Items/References Remove the 4 screws from the cylinder head. Refer to Fig. 85 - 108. Remove the 10 screws on the cylinder head cover Refer to Fig.
  • Page 575 E4 Series Reciprocating Maintenance Manual Engine Screw 10x Screw Screw Fig. 85 - 109 cylinder head screws removal sequence Page 287 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 576: Install The Cylinder Head

    E4 Series Reciprocating Maintenance Manual Engine B. Install the Cylinder Head For engine model E4: Use cylinder head assembly E4A-12-R10-000 for replacement. For engine model E4P: Use cylinder head assembly E4PA-12-R10-000 for replacement. Make sure you see no “EU5” mark on the cylinder head.
  • Page 577 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Clean the sealing surface of the cylinder head, if the cylinder head is installed again. Do not damage the cylinder head gasket. Put a new cylinder head gasket in position on the Refer to Fig.
  • Page 578 E4 Series Reciprocating Maintenance Manual Engine Screw Screw Screw Cylinder head Gasket Fig. 85 - 110 Cylinder head sub-assembly installation Fig. 85 - 111 Crankshaft TDC position Page 290 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 579 E4 Series Reciprocating Maintenance Manual Engine installation bushes Fig. 85 - 112 Crankcase installation bushes Screw [01] 10x Screw [02] Screw [02] Screw [03] Fig. 85 - 113 Cylinder head screws tightening sequence Page 291 85-Maintenance Procedures E4.08.04 Rev. 29...

  • Page 580: (B) Install The Egr Closing Cover Top

    E4 Series Reciprocating Maintenance Manual Engine (b) Install the EGR closing cover top Detail Steps/Work Items Key Items/References Put the EGR cover in place on the crankcase. Refer to Fig. 85 - 114. Tighten the 2 screws on the EGR cover.

  • Page 581: (D) Install The Camshafts

    E4 Series Reciprocating Maintenance Manual Engine Screw EGR cover Fig. 85 - 115 EGR cover bottom installation (d) Install the camshafts Detail Steps/Work Items Key Items/References Replace the camshafts when you replace the cylinder head. Camshafts can easily become damaged! Install the front and rear camshaft bearing Refer to Fig.
  • Page 582 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Make sure the camshafts turn easily, smoothly, and with no scratches after installation. Page 294 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 583 E4 Series Reciprocating Maintenance Manual Engine Camshaft bearing cover Screw Screw Bracket Screw Camshaft bearing cover Camshaft bearing cover Camshaft Camshaft Bearing bracket assembly Bearing bracket assembly Fig. 85 - 116 Camshafts installation Page 295 85-Maintenance Procedures E4.08.04 Rev. 29...
  • Page 584 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 117 Camshaft locking tool AE300T-009 Fig. 85 - 118 Camshaft locking tool AE300T-009 Page 296 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 585: (E) Install The Chain Gear

    E4 Series Reciprocating Maintenance Manual Engine (e) Install the chain gear Detail Steps/Work Items Key Items/References Fix the camshafts in position. Use Tool AE300T-009. Align the timing chain gear until it engages on the installed pin on Install the chain on the chain gear.

  • Page 586: (F) Install The Chain Tensioner

    E4 Series Reciprocating Maintenance Manual Engine (f) Install the chain tensioner Detail Steps/Work Items Key Items/References Torque 80 Nm. Tighten the chain tensioner with the sealing ring into the cylinder head. Refer to Fig. 85 - 121. Turn the engine and make sure that all parts move freely.

  • Page 587: (G) Install The Front Cylinder Head Cover

    E4 Series Reciprocating Maintenance Manual Engine (g) Install the front cylinder head cover Detail Steps/Work Items Key Items/References Clean the sealing surface on the front cylinder Refer to Fig. 85 - 122 and Fig. 85 head cover. - 123. Refer to the consumable list.

  • Page 588: (H) Install The Rear Cylinder Head Cover

    E4 Series Reciprocating Maintenance Manual Engine Cylinder head cover O-Ring Screw Fig. 85 - 123 Front cylinder head cover installation Cover Screw Fig. 85 - 124 Front cylinder head cover (Cylinder head version 2) (h) Install the rear cylinder head cover...

  • Page 589: (I) Install The Camshaft Sensor Housing For Cas 2

    E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Guide the two aligning pins into the corresponding bore at the cylinder head. Torque 12 Nm. Tighten the 4 screws on the cylinder head cover. Refer to Fig. 85 - 126.
  • Page 590 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Put the gasket in the groove of the sensor housing. Lubricate the O-Ring with engine oil. Use only a new O-Ring. Put the O-Ring in the groove of the sensor housing.
  • Page 591 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Install the shaft coupling assembly. If the stop bolt and/or the stop nut is loose, do the following steps: Remove the stop nut. Discard the stop nut. Remove any unwanted particles from the stop bolt and the sensor housing cover.
  • Page 592 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 127 Shaft coupling installation Fig. 85 - 128 CAS 2 Gasket O-Ring Screw Nose Sensor housing cover Washer Sensor housing Stop bolt Shaft coupling assembly Stop nut Screw Fig. 85 - 129 CAS 2 housing installation...

  • Page 593: (J) Install The Cylinder Head Cover

    E4 Series Reciprocating Maintenance Manual Engine (j) Install the cylinder head cover Detail Steps/Work Items Key Items/References Use only new seals. Install the inner and the outer seal into the cylinder head cover. Refer to Fig. 85 - 130. Before the cylinder head cover installation, apply engine oil on the screws.
  • Page 594 E4 Series Reciprocating Maintenance Manual Engine Screw [03] Screw [01] Screw [02] CAS 1 Cylinder head cover Screw [03] Outer seal Inner seal Fig. 85 - 130 Cylinder head cover installation Page 306 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 595 E4 Series Reciprocating Maintenance Manual Engine Tightening sequence for the cylinder head cover Tightening sequence ; Part number Fig. 85 - 131 Cylinder head cover - Tightening sequence Hexagon screw Plug O-Ring Fig. 85 - 132 CAS2 Sensor closure Page 307 85-Maintenance Procedures E4.08.04...

  • Page 596: (K) Install The Parts Attached To The Cylinder Head

    E4 Series Reciprocating Maintenance Manual Engine (k) Install the parts attached to the cylinder head Detail Steps/Work Items Key Items/References For assembly of the A/C installation, refer to the related A/C Maintenance Manual. Refer to Section 80-10-00 Install the glow plugs.
  • Page 597  Smooth engine run on ECU B (camshaft system correctly configured). Austro Engine GmbH will do a check of the data collected after the power analysis to make sure that no power loss occurred and to determine the airworthiness.

  • Page 598: Reciprocating Engine - Rear Section

    E4 Series Reciprocating Maintenance Manual Engine 85-40-00 Reciprocating Engine - Rear section 1. V-Ribbed Belt Do not lubricate the V-Ribbed belt. A. Remove the V-Ribbed Belt Detail Steps/Work Items Key Items/References Turn the screw on the tensioner Move the V-belt tensioner pulley clockwise to pulley.
  • Page 599 E4 Series Reciprocating Maintenance Manual Engine Screw Screw Locking pin Tensioner pulley Fig. 85 - 133 V-Ribbed belt Fig. 85 - 134 Locking pin Page 311 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 600: Belt Tensioner

    E4 Series Reciprocating Maintenance Manual Engine 2. Belt Tensioner A. Remove the Belt Tensioner Detail Steps/Work Items Key Items/References Remove the V-Ribbed belt. Refer to Paragraph 1.A. Remove the three screws from the tensioner. Remove the two hexagon socket screws from the bottom of the tensioner bracket.

  • Page 601: Belt Tensioner - Roller

    E4 Series Reciprocating Maintenance Manual Engine Screw Screw Screw V-belt tensioner Screw Tensioner pulley Washer Fig. 85 - 135 Belt tensioner 3. Belt Tensioner – Roller A. Remove the Belt Tensioner – Roller Detail Steps/Work Items Key Items/References Remove the V-Ribbed belt.

  • Page 602: Timing Chain

    E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Refer to Fig. 85 - 136. Install the V-Ribbed belt. Refer to Paragraph 1.B. Do an engine ground run. Refer to Section 71-00-01. Idler pulley Screw Screw Screw Tensioner pulley Fig.

  • Page 603: (B) Timing Chain Measuring Tool (Tcmt)

    E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Move the manifold until you get access to the chain tensioner. Air tube Intake air manifold Chain tensioner Coolant tank Fig. 85 - 137 Engine overview after cowling was removed (e.g. DA 42 installation)

  • Page 604: (C) Complete A Check Of The Timing Chain

    E4 Series Reciprocating Maintenance Manual Engine Aluminium seal Fig. 85 - 138 Timing Chain Measuring Tool (TCMT) Chain length not ok Red Indicator Rings Chain length ok Fig. 85 - 139 Indicator scale TCMT (c) Complete a check of the timing chain...
  • Page 605 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Refer to Fig. 85 - 140. Because of the aircraft system structure, identify the TDC position with a mirror or a torch light when the engine is installed on the aircraft.

  • Page 606: (D) Results Of The Timing Chain Check

    E4 Series Reciprocating Maintenance Manual Engine Pointer TDC Indicator Fig. 85 - 140 Belt pulley with TDC („OT“) indicator (d) Results of the timing chain check  If during the check sequence, in one of the check steps you see one or less of the red indicator ring on the TCMT scale, replace the timing chain and the camshaft chain wheel.

  • Page 607: (E) Assemble The Engine After The Timing Chain Check

    E4 Series Reciprocating Maintenance Manual Engine (e) Assemble the engine after the timing chain check Detail Steps/Work Items Key Items/References All engine configurations Remove the TCMT. Turn the TCMT by hand. Use a new gasket for the chain Put the chain tensioner in place at the related tensioner (Part No.

  • Page 608: Replace The Timing Chain And The Camshaft Chain Wheel

    E4 Series Reciprocating Maintenance Manual Engine B. Replace the Timing Chain and the Camshaft Chain Wheel The following parts are used to replace the timing chain and the chain wheel: Part Number Quantity Description E4A-75-100-000 Timing chain, open version Chain link, part of Timing chain...

  • Page 609: (A) Prepare For Timing Chain And Camshaft Chain Wheel Replacement

    E4 Series Reciprocating Maintenance Manual Engine (a) Prepare for timing chain and camshaft chain wheel replacement Detail Steps/Work Items Key Items/References To get access to the chain drive, do the following steps. Remove the intake air hoses. Refer to the applicable Aircraft Maintenance Manual.
  • Page 610 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References the chain wheel seen from the rear side of the engine. Refer to Fig. 85 - 145. (15) Remove the TCMT. Turn the TCMT by hand. Fig. 85 - 142 Cylinder head cover removal Fig.
  • Page 611 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 144 Chain guiding bar (AEP-00139) installed at the cylinder head Page 323 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...

  • Page 612: (B) Replace The Timing Chain

    E4 Series Reciprocating Maintenance Manual Engine (b) Replace the timing chain Detail Steps/Work Items Key Items/References Choose a pin between chain guiding bar and cable retainer. Make sure the pin is in the counterclockwise hole of an inner To open the chain, put the chain opening tool link.
  • Page 613 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Tighten the new chain on the chain wheel (10) with a cable retainer at approx. two links from the connection link. Make sure the chain coupling from the tool kit is not left in the engine.
  • Page 614 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Do the same riveting procedure for the (20) second pin. (21) Remove the chain closing tool. (22) Complete a check of the pin head riveting. Refer to Fig. 85 - 152.
  • Page 615 E4 Series Reciprocating Maintenance Manual Engine AEP-00160 Fig. 85 - 146 Chains connection via link Fig. 85 - 147 Thread in the new timing chain Page 327 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 616 E4 Series Reciprocating Maintenance Manual Engine Open chain link Fig. 85 - 148 Connection of the new chain ends and the open link Chain clip Pressure pad Fig. 85 - 149 Chain clip positioned in the chain closing tool Page 328 85-Maintenance Procedures E4.08.04...
  • Page 617 E4 Series Reciprocating Maintenance Manual Engine Open chain link Open chain clip Fig. 85 - 150 Riveting of the chain link Fig. 85 - 151 Riveting slot at the chain closing tool Page 329 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 618 E4 Series Reciprocating Maintenance Manual Engine Riveted pin heads Fig. 85 - 152 Riveted pin heads of the new timing chain Page 330 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 619: (C) Replace The Timing Chain Wheel

    E4 Series Reciprocating Maintenance Manual Engine (c) Replace the timing chain wheel Detail Steps/Work Items Key Items/References Turn the engine to the TDC (top dead center) Refer to Fig. 85 - 153. position. Incorrect alignment of the marks on the camshafts timing wheels will reduce the available power.
  • Page 620 E4 Series Reciprocating Maintenance Manual Engine Detail Steps/Work Items Key Items/References Before you turn the engine, remove all materials used as covers for the chain slot. Turn the engine carefully. If a stop or resistance occurs, turn the engine back and do the timing setting check again.
  • Page 621 E4 Series Reciprocating Maintenance Manual Engine Fig. 85 - 154 Punch marks at timing wheels of two camshafts. Fig. 85 - 155 AE300-T009 at the camshafts Page 333 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 622 E4 Series Reciprocating Maintenance Manual Engine Centering pin Fig. 85 - 156 New chain wheel with timing chain installed at the camshaft Page 334 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 623: (D) Assemble The Engine After Timing Chain And Chain Wheel Replacement

    E4 Series Reciprocating Maintenance Manual Engine (d) Assemble the engine after timing chain and chain wheel replacement Detail Steps/Work Items Key Items/References Clean the sealing surfaces at the side cover and the cylinder head. Apply a line of sealant to the sealing surface of the cylinder head.
  • Page 624 E4 Series Reciprocating Maintenance Manual Engine Camshaft slot Fig. 85 - 157 Side cover at cylinder head Page 336 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...

  • Page 625: Reciprocating Engine - Liquid Cooling

    E4 Series Reciprocating Maintenance Manual Engine 85-50-00 Reciprocating Engine – Liquid Cooling 1. Coolant Temperature Sensor A. Remove the Coolant Temperature Sensor Detail Steps/Work Items Key Items/References Refer to the applicable Aircraft Drain the coolant. Maintenance Manual. Disconnect the electrical connector “CTS, CTS_GPC”.

  • Page 626: Water Pump

    E4 Series Reciprocating Maintenance Manual Engine 2. Water Pump A. Remove the Water Pump Detail Steps/Work Items Key Items/References Drain the coolant. Refer to the applicable Aircraft Maintenance Manual. Remove the coolant pipe. Refer to Section 85-40-00 Paragraph Remove the V-Ribbed belt.
  • Page 627 E4 Series Reciprocating Maintenance Manual Engine Water pump Screw Sealing ring O-Ring Screw Fig. 85 - 158 Water Pump Fig. 85 - 159 Water Pump C. Remove the Water Pump Bearing Housing Assembly Detail Steps/Work Items Key Items/References Drain the coolant.
  • Page 628 E4 Series Reciprocating Maintenance Manual Engine D. Install the Water Pump Bearing Housing Assembly Detail Steps/Work Items Key Items/References Use a new profile gasket. Lubricate the profile gasket with engine oil. Put the profile gasket in the specified notch of Refer to Fig.
  • Page 629 E4 Series Reciprocating Maintenance Manual Engine Water pump bearing housing Water pump bearing housing Gasket Screw Belt pulley Bolt Fig. 85 - 160 Exploded view of the water pump bearing housing Belt pulley Gasket Bolt Water pump bearing housing Fig. 85 - 161...
  • Page 630 E4 Series Reciprocating Maintenance Manual Engine 3. Heat Exchanger A. Remove the heat exchanger Detail Steps/Work Items Key Items/References Refer to Section 79-20-00 Paragraph Remove the oil filter housing drain line. 4.A. Refer to Section 79-20-00 Paragraph Remove the oil filter housing.
  • Page 631 E4 Series Reciprocating Maintenance Manual Engine Screw Screw Heat exchanger Fig. 85 - 162 Heat Exchanger Page 343 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 632 E4 Series Reciprocating Maintenance Manual Engine 4. Coolant Thermostat A. Remove the coolant thermostat Detail Steps/Work Items Key Items/References Drain the coolant. Refer to the applicable Aircraft Remove the coolant hoses attached to the Maintenance Manual. coolant thermostat. Remove the two screws from the coolant thermostat.
  • Page 633 E4 Series Reciprocating Maintenance Manual Engine Screw Coolant thermostat Fig. 85 - 163 Coolant thermostat Fig. 85 - 164 Coolant thermostat installation Page 345 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 634 E4 Series Reciprocating Maintenance Manual Engine 85-60-00 Governor The Governor is not part of the engine. For detailed information, refer to the applicable Aircraft Maintenance Manual. A. Remove the Governor Detail Steps/Work Items Key Items/References Remove the electrical connector (GOV).
  • Page 635 E4 Series Reciprocating Maintenance Manual Engine Oil hose Fig. 85 - 165 Governor installation Fig. 85 - 166 Governor installation Fig. 85 - 167 Gasket installation Page 347 85-Maintenance Procedures E4.08.04 Rev. 29 01-Jul-2020...
  • Page 636 E4 Series Reciprocating Maintenance Manual Engine Intentionally left blank Page 348 85-Maintenance Procedures E4.08.04 01-Jul-2020 Rev. 29...
  • Page 637 E4 Series Additional Maintenance Manual Information CHAPTER 92 ADDITIONAL INFORMATION Page 1 92 - Title E4.08.08 Rev. 29 01-Jul-2020...
  • Page 638 E4 Series Additional Maintenance Manual Information Intentionally left blank Page 2 92 - Title E4.08.04 01-Jul-2020 Rev. 29...
  • Page 639 E4 Series Additional Maintenance Manual Information Table of Contents Chapter 92 92-00-00 Wiring Diagrams ....................1 Engine Wiring Diagrams for E4A-90-000-000 ..............1 Engine Wiring Diagrams for E4A(B)-95-000-000 Revision AA.1 and subsequent ....3 Engine Wiring Diagrams for E4A(B)-95-000-000 Revision AB.1 and higher ......5 Aircraft Interface Wiring ....................
  • Page 640 E4 Series Additional Maintenance Manual Information Intentionally left blank Page 2 92 - Contents E4.08.04 01-Jul-2020 Rev. 29...

  • Page 641: Wiring Diagrams

    E4 Series Additional Maintenance Manual Information 92-00-00 Wiring Diagrams A. Engine Wiring Diagrams for E4A-90-000-000 Fig. 92 - 1 Page 1 92 – Wiring Diagrams E4.08.09 Rev. 29 01-Jul-2020...
  • Page 642 E4 Series Additional Maintenance Manual Information Fig. 92 - 2 Page 2 92 – Wiring Diagrams E4.08.04 01-Jul-2020 Rev. 29...

  • Page 643: Engine Wiring Diagrams For E4A(B)-95-000-000 Revision Aa.1 And Subsequent

    E4 Series Additional Maintenance Manual Information B. Engine Wiring Diagrams for E4A(B)-95-000-000 Revision AA.1 and subsequent Fig. 92 - 3 Page 3 92 – Wiring Diagrams E4.08.09 Rev. 29 01-Jul-2020...
  • Page 644 E4 Series Additional Maintenance Manual Information Fig. 92 - 4 Page 4 92 – Wiring Diagrams E4.08.04 01-Jul-2020 Rev. 29...
  • Page 645 E4 Series Additional Maintenance Manual Information Engine Wiring Diagrams for E4A(B)-95-000-000 Revision AB.1 and higher Fig. 92 - 5 Page 5 92 – Wiring Diagrams E4.08.09 Rev. 29 01-Jul-2020...
  • Page 646 E4 Series Additional Maintenance Manual Information Fig. 92 - 6 Page 6 92 – Wiring Diagrams E4.08.04 01-Jul-2020 Rev. 29...

  • Page 647: Aircraft Interface Wiring

    E4 Series Additional Maintenance Manual Information D. Aircraft Interface Wiring A/C Interface CPC connector 1 EECU Sensor Supply Power Lever Sensor Signal Sensor Sensor GND ECU A Sensor Supply Sensor Signal Sensor GND Display and Connect to display unit and provide separate...
  • Page 648 E4 Series Additional Maintenance Manual Information Alternator Regulator E4A – 91-200-000 Supply Voltage Bus Voltage Lamp Alternator Enable Alternator CPC connector 2 Alternator Feather Feather Valve Used in twin engine installations Valve Switch Fuel Pump Relay Output A Fuel Pump Relay A...
  • Page 649 E4 Series Additional Maintenance Manual Information Regulator Plane Power R1224 Lamp Alternator Enable Alternator CPC connector 2 Alternator Feather Feather Valve Used in twin engine installations Valve Switch Fuel Pump Relay Output A Fuel Pump Relay A Fuel Pump Relay Output B...

  • Page 650: Propeller Self-Test (Automatic Run-Up Test)

    E4 Series Additional Maintenance Manual Information 92-10-00 Propeller Self-Test (Automatic Run-Up Test) Self-Test Overview: The following diagram shows the sequence of events, checks and results expected by the EECU software while running the propeller self-test procedure. Begin  A/C on the ground ...
  • Page 651 E4 Series Additional Maintenance Manual Information Diagnostic Trouble Code (DTC) = 1C01 Propeller self-test failure (MAX: Timeout during propeller self-test) Time of first and last occurrence Day, hour, minutes and second Propeller speed = 1886 rpm Propeller self-test internal state = 03 (Refer to figure “Self-Test Overview”)
  • Page 652 E4 Series Additional Maintenance Manual Information Troubleshooting Steps: 1. Display the FCM entry (fault details) 2. The “propeller self-test internal state” provides the number of the phase which has been aborted. Refer to the “Self-Test Overview” to understand what the expected result of the phase was.
  • Page 653 E4 Series Additional Maintenance Manual Information Each ECU senses the power lever position separately. So, if the power lever sensors are not properly aligned, one ECU might release the self-test with power lever position <5% while the other ECU might not release the self-test because it senses a position >5%.
  • Page 654 E4 Series Additional Maintenance Manual Information The AE 300 Wizard will display the Data Logger record of a failure during the propeller self-test similar to the following example (a faulty propeller governor with SW-Version VC33_x_05_yy): The self-test occurrence can be found by looking for the characteristic two “humps” in the propeller speed-line when at the same time the power lever is at “0%”.
  • Page 655 E4 Series Additional Maintenance Manual Information 92-20-00 Special Tools Title Tool Remark AE 300 Wizard EECU Software Read Out Program For installation and usage of the The user guide E4.08.09 of the AE 300 Wizard will Software, refer to be delivered with the program the user guide E4.08.09.

  • Page 656: Special Tools

    E4 Series Additional Maintenance Manual Information Title Tool Remark Two-Mass- AEP-00061 Flywheel Tester Hammering tool AE300T-010 Camshaft locking AE300T-009 tool Page 16 92 – Special Tools E4.08.04 01-Jul-2020 Rev. 29...
  • Page 657 E4 Series Additional Maintenance Manual Information Title Tool Remark Gearbox shaft AEP-00131 seal installation Protective tube AEP-00132 for gearbox Sna pshot of AEP-00131 AA.1 - 09.03.2017 08:46:58 input shaft Page 17 92 – Special Tools E4.08.04 Rev. 29 01-Jul-2020...
  • Page 658 These technical data and the information contain therein are the property of Austro Engine GmbH and may not be reproduced either in full or in part or passed on to a third party without written consent from Austro Engine GmbH.

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