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BRP ROTAX 916 i A Series Maintenance Manual
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BRP ROTAX 916 i A Series Maintenance Manual

BRP ROTAX 916 i A Series Maintenance Manual

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MAINTENANCE
MANUAL LINE
FOR ROTAX ENGINE TYPE 916 i A/C24 SERIES
REF NO.: MML-916 i A/C24 | PART NO.: 898869

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Summary of Contents for BRP ROTAX 916 i A Series

  • Page 1 MAINTENANCE MANUAL LINE FOR ROTAX ENGINE TYPE 916 i A/C24 SERIES REF NO.: MML-916 i A/C24 | PART NO.: 898869...
  • Page 2 WARNING Before starting any maintenance work, please read the ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the Maintenance Manual completely as it contains important following document the short form of BRP-Rotax GmbH & safety relevant information. Failure to do so may result Co KG = BRP-Rotax is used.

  • Page 3: Table Of Contents

    BRP-Rotax MAINTENANCE MANUAL LINE Table of Content Chapter INTRO – GENERAL NOTE Chapter LEP – LIST OF EFFECTIVE PAGES Chapter TOA – TABLE OF AMENDMENTS Chapter 00–00–00 – GENERAL NOTE Chapter 04–00–00 – AIRWORTHINESS LIMITATIONS Chapter 05–00–00 – MAINTENANCE Chapter 05–10–00 –...
  • Page 4 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 916 i A / C24 December 01 2023...

  • Page 5: General Note

    ROTAX® Authorized Aircraft Engines Distributors or their independent Service Centers. BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX®-aircraft engine. The structure of the Manual follows whenever it is possible the structure of the ATA (Air Transport Association) standards.
  • Page 6 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 916 i A / C24 December 01 2023...
  • Page 7 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: LEP LIST OF EFFECTIVE PAGES Each new revision to the Maintenance Manual Line will have a new List of Effective Pages. Chapter Page Date Chapter Page Date Cover December 01 2023 page 05-00-00 December 01 2023...
  • Page 8 BRP-Rotax MAINTENANCE MANUAL LINE Chapter Page Date Chapter Page Date December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023...
  • Page 9 BRP-Rotax MAINTENANCE MANUAL LINE Chapter Page Date Chapter Page Date December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023 December 01 2023...
  • Page 10 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 4 Effectivity: 916 i A / C24 December 01 2023...
  • Page 11 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: TOA TABLE OF AMENDMENTS Approval* The technical content of this document is approved under the authority of the DOA ref. EASA.21J.048 NOTE THE APPROVAL IS GIVEN TO ALL CHAPTERS EXCEPT THE AIRWORTHINESS LIMITATIONS SECTION 04-00-00 WHICH IS SUBJECT TO SPECIFIC APPROVAL OF THE EASA.
  • Page 12 BRP-Rotax MAINTENANCE MANUAL LINE page chapter date of change remark for date of date of signature approval approval inclusion from authorities 05-10-00 Dec. 01 2023 DOA* 05-20-00 Dec. 01 2023 DOA* 05-50-00 Dec. 01 2023 DOA* 12-00-00 Dec. 01 2023...
  • Page 13 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 00–00–00 GENERAL NOTE TOPICS IN THIS CHAPTER General..............................2 Abbreviations and terms (depending on respective engine type)............3 Wiring color codes ..........................8 Conversion table ...........................9 Safety notice ............................10 Safety information ..........................11 Instruction............................13 Maintenance Concept..........................14 Technical documentation........................15 Use for intended purpose ........................17...

  • Page 14: General

    BRP-Rotax MAINTENANCE MANUAL LINE GENERAL Purpose The purpose of this Manual is to provide aircraft manufacturers with technical require- ments (e.g. interface descriptions and limitations) that must be adhered to when installing this type of engine into an aircraft or certifying aircraft powered by this engine type. Fur- thermore it should allow independent ROTAX®...

  • Page 15: Abbreviations And Terms (Depending On Respective Engine Type)

    BRP-Rotax MAINTENANCE MANUAL LINE ABBREVIATIONS AND TERMS (DEPENDING ON RESPECTIVE ENGINE TYPE) Abbreviations Description Reference to another section center of gravity The drop symbol indicates use of sealing agents, adhesives or lubri- cants (only in the Maintenance Manual Heavy) °C Degrees Celsius (Centigrade) °F...
  • Page 16 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description clockwise counter-clockwise CGSB Canadian General Standards Board DCDI Dual Capacitor Discharge Ignition direct current Design Organisation Approval Department of Transport EASA European Aviation Safety Agency Installation Manual Engine Control Unit Exhaust Gas Temperature Introduction...
  • Page 17 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description Illustrated Parts Catalog inch per second iRMT independent ROTAX Maintenance Technician International Standard Atmosphere Kilograms KNOCK Knock sensor Lane A System A of Engine Management System Lane B System B of Engine Management System...
  • Page 18 MAINTENANCE MANUAL LINE Abbreviations Description Power Take Off Rev. Revision ROTAX® is a trademark of BRP-Rotax GmbH & Co KG Research Octane Number RON 424 ROTAX® Standard 424 s.v. still valid (only Illustrated Parts Catalog) Serial Number Society of Automotive Engineers...
  • Page 19 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description Connector on Engine Management System wiring harness which serves as an interface for power supply XXXX shows the component serial number Effectivity: 916 i A / C24 00–00–00 Edition 0/Rev. 1 Page 7 December 01 2023...

  • Page 20: Wiring Color Codes

    BRP-Rotax MAINTENANCE MANUAL LINE WIRING COLOR CODES Figure 1.2 00–00–00 Effectivity: 916 i A / C24 Edition 0/Rev. 1 Page 8 December 01 2023...

  • Page 21: Conversion Table

    BRP-Rotax MAINTENANCE MANUAL LINE CONVERSION TABLE Units of length: Units of power: 1 mm = 0.03937 in 1 kW = 1.341 hp 1 in = 25.4 mm 1 hp = 0.7457 kW 1 ft = 12 in 1 kW = 1.3596 PS = 0.3048 m...

  • Page 22: Safety Notice

    The information and descriptions of components and systems contained in this Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous im- provement of its products without imposing upon itself any obligation to retrofit products previously manufactured.

  • Page 23: Safety Information

    • Due to the varying designs, equipment and types of aircraft, BRP-Rotax grants no war- ranty on the suitability of its engines use on any particular aircraft. Further, BRP-Rotax...
  • Page 24 BRP-Rotax MAINTENANCE MANUAL LINE Engine operation • The engine must always be operated according to the content of the latest Operators Manual (OM) • To eliminate the risk of injury or damage, ensure any loose equipment or tools are prop- erly secured before starting the engine •...

  • Page 25: Instruction

    Accessories This engine must only be operated with accessories supplied, recommended and re- leased by BRP-Rotax. Modifications are only allowed after consent of the engine manufacturer. Spare parts See Illustrated Parts Catalog (IPC), latest issue for the respective engine type.

  • Page 26: Maintenance Concept

    BRP-Rotax MAINTENANCE MANUAL LINE MAINTENANCE CONCEPT General note The maintenance functions detailed in this Manual are divided into two categories: • Maintenance I (Line Maintenance) • Maintenance II (Heavy Maintenance) Repairs beyond the levels detailed in Manual I and Maintenance Manual II are not recom- mended as maintenance functions and must be in accordance to the current Overhaul Manual (OHM) for the respective engine type.

  • Page 27: Technical Documentation

    BRP-Rotax MAINTENANCE MANUAL LINE TECHNICAL DOCUMENTATION These documents form the instructions ensuring continued airworthiness of ROTAX® air- craft engines. The information contained herein is based on data and experience that are considered ap- plicable for authorized mechanics (iRMT, see MML, Chapter 05–00–00 section “Author- ized Personnel”) under normal conditions for engine removal and installation.
  • Page 28 BRP-Rotax MAINTENANCE MANUAL LINE This symbol informs you of additional references (data sheets, Manuals, etc.) associated with the given subject. Illustrations The illustrations in this Manual are merely sketches and show typical arrangements. They may not represent full detail or the exact shape of the parts but should outline the same or similar function.

  • Page 29: Use For Intended Purpose

    NOTE These engines are technically equivalent to certified engines and have been man- ufactured by BRP-Rotax using the same quality assurance system. Engine stoppage In using the engine the operator assumes all risk of use and acknowledges that he/she knows this engine is subject to sudden stoppage.
  • Page 30 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 18 Effectivity: 916 i A / C24 December 01 2023...

  • Page 31: Airworthiness Limitations

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 04–00–00 AIRWORTHINESS LIMITATIONS TOPICS IN THIS CHAPTER Approval THE AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE EUROPEAN AVIATION SAFETY AGENCY (EASA) IN ACCORDANCE WITH PART 21A.31(a)(3) AND FAR 33.4. ANY CHANGE TO MANDATORY REPLACEMENT TIME, INSPECTION INTERVAL, AND RELATED PROCEDURES CONTAINED IN THIS AIRWORTHINESS LIMITATIONS SECTION MUST ALSO BE APPROVED.
  • Page 32 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 916 i A / C24 December 01 2023...

  • Page 33: Maintenance

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–00–00 MAINTENANCE TOPICS IN THIS CHAPTER General note ............................2 Authorized personnel ..........................4 Procedure notes ............................5 Troubleshooting ............................7 Consumable materials..........................8 Acceptable methods, techniques and practice ..................12 Introduction The information given in the Maintenance Manual is based on data and experience which are considered to be applicable for a skilled aviation mechanic (iRMT) under normal working conditions.

  • Page 34: General Note

    We particularly emphasize that parts and accessories not supplied as genuine BRP-Rotax accessories parts are not verified for suitability by BRP-Rotax and thus are not authorized for use. In- stallation and/or use of such products may possibly change or negatively influence the constructive characteristics of the engine.
  • Page 35 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE Be sure to use the recommended tightening torque for the specified fastener. NOTE When possible, always apply torque on the nut. NOTE Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are used to secure a part. Some parts must be torqued according to a specific sequence and torque pattern as detailed in the installation procedure.

  • Page 36: Authorized Personnel

    • ensure the requirements of the applicable regulatory authority regarding running a maintenance organization are met For more detailed information, maintenance organizations and individuals are encouraged to contact BRP-Rotax through its worldwide distribution network for information and guid- ance on any of the tasks outlined herein. Chapter 00-00-00 section Technical Documentation.

  • Page 37: Procedure Notes

    BRP-Rotax MAINTENANCE MANUAL LINE PROCEDURE NOTES General note m WARNING Non-compliance can result in serious injuries or death! When carrying out maintenance and service work, respect all safety regulations. Ignition “OFF“ m WARNING Non-compliance can result in serious injuries or death! This precautionary measure serves to avoid any injuries in case of an unintentional start of the engine.
  • Page 38 BRP-Rotax MAINTENANCE MANUAL LINE Disassembly At disassembly of the engine, mark the components as necessary to avoid any mix-up. Take care of these marks, don’t ruin them. Tool NOTICE In order to avoid mechanical damage, always loosen or tighten screws and nuts with specified tools.

  • Page 39: Troubleshooting

    BRP-Rotax MAINTENANCE MANUAL LINE TROUBLESHOOTING General notes Possible problems are listed in the Operators Manual (OM). At the same time, a brief de- scription of the necessary remedial action is given. See Chapter 4 in the Operators Manual (OM) for engine type 916 i A Series.

  • Page 40: Consumable Materials

    BRP-Rotax MAINTENANCE MANUAL LINE CONSUMABLE MATERIALS NOTICE Use only the specified or technically equivalent materials for all maintenance work. NOTICE When handling chemicals, comply with all the customary regulations and specifi- cations of the producer, including the expiry date and instructions of use.
  • Page 41 BRP-Rotax MAINTENANCE MANUAL LINE Part no. Description, application Qty. 897330 LITHIUM-BASE GREASE 250 g Electrical isolating (0.55 lb) n.a. Engine oil For easier assembly of components or for first lubrica- tion before first engine start 899791 LOCTITE 5910 50 ml (0.013 gal...
  • Page 42 BRP-Rotax MAINTENANCE MANUAL LINE Additional materials NOTICE All metal and synthetic parts should be cleaned with suitable cleaning agents. Before using new and unknown cleaning agents, check their compatibility with the materials they are being used on. Part no. Description, application Qty.
  • Page 43 BRP-Rotax MAINTENANCE MANUAL LINE Part no. Description, application Qty. n.a. Valve lapping paste This paste, produced by various manufacturers, is a fine granulate lapping paste for manual lapping of valve seats and valves. The paste is usually available in 3 dif- ferent granulate sizes.

  • Page 44: Acceptable Methods, Techniques And Practice

    BRP-Rotax MAINTENANCE MANUAL LINE ACCEPTABLE METHODS, TECHNIQUES AND PRACTICE General note All general inspection, maintenance and repair has to be carried out in accordance with Advisory Circular AC 43.13 from FAA. Advisory Circular This Manual "Advisory Circular" AC describes maintenance methods, techniques and practice.
  • Page 45 BRP-Rotax MAINTENANCE MANUAL LINE NOTE Lock washer When fitting lock washers, the curved-up ends (1) must point towards the screw head or nut. Figure 2.2: Lock washer Effectivity: 916 i A / C24 05–00–00 Edition 0/Rev. 1 Page 13 December 01 2023...
  • Page 46 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 14 Effectivity: 916 i A / C24 December 01 2023...

  • Page 47: Time Limits

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–10–00 TIME LIMITS TOPICS IN THIS CHAPTER Definition of terms ...........................2 Operating hours ............................2 Terminology ............................2 Time limit ..............................3 Life cycle ..............................3 General overhaul (TBO).........................3 Purging the oil system..........................3 Time Limit..............................4 Time limit for parts ..........................6 Time limit for the coolant ........................6...

  • Page 48: Definition Of Terms

    • In aviation there are different measurement methods used as an acceptable means to record operating time elapsed. • BRP-Rotax does not mandate a specific method to record time elapsed as a basis for maintenance and overhaul intervals. • BRP-Rotax therefore relies on common practice and defers to the aircraft original equip- ment manufacturer and/or local regulations.

  • Page 49: Time Limit

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT Definition Time limits are predetermined time spans and intervals which are based either on calen- dar intervals or the number of engine operating hours. Once the time limits have been reached, the affected parts must either be replaced for a general overhaul, or mainte- nance work must be performed.

  • Page 50: Time Limit

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT General NOTICE A general overhaul is due after a defined period of operation or after a specified calendar life since initial start of operation (whichever comes first). The time limit for engine operation will be specified by the TBO.
  • Page 51 BRP-Rotax MAINTENANCE MANUAL LINE Shipment The appropriation for the overhaul must include the following: Engine log book (including date and time of engine removal). Maintenance records of the engine (i.e. all maintenance check lists, and re- ports of operation, of maintenance, of findings and of oil analyses).

  • Page 52: Time Limit For Parts

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT FOR PARTS General note NOTICE This time limit must be followed independently and in addition to the visual in- spections (see Chapter 05-20-00 section: Visual Inspection) of the respective components. Time limit The following components and systems must be replaced every 5 years: •...

  • Page 53: Scheduled Maintenance Checks

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–20–00 SCHEDULED MAINTENANCE CHECKS TOPICS IN THIS CHAPTER Scheduled maintenance checks ......................2 Unscheduled maintenance checks ......................3 Visual inspection .............................4 Maintenance schedule procedures (maintenance check list) ..............5 Check List/Maintenance Schedule......................6 Maintenance Schedule ..........................8 Introduction The owner and/or user is primarily responsible for the maintenance and airworthiness of the engine.

  • Page 54: Scheduled Maintenance Checks

    BRP-Rotax MAINTENANCE MANUAL LINE SCHEDULED MAINTENANCE CHECKS Definition This section lists the periodic inspections which must be carried out after specified periods of operation. Intervals Periodic inspections are those which must be performed at 25, 100, 200, 600 hr. intervals...

  • Page 55: Unscheduled Maintenance Checks

    BRP-Rotax MAINTENANCE MANUAL LINE UNSCHEDULED MAINTENANCE CHECKS Operating limits An inspection of the engine must be performed if the operating limits of the engine have exceeded been exceeded (e.g. overspeed, excessive temperature etc.), or if unusual operating con- ditions have occurred during operation (e.g. lightning strike). In such cases the engine must be inspected in accordance with the applicable unscheduled maintenance checks.

  • Page 56: Visual Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE VISUAL INSPECTION General note The scope of a visual inspection generally includes, but is not necessarily limited to, the following: Moving parts Normal operating condition, accurate alignment, leak-tightness, cleanliness, ease of movement, adjustment, mechanical stress, travel, catching, extreme wear, cracks, corro- sion, deformation and other visually evident damage.

  • Page 57: Maintenance Schedule Procedures (Maintenance Check List)

    BRP-Rotax MAINTENANCE MANUAL LINE MAINTENANCE SCHEDULE PROCEDURES (MAINTENANCE CHECK LIST) Inspections All stated checks are visual inspections for damage and wear, unless otherwise stated. Specified period All listed work must be carried out within the specified period. Maintenance Checks are carried out as per the maintenance check lists, where type and volume of check lists maintenance work is outlined in key words.

  • Page 58: Check List/Maintenance Schedule

    BRP-Rotax MAINTENANCE MANUAL LINE CHECK LIST/MAINTENANCE SCHEDULE Identification AIRCRAFT Registration number Aircraft make Aircraft model and S/N Time since new ENGINE Engine type Engine S/N TSN (time since new) TSO (time since overhaul) ECU S/N FUSE BOX Used operating fluids: Coolant •...
  • Page 59 BRP-Rotax MAINTENANCE MANUAL LINE Identification AIRCRAFT OPERATOR Name Contact Address Telephone/Fax E-mail MAINTENANCE FACILITY Maintenance workshop Address Telephone/Fax E-mail Certificate This check is applica- 1000 50 hr. 25 hr. 100 hr. 200 hr. 400 hr. 600 hr. ble (circle on)

  • Page 60: Maintenance Schedule

    If the tasks 1-3 are correct continue with the maintenance schedule. If one of the tasks 1-3 is not fulfilled, the engine must be checked and repaired in accordance with the BRP-Rotax instructions for continued airworthiness. Interval Operating hours Chapter...
  • Page 61 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 1000 quirement after the first 25 hours of operation) 3) Spark plug Check that spark plug connectors fit 12–20–00 tightly on the spark plugs. Minimum Inspection of pull-off force is 30 N (7 lb).
  • Page 62 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 1000 quirement after the first 25 hours of operation) Inspect temperature sensors and oil pressure sensor for secure fit and signs of wear.
  • Page 63 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 1000 quirement after the first 25 hours of operation) 7) Oil change Drain oil from oil tank. 12–20–00 Oil change Check the oil tank and clean the oil 12–20–00...
  • Page 64 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 1000 quirement after the first 25 hours of operation) 11) Checking the turbocharger Check the wastegate lever for free 12–20–00 running and correct position Turbocharg- Lubricate the wastegate lever.
  • Page 65 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 1000 quirement after the first 25 hours of operation) Inspect radiator cap. Inspect protec- tank, radia- tion rubber on expansion tank base tor cap for correct fit.
  • Page 66 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 1000 quirement after the first 25 hours of operation) 18) Crankcase pressure check Check the crankcase pressure. See Installa- Test pressure________mbar (psi)
  • Page 67 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–50–00 UNSCHEDULED MAINTENANCE CHECKS TOPICS IN THIS CHAPTER Engine check after propeller strike incidents ..................2 Removal of the propeller gearbox ......................2 Drive gear – Removal ..........................6 Propeller Strike Inspection ........................7 Installation of propeller gearbox ......................12 Examination after engine failure ......................18...

  • Page 68: Engine Check After Propeller Strike Incidents

    BRP-Rotax MAINTENANCE MANUAL LINE ENGINE CHECK AFTER PROPELLER STRIKE INCIDENTS Definition A propeller strike is: • Any incident while the engine is stationary or running which makes it necessary to per- form repairs on the propeller. REMOVAL OF THE PROPELLER GEARBOX...
  • Page 69 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Lock the crankshaft into place according to Chapter 12-20-00 section Locking/Loosen of the crankshaft. Figure 5.1: TYPICAL Hex. screw Step Procedure Loosen M12x20 hex. screw with sealing ring. NOTE Do not remove the hex. screw completely.
  • Page 70 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE When removing the propeller gearbox, take care not to damage the bearing point and the oil seal running surface (on the roller bearing side) of the propeller shaft. Figure 5.2: TYPICAL Hex./Torx-flange screw M8x45 Hex./Torx-flange screw M6x40...
  • Page 71 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.3: TYPICAL Puller part no. 877660 Handle Gearbox housing Effectivity: 916 i A / C24 05–50–00 Edition 0/Rev. 1 Page 5 December 01 2023...

  • Page 72: Drive Gear - Removal

    BRP-Rotax MAINTENANCE MANUAL LINE DRIVE GEAR – REMOVAL NOTICE The large and small gears are considered the same part (with the same part num- ber and same serial number). They must not be mixed up with other gear sets. Step Procedure Lock the crankshaft into place.

  • Page 73: Propeller Strike Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.5 Drive gear Crankshaft Friction washer Hex. nut M30x1.5 PROPELLER STRIKE INSPECTION General note NOTICE Damage to a propeller is serious and can cause the engine to be unairworthy. After any propeller strike the following inspections must be performed before operation can continue.
  • Page 74 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Remove the propeller as per the airframe and propeller manufacturer’s instructions. Inspect the engine for damage. If any damage is detected, inspect, re- pair or overhaul the whole engine in accordance with the relevant Man- ual.
  • Page 75 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.6: Components for inspection Propeller gear assy. Drive gear See latest Illustrated Parts Catalog (IPC) for the respective engine type. Step Procedure Inspect , repair or perform service of the whole gearbox in accordance with Chapter 72-10-00 of the latest Maintenance Manual Heavy (MMH).
  • Page 76 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.7: NDT inspection Step Procedure If cracks are detected on any these components the parts need to be replaced. These parts need to be replaced 100% in course of a propeller strike inspection. Figure 5.8: 100% replacement parts after propeller strike Sealing ring A12x18 Retaining ring 40x1.75...
  • Page 77 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Disassemble overload clutch and damper clutch. See Chapter 72-10-00 Maintenance Manual Heavy (MMH). Check all given wear limits about the gearbox assy. See Chapter 72-10- 00 Maintenance Manual Heavy (MMH) section “Inspection” and “Wear Limits”.

  • Page 78: Installation Of Propeller Gearbox

    BRP-Rotax MAINTENANCE MANUAL LINE INSTALLATION OF PROPELLER GEARBOX Preparation NOTICE No hammering or pressing! The drive gear must only be pushed on by hand. NOTICE Ensure that the friction washer is in the correct installation position. NOTICE The dog and drive gears are in pairs.
  • Page 79 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Push the drive gear onto the crankshaft. NOTE Due to limited tolerances, it may be difficult to push the drive gear onto the end of the crankshaft. If necessary, push it on in another position.
  • Page 80 BRP-Rotax MAINTENANCE MANUAL LINE NOTE If there is slight vertical run-out, replace the nut and repeat the measurement. Step Procedure Insert 2 6x20 dowel pins into the crankcase. Apply Engine oil into the needle bearing and lubricate the crankshaft with LOCTITE Anti Seize.
  • Page 81 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.12 Overload clutch assy. Torision shaft Step Procedure Apply LOCTITE 5910 surface sealing compound to the sealing surface of the gearbox housing and place on the gear cover assy. with the pre- assembled gearbox. NOTE Move the propeller shaft a little to allow the dog gear to engage.
  • Page 82 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.13 Hex./Torx-flange screw M8x45 Hex./Torx-flange screw M6x40 Figure 5.14: Screw diagram Step Procedure Inspect the propeller flange run-out. See also Chapter 72-10-00 section Wear limits. (GB18). Lock the crankshaft into place according to Chapter 12-20–00 section "Locking/Loosen of the crankshaft''...
  • Page 83 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.15 Hex. screw M12 x 20 Effectivity: 916 i A / C24 05–50–00 Edition 0/Rev. 1 Page 17 December 01 2023...

  • Page 84: Examination After Engine Failure

    BRP-Rotax MAINTENANCE MANUAL LINE EXAMINATION AFTER ENGINE FAILURE General note In order to find possible causes of the failure, it is important to pass on all available data. Observations on the aircraft and the engine suspension can also be of help. It is important to pay particular attention to any of the following engine phenomena to facilitate troubleshooting.

  • Page 85: Returning Engine To Service After Submerging In Water

    The engine must be marked clearly “Engine submerged in water“. Define if it was fresh water or salt water. An engine which has been submerged in water must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. See current Maintenance Manual of the respective engine type. Inspection •...

  • Page 86: Inspection In Extreme Climatic Conditions

    BRP-Rotax MAINTENANCE MANUAL LINE • gearbox • valve train system • engine suspension frame • exhaust system • fuel system • lubrication system • cylinder unit • start system In most cases an overhaul is necessary, in this regard the engine has to be overhauled ac- cording to the current Overhaul Manual (OHM) for the respective engine type.

  • Page 87: Returning Engine To Service After Influence By Fire

    MAINTENANCE MANUAL LINE RETURNING ENGINE TO SERVICE AFTER INFLUENCE BY FIRE General note An engine after influence by fire must be inspected, repaired or overhauled according to the BRP-Rotax instructions for continued airworthiness. Inspection • Inspect all systems for correct functioning. NOTE Prior to the detailed inspection, all parts should be cleaned and inspected for burn penetration or melted materials.
  • Page 88 Step Procedure The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Check that the push-rods are straight. Inspect the crankshaft for out-of-roundness and distortion. See Chapter 72- 00-00 of the latest Maintenance Manual Heavy (MMH).

  • Page 89: Exceeding Of Max. Coolant Temperature

    BRP-Rotax MAINTENANCE MANUAL LINE EXCEEDING OF MAX. COOLANT TEMPERATURE General note NOTICE If the maximum coolant temperature is exceeded, other limits are also often ex- ceeded, e.g. oil temperature. Please observe the relevant instructions. NOTE Any exceeding of the max. admissible coolant temperature must be entered by the pilot into the engine log book, stating duration, extent of excess temperature and pertinent detail.
  • Page 90 Procedure Step The whole cooling system must be inspected, repaired or overhauled in ac- cordance with the BRP-Rotax instructions for continued airworthiness. Inspect all further systems for correct functioning. Carry out detailed inspection of the affected engine components such as: •...

  • Page 91: Non Compliance With The Coolant Specification

    BRP-Rotax MAINTENANCE MANUAL LINE NON COMPLIANCE WITH THE COOLANT SPECIFICATION General note NOTICE Use only coolant as recommended in the current Operators Manual (OM). Non compliance with the coolant specification Step Procedure When a different coolant than the former one (conventional coolant) used, then the coolant system has to be flushed.

  • Page 92: Checking Of The Cooling System / Radiator Cap

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING OF THE COOLING SYSTEM / RADIATOR CAP General Cooling system / radiator cap. check in case of unusual leakage and deposits or exceed- ing of max. cooling system temperature. m WARNING Risk of burns and scalds. Hot engine parts.
  • Page 93 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.17: Special tool Instruction NOTE Perform a visual check of the entire cooling system, check for chafing and coolant residue. Step Procedure Remove one coolant hose at the upper outlet elbow on the cylinder head, hold the hose up and drain the hose and expansion tank.
  • Page 94 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.18: TYPICAL Upper coolant hose Coolant outlet elbow Clean container Step Procedure Seal the open elbow side with a temporary piece of coolant hose, with a plug inserted in the open end. The plug needs to hold a pressure of 2 bar (29 psi).
  • Page 95 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.19: TYPICAL Self compensating clamp 25 part no. water hose part no. 922250 851645 Plug Step Procedure To the open coolant hose, attach an adapter and connect to a manual pump or pressure reduction valve. Use the standard spring clamp to se- cure the hose on the adapter.
  • Page 96 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Remove the connection hose from expansion tank to overflow bottle and install a temporary clear hose. Refill the cooling system at the expansion tank and overflow bottle to standard levels. Apply small amount of coolant to rubber surfaces inside cap (provides lu- brication to prevent binding).
  • Page 97 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE Use only coolant as recommended in the current Operators Manual (OM). Step Procedure Check if the relief pressure lies within following limits for both radiator cap types. • Min. relief pressure: 1.2 bar (17.4 psi) •...
  • Page 98 BRP-Rotax MAINTENANCE MANUAL LINE NOTE To make the entire cooling system check easier, the coolant may be entirely drained, and the system pressurized with air only, up to 1.6 bar (23.2 psi.). Check can be performed with leak detection fluid to locate the leakage.

  • Page 99: Exceeding The Max. Permissible Oil Temperature

    BRP-Rotax MAINTENANCE MANUAL LINE EXCEEDING THE MAX. PERMISSIBLE OIL TEMPERATURE General note NOTICE If the max. permissible oil temperature is exceeded, other limits are often ex- ceeded, too, e.g. the cylinder head temperature and coolant temperature. Please observe the relevant instructions.

  • Page 100: Oil Pressure Below Minimum Value

    Procedure Step The whole oil system must be inspected, repaired or overhauled according to the BRP-Rotax instructions for continued airworthiness. Inspect oil level in the oil tank. Inspect oil cooler for contamination and check the entire oil circuit for cor- rect functioning.
  • Page 101 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.24: Overview and instruction Oil pressure below minimum oil pressure on the ground If noticed on ground, immediately stop the engine and determine the cause. • Inspect the complete lubrication system, trace cause and rectify.
  • Page 102 If after the previous checks and oil change the oil pressure is still too low, repair or overhaul the engine in accordance with the BRP-Rotax instruc- tions for continued airworthiness. Inspect all systems for correct functioning.

  • Page 103: Oil Specification Not Respected

    BRP-Rotax MAINTENANCE MANUAL LINE OIL SPECIFICATION NOT RESPECTED General note NOTE An entry by the pilot in the engine log book of all pertinent details is required. If by error engine was serviced with oil, which does not correspond with oil specification in...
  • Page 104 Procedure Remove propeller gearbox. The gearbox must be inspected, repaired or overhauled according to the BRP-Rotax instructions for continued airworthiness. Carry out detailed inspection of the affected engine components. Carry out an oil change. Remove the lowest positioned banjo screw (banjo bolt, plug screw or screw socket) and drain the remaining oil from the crankcase.

  • Page 105: Spark Plug Not In Accordance With Specification

    If parts are damaged, the engine must be inspected, repaired or overhauled according to the BRP-Rotax instructions for continued airworthiness. Inspect all systems for correct function.

  • Page 106: Smooth Performance Of The Engine

    BRP-Rotax MAINTENANCE MANUAL LINE Independent of subsequent following inspections are required: Non compliance with fuel quality Step Procedure Visual inspection of engine. Empty the fuel system according to the instructions of aircraft manufacturer. Flush fuel system. Check cylinder differential pressure.

  • Page 107: Sudden Drop In Boost Pressure And Speed

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.26: Inspection of smooth performance TYPICAL NOTE Always use protection of propeller edge when doing this test. SUDDEN DROP IN BOOST PRESSURE AND SPEED General note NOTICE If there is damage to the turbocharger, the engine must be sent to the authorized over- haul facility for overhaul.

  • Page 108: Sudden Increase In Boost Pressure And Speed

    BRP-Rotax MAINTENANCE MANUAL LINE Sudden drop in boost pressure and speed Step Procedure Check wiring. See Chapter 12–20–00 section Check wiring. NOTE If no mechanical damage is detected during the visual in- spection, check the boost pressure control. See Chapter 76–00–00 of the Maintenance Manual Heavy (MMH).

  • Page 109: Periodic Rise And Fall In Boost Pressure And Speed (Oscillation Of Turbo Control Unit)

    BRP-Rotax MAINTENANCE MANUAL LINE PERIODIC RISE AND FALL IN BOOST PRESSURE AND SPEED (OSCILLATION OF TURBO CONTROL UNIT) General note m WARNING Non-compliance can result in serious injuries or death! The engine must not be taken into operation before having corrected the cause of deficiency.
  • Page 110 BRP-Rotax MAINTENANCE MANUAL LINE Indirect lighting strike Step Procedure Crank the engine and check that it rotates freely. Perform an engine test run. Inspect FUSE BOX. Heat damage due to indirect lightning strike: Detailed findings will need to be obtained for affected components. Always replace com- ponents if visible signs of damage are evident or if you are in any doubt.

  • Page 111: Reporting

    BRP-Rotax MAINTENANCE MANUAL LINE Direct lightning strike NOTICE After direct lightning strike, the engine has to be overhauled according to the cur- rent Overhaul Manual (OHM) for the respective engine type. Overhaul Manual (OHM) and its appendix is available for any appropriately rated per- son or entity on request and by following the standards of the original manufacturer.
  • Page 112 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.27: Form 05–50–00 Effectivity: 916 i A / C24 Edition 0/Rev. 1 Page 46 December 01 2023...

  • Page 113: Maintenance Of The Systems

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 12–00–00 MAINTENANCE OF THE SYSTEMS TOPICS IN THIS CHAPTER Introduction The section “Maintenance of the systems“ is associated with other sections. It serves only as a supplement to and further explanation of the maintenance check list (See Chapter 05-20-00).
  • Page 114 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 916 i A / C24 December 01 2023...

  • Page 115: Replenishing Operating Fluids

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 12–10–00 REPLENISHING OPERATING FLUIDS TOPICS IN THIS CHAPTER Servicing points on the engine ........................2 Fluid capacities ............................3 Cooling system ............................4 Coolant check/replenish.........................4 Lubrication system..........................7 Oil level check/Replenish ........................7 Introduction The engine should always be in a horizontal position before checking the fill levels.

  • Page 116: Servicing Points On The Engine

    BRP-Rotax MAINTENANCE MANUAL LINE SERVICING POINTS ON THE ENGINE Overview Figure 6.1 Expansion tank Radiator cap Oil filter Oil tank Oil dipstick 12–10–00 Effectivity: 916 i A / C24 Edition 0/Rev. 1 Page 2 December 01 2023...

  • Page 117: Fluid Capacities

    3.0 l (0.8 US gal.). NOTE BRP-Rotax can give an approx value on the fill capacity depending on aircraft de- sign and positions of radiators and tanks. The volume may difference from this value. Always check the relevant specifications provided by the aircraft manufacturer.

  • Page 118: Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE COOLING SYSTEM General note m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Risk of Burns! Never open the radiator cap when the cooling system is hot. For safety’s sake, cover cap with a rag and open slowly.
  • Page 119 BRP-Rotax MAINTENANCE MANUAL LINE Instruction To refill the coolant the following steps are necessary. See also following figure. Procedure Step Open the radiator cap (1) on the expansion tank (2). Visually check the rub- ber seats inside the cap for condition and orientation.
  • Page 120 BRP-Rotax MAINTENANCE MANUAL LINE Figure 6.3: Coolant check/replenish TYPICAL Radiator cap Expansion tank Engine test run Engine test run is necessary: Step Procedure Operate the engine until the temperatures have stabilized for a period of 5 min. (engine oil temperature between 50 to 70 °C (122 - 160 °F).

  • Page 121: Lubrication System

    BRP-Rotax MAINTENANCE MANUAL LINE LUBRICATION SYSTEM General note m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Disconnect negative terminal of battery.
  • Page 122 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE For longer flights replenish oil to max. mark to warrant more oil reserve. NOTICE Only use brand name oil in accordance with the latest Operators Manual (OM) and the latest Service Instruction “Selection of suitable operating fluids“ of the respective engine type.
  • Page 123 BRP-Rotax MAINTENANCE MANUAL LINE Engine test run An engine test run is necessary: Step Procedure Check the oil level and top up with oil as required. Operate the engine until the temperatures have stabilized for a period of 5 min. (engine oil temperature between 50 to 70 °C (122 - 160 °F).
  • Page 124 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 10 Effectivity: 916 i A / C24 December 01 2023...

  • Page 125: Scheduled Maintenance

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 12–20–00 SCHEDULED MAINTENANCE TOPICS IN THIS CHAPTER Engine cleaning............................3 Visual inspection .............................4 Checking the engine suspension ......................4 Corrosion..............................5 Leakage check............................6 Differential and crankcase pressure check....................8 Engine control unit (ECU) ........................13 Checking ECU ............................13 Read out the ECU data memory ......................14 Checking the AC-DC Converter warning lamps..................14...
  • Page 126 BRP-Rotax MAINTENANCE MANUAL LINE Checking and cleaning plug screw (turbo oil sump assy.)................49 Propeller gearbox ..........................51 Checking the propeller gearbox ......................51 Check POP-OFF VALVE ........................52 Introduction This chapter relates in particular to the maintenance work mentioned in the Maintenance Schedule for the various engine systems and covers the work in more detail.

  • Page 127: Engine Cleaning

    BRP-Rotax MAINTENANCE MANUAL LINE ENGINE CLEANING General note ENVIRONMENTAL NOTE When cleaning the engine, the dissolved residues of fuel, oil and other environ- ment-contaminating agents are rinsed off. Collect the residual liquids and dispose of them in an environmentally sound way.

  • Page 128: Visual Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE VISUAL INSPECTION General note General visual inspection of the engine for damage or abnormalities. For definition and scope of visual inspection. See Chapter 05-20-00 section Visual inspection. Abnormalities Take note of changes caused by temperature influence.

  • Page 129: Corrosion

    BRP-Rotax MAINTENANCE MANUAL LINE CORROSION Definition Corrosion is a natural process which attacks and potentially damages metals via an elec- trochemical reaction. For more detailed information about different types of corrosion and corresponding methods for dealing with corrosion refer to the FAA Advisory Circular AC 43.13.

  • Page 130: Leakage Check

    BRP-Rotax MAINTENANCE MANUAL LINE LEAKAGE CHECK General note NOTICE Leaking connections can lead to engine problems or engine failure! Visual inspection of the whole engine for leaks. If leaks are visible, locate the cause and remedy the fault. Water pump Checking water pump for leaks.
  • Page 131 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.1: Connections and fuel lines Fuel rail 2/4 outlet line Fuel rail 1/3 feed line Fuel line assy. Fuel rail Fuel injector Fuel pressure regulator assy. Effectivity: 916 i A / C24 12–20–00 Edition 0/Rev. 1...

  • Page 132: Differential And Crankcase Pressure Check

    BRP-Rotax MAINTENANCE MANUAL LINE DIFFERENTIAL AND CRANKCASE PRESSURE CHECK General note m WARNING Risk of electric shock! Ignition “OFF” and system grounded! m WARNING Danger of life threatening injuries caused by the propeller, rotating and stressed parts of the engine! Engine (and propeller) may suddenly rotate if the piston is not at top dead center.Al-...
  • Page 133 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.2: Checking the compression Adaptor Manometer/Test gauges set Orifice jet Compressor Special tools To measure the compression pressure the following special tools and equipment are necessary. Part number Description n.a. Compressed air approx. 6 bar (87 psi).
  • Page 134 BRP-Rotax MAINTENANCE MANUAL LINE Part number Description Orifice jet*, of 1 mm (0.04 in) inner diameter and 3 mm (0.12 in) length. * or equivalent e.g. orifice diameter 0.040 in., long 0.0250 in., 60° degree approach angle according to AC43.13, latest issue.
  • Page 135 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Turn the crankshaft into a position, so that the exhaust valve is closed and perform step 3 and 4 for the exhaust valve. Install valve cover according to the latest Maintenance Manual Heavy (MMH).
  • Page 136 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE Exceeded pressure readings: If crankcase pressure readings where exceeded, the pistons need to be removed, cleaned and inspected according to the current Maintenance Manual Heavy (MMH). If the wear limits are out of the specified range, the pistons must be replaced. Also new piston rings has to be installed.

  • Page 137: Engine Control Unit (Ecu)

    BRP-Rotax MAINTENANCE MANUAL LINE ENGINE CONTROL UNIT (ECU) Safety notice m WARNING Non-compliance can result in serious injuries or death! When working on the ECU, the general safety instruction must be observed. See chap- ter „INTRO“. Figure 7.4: Engine control unit (ECU)

  • Page 138: Read Out The Ecu Data Memory

    BRP-Rotax MAINTENANCE MANUAL LINE READ OUT THE ECU DATA MEMORY Instruction To read out the ECU data memory proceed as follows: Step Procedure Connect the decoding unit (Dongle) with ECU data cable to the computer. Select the menu item BUDS in the maintenance software and print out the report.

  • Page 139: Locking/Loosen Of The Crankshaft

    BRP-Rotax MAINTENANCE MANUAL LINE LOCKING/LOOSEN OF THE CRANKSHAFT Locking of the crankshaft m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. Special tool For accomplishment the following special tool is required: Figure 7.5: Special tool...
  • Page 140 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.6: Locking/Loosen of the crankshaft. TYPICAL Allen screw M8x20 (crankcase) with Locking pin sealing ring 8x13 Crankshaft Loosening of the After completion of work/check: crankshaft Procedure Step Remove the locking pin (2) and refit Allen screw M8x20 (1) along with a new sealing ring 8x13 with a torque of 15 Nm (133 in.lb).

  • Page 141: Test Run Of Engine

    BRP-Rotax MAINTENANCE MANUAL LINE TEST RUN OF ENGINE General note m WARNING Danger of life threatening injuries caused by the propeller, rotating and stressed parts of the engine! Always observe the engine from a safe place while it is running. Check that the cockpit is occupied by a competent operator.
  • Page 142 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Shut engine down. NOTE Switch “OFF” lanes, fuel pumps and master switch. Inspect rotary seal leakage bore. NOTE Due to the design of the rotary seal, the manufacturer tolerates a certain amount of leakage. If the leakage is in excess of the limit ro- tary seal must be renewed.

  • Page 143: Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE COOLING SYSTEM Figure 7.7: Overview Expansion tank assy. Form hose Water pump housing Water hose Water inlet elbow Form hose Cooling air baffle Protection tube Coolant Temperature Sensor (CTS) Effectivity: 916 i A / C24 12–20–00 Edition 0/Rev.

  • Page 144: Checking The Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING THE COOLING SYSTEM General note See Figure Overview. m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Non-compliance can result in serious injuries or death! Any of the following conditions require a check of the cooling system/radiator cap check as described in Chapter 05-50-00 Unscheduled Maintenance.

  • Page 145: Replacing The Coolant

    BRP-Rotax MAINTENANCE MANUAL LINE REPLACING THE COOLANT General note m WARNING Risk of Burns! Never open the radiator cap when the cooling system is hot. For safety’s sake, cover cap with a rag and open slowly. Sudden opening of the cap could provoke the escape of boiling coolant and result in scalding.
  • Page 146 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Open the radiator cap on the expansion tank. Remove the bottom Allen screw (1) (with gasket ring (2) ) of water pump (3). Drain the engine coolant. NOTE If the radiator is located below the engine, also detach the lowest positioned coolant hose.

  • Page 147: Flushing The Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE FLUSHING THE COOLING SYSTEM General note m WARNING Risk of Burns! Never open the radiator cap when the cooling system is hot. For safety’s sake, cover cap with a rag and open slowly. Sudden opening of the cap could provoke the escape of boiling coolant and result in scalding.

  • Page 148: Expansion Tank, Radiator Cap

    BRP-Rotax MAINTENANCE MANUAL LINE EXPANSION TANK, RADIATOR CAP Figure 7.9: Expansion tank, radiator cap Pressure relief valve Return valve Pressure spring Rubber seal Opening pressure of the radiator cap Connection to overflow bottle Sealing surface Tube connections Sight glass General note To equalize pressure in the cooling system, an expansion tank is required.

  • Page 149: Fuel System

    BRP-Rotax MAINTENANCE MANUAL LINE FUEL SYSTEM Figure 7.10: Overview Fuel rail (1/3) and feed line Fuel out/return line Fuel rail (2/4) Fuel line assy. Fuel injector Fuel pressure regulator assy. Effectivity: 916 i A / C24 12–20–00 Edition 0/Rev. 1...

  • Page 150: Leak Tests

    BRP-Rotax MAINTENANCE MANUAL LINE LEAK TESTS General note NOTICE Avoid over-tightening the fasteners. Use a suitable torque wrench for all work. Instruction To check the following steps are necessary: Step Procedure Inspect all fuel lines (steel on engine), their connections and unions.

  • Page 151: Fuel Injectors

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.11: Fuel pressure regulator TYPICAL Fuel pressure regulator Connections FUEL INJECTORS General note Check for leaks. FUEL RAIL General note Check for leaks. Effectivity: 916 i A / C24 12–20–00 Edition 0/Rev. 1 Page 27...

  • Page 152: Lubrication

    BRP-Rotax MAINTENANCE MANUAL LINE LUBRICATION Overview Figure 7.12 Oil pressure regulator Oil pump Oil filter Oil tank Venting hose Oil temperature sensor Oil pressure sensor Plug screw assy. (oil sump turbocharger) Oil radiator 12–20–00 Effectivity: 916 i A / C24 Edition 0/Rev.
  • Page 153 BRP-Rotax MAINTENANCE MANUAL LINE General note m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Disconnect negative terminal of battery.

  • Page 154: Oil Change

    BRP-Rotax MAINTENANCE MANUAL LINE OIL CHANGE Instruction NOTE Run engine to warm oil before beginning oil change procedure. To change the oil the following steps are necessary: Step Procedure Crank engine slowly by hand to transfer the oil from the crankcase.

  • Page 155: Oil Filter - Removal

    BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Install new oil filter. See New oil filter - installation. Pour in approx. 3 l (0.8 gal (US)) of fresh oil. After carrying out the oil change, the engine should be slowly cranked by hand in the direction of engine rotation (approx.
  • Page 156 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.13: Special tool Oil filter wrench part no. 877620* Cutting tool part no. 276275 *or equivalent Procedure To remove the oil filter the following steps are necessary: Step Procedure Remove used oil filter with oil filter wrench.

  • Page 157: Inspecting Of The Oil Filter Components

    If an increased amount of metal particles is found, such as brass- or bronze chips or silver matter from bearing abrasion, repair or overhaul the engine in accordance with the BRP-Rotax in- structions for continued airworthiness. If the filter mat is clogged by foreign matter, oil reaches the bearing points unfiltered via the by-pass valve in the oil filter.
  • Page 158 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Engine test run. See Chapter 12-20-00 section: Test run of engine. Inspect the oil filter once more. Contaminated NOTICE If the oil circuit is contaminated, replace the oil cooler and flush the oil circuit.

  • Page 159: New Oil Filter - Installation

    BRP-Rotax MAINTENANCE MANUAL LINE NEW OIL FILTER - INSTALLATION Procedure To mount the oil filter the following steps are necessary: Procedure Step Clean the contact surface (1) of the oil pump housing (2) with a clean cloth. Apply thin film engine oil on the gasket (3) of the oil filter (4).

  • Page 160: Cleaning The Oil Tank

    BRP-Rotax MAINTENANCE MANUAL LINE CLEANING THE OIL TANK General note NOTE This procedure is optional and requires purging of the oil system. See Chapter 12–20–00 section Purging the oil system. If using leaded fuel it is required to clean the tank according to the limits mentioned in Chapter 05-20-00, section Scheduled maintenance checks.
  • Page 161 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.16: Oil tank Profile clamp Hex. screw M12x12 Oil tank cover assy. Metric/UNF O-ring Baffle insert Partition/screen Gasket ring 12x18 Oil tank Safety wire Dipstick Oil tank cover Effectivity: 916 i A / C24 12–20–00 Edition 0/Rev.

  • Page 162: Purging The Oil System

    BRP-Rotax MAINTENANCE MANUAL LINE PURGING THE OIL SYSTEM General note NOTICE Purging of the oil system is extremely important for operation and service life of the engine and therefore the procedure must be followed meticulously. See current Installation Manual (IM) for the engine type 916 i A Series, Chapter 79-00-00 section Purging the lubrication system and latest ver- sion of SI-916 i-003.
  • Page 163 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE The oil level in the tank must not drop below the end of suction pipe, otherwise air will be sucked in again. Step Procedure Turn engine by hand in direction of engine rotation to return the oil from the oil tank into the engine and into the collection container.

  • Page 164: Inspecting The Magnetic Plug

    Steel chips in If there are larger accumulations of metal chips on the magnetic plug, the engine must be larger numbers repaired or overhauled according to the BRP-Rotax instructions for continued airworthiness. Unclear findings In the case of unclear findings:...

  • Page 165: Installation Of The Magnetic Plug

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.17: Overview INSTALLATION OF THE MAGNETIC PLUG Install The following steps are necessary: Step Procedure Clean the magnetic plug. Install the magnetic plug. Tightening torque 25 Nm (18 ft lb.) Lock-wire magnetic plug. Inspect whole system for correct function. Detailed inspection of affected engine components.

  • Page 166: Electric System

    BRP-Rotax MAINTENANCE MANUAL LINE ELECTRIC SYSTEM 916 i TYPE A Figure 7.18: Overview Spark plug connectors Double ignition coil Engine Control Unit (ECU) FUSE BOX assy. Connector Generator A Connector Generator B Crankshaft Position Sensor (CPS 1/2) Generator A and B 12–20–00...
  • Page 167 BRP-Rotax MAINTENANCE MANUAL LINE 916 i TYPE C24 Figure 7.19: Overview Spark plug connectors Double ignition coil Engine Control Unit (ECU) FUSE BOX assy. Connector Generator A Connector Generator B Crankshaft Position Sensor (CPS 1/2) Generator A and B 24 V Connector Effectivity: 916 i A / C24 12–20–00...

  • Page 168: Check Of Wiring

    BRP-Rotax MAINTENANCE MANUAL LINE CHECK OF WIRING General note m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Disconnect negative terminal of battery. m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work.

  • Page 169: Replacement Of Spark Plugs

    BRP-Rotax MAINTENANCE MANUAL LINE REPLACEMENT OF SPARK PLUGS General note NOTICE Use of incorrect spark plugs can result in ignition problems and pre-ignition and consequent engine damage. In numerous tests the best possible heat range has been determined to make sure that the spark plug will burn off deposits but will not overheat.
  • Page 170 BRP-Rotax MAINTENANCE MANUAL LINE Spark plug face Spark plug face reveals the following about the operating condition of the engine: Spark plug face Information light tan- colored plug and calibration of the engine are correct velvet black Possibly indicates one or more of the following: •...

  • Page 171: Installation Of Spark Plug

    BRP-Rotax MAINTENANCE MANUAL LINE INSTALLATION OF SPARK PLUG Figure 7.20: Spark plugs Ground electrode Head area Cleaning m WARNING Eyes and skin irritation! Rinse off with water in the case of contact with eyes or skin. May be harmful if swallowed.

  • Page 172: Fuse Box

    BRP-Rotax MAINTENANCE MANUAL LINE Installation NOTICE Always replace both spark plugs of a cylinder and do not interchange spark plugs between cylinders. NOTICE Silicone heat compound at the ground electrode or the head area can lead to igni- tion problems. Apply heat compound sparingly and do not apply to the first three threads.

  • Page 173: Turbocharger

    BRP-Rotax MAINTENANCE MANUAL LINE TURBOCHARGER Checking the Procedure Step waste gate lever Check the waste gate lever for free movement. If it does not move freely, lubricate the axle of the waste gate with LOCTITE ANTI SEIZE 15378. Figure 7.21 CHECKING AND CLEANING PLUG SCREW (TURBO OIL SUMP ASSY.)
  • Page 174 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.22: Oil sump assy. Plug screw assy. M22x1.5 O-ring 18x2.5 12–20–00 Effectivity: 916 i A / C24 Edition 0/Rev. 1 Page 50 December 01 2023...

  • Page 175: Propeller Gearbox

    BRP-Rotax MAINTENANCE MANUAL LINE PROPELLER GEARBOX Figure 7.23: Overview CHECKING THE PROPELLER GEARBOX General note For checking of the propeller gearbox see Maintenance Manual Heavy (MMH) for Engine Type 916 i A Series. Effectivity: 916 i A / C24 12–20–00 Edition 0/Rev.

  • Page 176: Check Pop-Off Valve

    BRP-Rotax MAINTENANCE MANUAL LINE CHECK POP-OFF VALVE NOTE This functional check is to be performed on an assembled pop-off valve assembly. See Chapter 73-10-00 in Maintenance Manual Heavy (MMH) for the re- spective engine type for removal, disassembly, inspection and assembly and installation of the pop-off valve assy..
  • Page 177 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.25: Oil tank Step Procedure Remove vacuum tool and temporary lines and clamps. Attach control hose 600 mm (23.6 in.) (2) with new 1-ear clamp 10.3 - 12.8 mm (1) on hose nipple (3) of the pop-off valve.
  • Page 178 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.26: Oil tank 1-ear clamp 10.3-12.8 mm Control hose 600 mm (23.6 inch.) Hose nipple 12–20–00 Effectivity: 916 i A / C24 Edition 0/Rev. 1 Page 54 December 01 2023...
  • Page 179 BRP-Rotax MAINTENANCE MANUAL LINE Index Exceeding the max. permissible oil temperature ..33 Expansion tank ...........24 Abbreviations............3 Extreme climatic conditions........20 Acceptable methods, techniques and practice ..12 Airworthiness Limitations ........1 Annual inspection..........6 Authorized personnel ..........4 Fluid capacities .............3 Flushing the cooling system .........23 Flushing the oil circuit ..........38...
  • Page 180 BRP-Rotax MAINTENANCE MANUAL LINE Safety information ..........11 Scheduled maintenance ........2 New oil filter - installation ........35 Scheduled maintenance checks ......1–2 Non compliance — coolant specification ....25 Servicing points on the engine........2 Non compliance — fuel quality ......39 Smooth performance of the engine .......40 Spark plug not in accordance with specification ..39...
  • Page 182 Engine serial no. Type of aircraft Aircraft registration no. Rotax® authorized distributor FLYROTAX.COM ® and TM are trademarks of BRP-Rotax GmbH & Co KG. 2023 BRP-Rotax GmbH & Co KG. All rights reserved. ©...

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