MME40804 R 24

Maintenance Manual E4.08.
04
Issue date: 07-05-2009

Revision no: 1
Page: Intro-1
Maintenance Manual E4.08.04
Maintenance Manual E4
Date: Wiener Neustadt, 24-10-2014
Author: Austro Engine GmbH

Rudolf – Diesel – Straße - 11
A-2700 Wiener Neustadt
Document number: E4.08.04

Revision: 24

Revision no: 24
Page: Intro-2
Introduction
All revisions of this manual must be recorded in chapter “List of Revision“.
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.
Cover pages of Temporary revisions are inserted in front the cover page of this manual. The other
pages of Temporary revisions are inserted adjacent to or in front of the corresponding MM pages.
Temporary revisions are used to provide information on systems or equipment until the next
‘permanent’ revision of the Engine Manual.
It is the responsibility of the installer to ensure that this manual is maintained to a current status.
If the address or the ownership of the engine/aircraft changes, an address card has to be sent to
Austro Engine GmbH.

Revision no: 24
Page: Intro-3
List of Revision
Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur

No. Revision Approval Inserted
Authority
1 remarks All All 07.05.2009 DOA *) -
updated
Intro 2,4,5,6,7,
10,11,12,
13,14
01 1,2
02 1,2,3,4
03 1,2
04 1
05 1,2,3,4,5,
6,7
12 1,2
24 1,2
51 1,2,3,4,5,
6,8
71 1,2,4,5
73 1,2,3,4,5,
6,7,8,9
Authority 76 1,2,3,4
3 remarks 77 1 09.09.2009 DOA *) -
included 78 1,2
79 1,2,3,4,5,
6,7,8,9,
10,11,12,
13,14,15,
16,17,18
80 1,2,3
81 1,2,3
85 1,2,3,4,5,
6,7,8,9,1
0,11,12,
13,14,15,
16,17,18,
19,20,21,
22
92 1,2,3,4,5
Intro 2,4-16
02 3
05 4,5
12 1
24 2,3,4
MDC-E4- 51 1-6,8
4 2010-05-04 DOA *) -
117 71 2-25
73 1,2,4, 6-9
76 1-4
78 1,2
79 1-3, 5,
7-17

Revision no: 17
Page: Intro-4

80 2,3
81 1-4
85 1-5,7-9,
MDC-E4- 11,13,14
4 2010-05-04 DOA *) -
117 16-18,
20-22,
92 1-10
Last page
Intro 2,5,6,7,8,
12-16
05 4,8,9
MDC-E4-
5 73 1 2011-01-27 DOA *) -
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76 4-6
79 2
85 9
MDC-E4- Intro 2,5,6
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85 3-4,6-23
Intro 2,5,6,7
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10 2011-11-15 DOA *) -
237 81 1,2,4
85 14-16,23
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Intro 2, 5-9
13-21
01 1-2,4-46
03 1
05 2-9
MDC-E4- 12 2
11 2012-01-19 DOA *) -
257 24 1, 4-6
71 2-5,22,24
73 2-4,6-8
76 1,4-6
78 1
79 1,4,7-14

Revision no: 17
Page: Intro-5

16-20
80 1
81 1,3
DOA *) -
85 1,3,4,
7-11,13,
16, 19-24
Intro 2, 6-9,15
MDC-E4- 73 4
12 2012-02-27 DOA *) -
269 79 8
81 1-5
Intro 2, 6-9,
16-21
05 2-4
MDC-E4- 12.Apr.
13 73 4-5 2012-04-10 EASA 2012
270
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85 16
92 14
Intro 2,6-9,
16-22
24 6-23
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14 71 26 2012-07-10 DOA *) -
274
73 1-2,6
85 11-43
92 13,14
Intro 2,6-9
16-22
05 3,4
MDC-E4- 12 2
15 2012-09-05 DOA *) -
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79 18
85 4,7-45
92 14
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16 05 4 2012-10-03 DOA *) -
283
85 1,11
Intro 4-9
MDC-E4-
17 16-22 2012-12-05 DOA *) -
289
85 8-10
MDC-E4- Intro 2, 6-9 14.Feb.
18 2013-01-22 EASA 2013
285 05 2-3
Intro 2, 6-9;
15-21
01 1
MDC-E4-
19 24 11 2013-03-01 DOA *)
300
71 4;22;23;
26;45-52
85 10
Intro 2, 6-9
15-21
MDC-E4- 05 8-9
20 3
2013-05-28 DOA *)
302 76
5,9,10,12,
85 20

Revision no: 20
Page: Intro-6

Intro 2,7-22
MDC-E4-
21 05 2-10 06-09-2013 EASA 23.09.2013
275
24 15
Intro 2,7-10
73 6
MDC-E4- 79 12
318 and 85 20-26,
22 19-11-2013 DOA *)
MDC-E4- 29-31,
238c 33,35,36,
38-40,
42-44
Intro 2,7-10,
16-22
23 MDC-E4-314 14.01.2014 DOA *)
05 4,6
85 1-47
Intro 2,3,7-24
01 31-42
03 1
05 4-6,8
24 1,2,3,5
24 MDC-E4-343 7-38 24-10-2014 DOA *)
71 3-61
73 6-10
79 4,5
81 5
85 4,44-65
*) The technical content of this document is approved under the authority of DOA ref. EASA.21J.0399.

Revision no: 24
Page: Intro-7
List of incorporated Temporary Revisions
Temporary Revision Number Title of Temporary Revision

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
MM-TR-MDC-E4-317 LETRIKA Alternator

MM-TR-MDC-E4-325d Exchange of timing chain
MM-TR-MDC-E4-331 Sealant engine
MM-TR-MDC-E4-342 Lifetime extension of HPP spur gear
MM-TR-RDC-E4-038 Engine Harness alternator connector repair kits
MM-TR-RDC-E4-041 Repair connector alternator E4A-91-000-000

Revision no: 24
Page: Intro-8
25 11 19.01.2012
List of Valid Pages 26 11 19.01.2012
27 11 19.01.2012
28 11 19.01.2012
Chapter Page Revision Date
29 11 19.01.2012
1 1 07.05.2009
30 11 19.01.2012
2 24 24.10.2014
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Introduction
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03-00-00
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1 19 01.03.2013
2 11 19.01.2012
3 9 11.08.2011
4 11 19.01.2012 1 3 09.09.2009
5 11 19.01.2012 2 1 07.05.2009
(Authority
approved
04-00-00
chapter)
6 11 19.01.2012
7 11 19.01.2012
8 11 19.01.2012
9 11 19.01.2012 1 3 09.09.2009
10 11 19.01.2012 2 21 06.09.2013
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01-00-00
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05-00-00
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Revision no: 24
Page: Intro-9
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Revision no: 24
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2 14 10.07.2012 5 24 24.10.2014
3 11 19.01.2012 6 13 10.04.2012
4 13 10.04.2012 1 23 14.01.2014
73-00-00
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Revision no: 24
Page: Intro-11
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11 10 15.11.2011
12 10 15.11.2011
13 14 10.07.2012
14 15 05.09.2012

Revision no: 24
Page: Intro-12
List of Abbreviation
AE Austro Engine
BATT Battery
BPA Boost Pressure Actuator
BPS1 Boost Pressure Sensor 1
BPS2 Boost Pressure Sensor 2
CAD Computer Aided Design
CAN Controller Area Network
CAS 1 Camshaft Sensor 1
CAS 2 Camshaft Sensor 2
CCW Counter-Clockwise
CPC Connector Type
CRS 1 Crankshaft Sensor 1
CRS 2 Crankshaft Sensor 2
CS Certification Specification
CTS Coolant Temperature Sensor
CTS_GPC GPC Coolant Temperature
DOHC Double Overhead Camshaft
EASA European Aviation Safety Agency
EECS Electric Engine Control System
EECU Electric Engine Control Unit
ECU Electric Control Unit
EMI Electromagnetic Interference
EPC Electric Pneumatic Converter
ESD Electrostatic Sensitive Device
FAR Federal Aviation Regulations
FMU Fuel Metering Unit
FPS Fuel Pressure Sensor
FTS Fuel Temperature Sensor
GBTS Gearbox Temperature Sensor
GEN Alternator Plug
GND Ground
GOV Governor Actuator
GPC Glow Plug Control Unit
GP 1 Glow Plug 1
GP 2 Glow Plug 2
GP 3 Glow Plug 3
GP 4 Glow Plug 4
HIRF High Intensity Radiated Field
HPP High Pressure Pump
IAT 1 Intake Air Temperature 1
IAT 2 Intake Air Temperature 2
INJ 1 Fuel Injector 1
MA Manual Amendments
MBN Mercedes Benz Norm
MDC Mandatory Design Change Advisory

Revision no: 24
Page: Intro-13
MOK Oil Combinant Sensor Temperature

ODC Optional Design Change Advisory
OPS Oil Pressure Sensor
PCV Pressure Control Valve
RPM Revolutions Per Minute
RPS Rail Pressure Sensor
SB Service Bulletin
SL Service Letter
SW Soft Ware
TDD Type Design Definition
TC Turbo Charger
TVD Torsional Vibration Damper
Ubatt Battery Voltage

Revision no: 24
Page: Intro-14
Conversion Table of Given Torque Values
Newton Meter (Nm) Pound-force inch (lbf in)

1 9
2 18
3 27
4 35
5 44
6 53
7 62
8 71
9 80
10 89
11 97
12 106
13 115
14 124
15 133
16 142
17 150
18 159
19 168
20 177
21 186
22 195
23 204
24 212
25 221
26 230
27 239
28 248
29 257
30 266
35 310
40 354
50 443

Revision no: 24
Page: Intro-15
Conversion Table of Given Pressure Values
Pressure Pressure Pressure

[bar] [psi] [lbf/ft²]
0,0 0 0
0,3 4 627
0,5 7 1044
1,0 15 2089
1,5 22 3133
2,0 29 4177
2,5 36 5221
3,0 44 6266
3,5 51 7310
4,0 58 8354
4,5 65 9398
5,0 73 10443
5,5 80 11487
6,0 87 12531
6,5 94 13576
7,0 102 14620
7,5 109 15664
8,0 116 16708
8,5 123 17753
9,0 131 18797
9,5 138 19841
10,0 145 20885

Revision no: 24
Page: Intro-16
Consumable List
Various types of consumables are necessary for the engine maintenance defined in this manual. These
consumables are listed in the table below including the applicability reference.
Consumables Material definition Parts applicability

MERCEDES BENZ A003989982010
Oil Sump
Or
Crankcase end cover (rear & front)
Sealant LOCTITE 5970 black
DOW CORNING 736
Fire Sleeve
Heat Resistant/Sealant
Released AE300 engine oils which are
Grease / defined in the AE300 Operation O-ring and Rubber Gaskets
Lubricant Manual.
(acid free lubrication) A001 989 42 51 10 - Mercedes Benz Injectors (see chapter 73-00-22
special grease Installation of the Injektor Seal)
No. 243 For the respective Loctite applicability
Loctite No. 542 refer to the relevant chapters of this
No. 2710 manual.
Suitable for flight purposes stainless
For applicability refer to the relevant
Safety Wire safety wire.
chapters of this manual.
Wire thickness 0.81 mm
Please contact the Austro Engine GmbH customer support under [email protected] or
+43 (0) 2622 23000 2525 in case of material availability.

Revision no: 24
Page: Intro-17
Contents
Introduction .....................................................................................................................3
List of Revision .....................................................................................................................4
List of incorporated Temporary Revisions .........................................................................................8
List of Valid Pages .....................................................................................................................9
List of Abbreviation ................................................................................................................... 13
Conversion Table of Given Torque Values ...................................................................................... 15
Conversion Table of Given Pressure Values .................................................................................... 16
Consumable List ................................................................................................................... 17
Contents ......................................................................................................................................18
Chapter 01-00-00 General ..........................................................................................................1
01-10-00 General Engine Description .................................................................................... 2
01-10-10 Intake/Exhaust System Description........................................................................13
01-10-20 Fuel System Description ........................................................................................15
01-10-30 Exhaust System Description ..................................................................................18
01-10-40 Coolant System Description ...................................................................................18
01-10-50 Lubricating System Description ..............................................................................21
01-10-60 Electrical System Description .................................................................................22
01-10-70 Governor Description ............................................................................................41
Chapter 02-00-00 Transport and Packaging ................................................................................1
02-00-10 Packaging ............................................................................................................. 1
02-00-20 Transport .............................................................................................................. 4
02-00-30 Protective Covers .................................................................................................. 5
02-00-40 Storage ................................................................................................................. 5
02-00-50 Return Parts Shipping Instruction ........................................................................... 5
Chapter 03-00-00 Engine Installation ..........................................................................................1
Chapter 04-00-00 Airworthiness Limitation ..................................................................................1
Chapter 05-00-00 Time Limits and Maintenance Check ................................................................1
05-00-01 General ................................................................................................................. 1
05-10-00 Time Limits ........................................................................................................... 2
05-10-01 Claimable Exceed of Maintenance Actions ............................................................... 2
05-10-02 Engine Time between Overhaul .............................................................................. 2
05-20-00 Schedule Maintenance Inspections and Checks ....................................................... 4
05-20-01 Two Mass Flywheel................................................................................................ 5
05-20-02 Alternator ............................................................................................................. 5
05-20-03 Engine Harness and Sensors .................................................................................. 5
05-20-04 EECU .................................................................................................................... 5
05-20-05 EECU Read Out ..................................................................................................... 5
05-20-06 Gearbox – Oil ........................................................................................................ 5
05-20-07 Gearbox Oil Filter .................................................................................................. 6
05-20-08 V-Ribbed Belt ........................................................................................................ 6
05-20-09 Engine – Oil .......................................................................................................... 6
05-20-10 Engine Oil Filter ..................................................................................................... 6
05-20-11 High Pressure Pump .............................................................................................. 6
05-20-12 Cylinder Head Drain............................................................................................... 7
05-20-13 Fuel System .......................................................................................................... 7
05-20-14 Fuel Filter ............................................................................................................. 7

Revision no: 24
Page: Intro-18
05-20-15 Waste Gate Controller ............................................................................................ 7

05-20-16 Exhaust System ..................................................................................................... 7
05-20-17 Coolant ................................................................................................................. 7
05-20-18 Cooling System ..................................................................................................... 8
05-20-19 Breather Line ........................................................................................................ 8
05-20-20 Zonal Inspection.................................................................................................... 8
05-20-21 Injector Cover ....................................................................................................... 8
05-20-22 Timing Chain ......................................................................................................... 8
05-50-00 Unscheduled Maintenance Checks .......................................................................... 9
05-50-01 Performance Deterioration ..................................................................................... 9
05-50-02 Over Temperature ................................................................................................. 9
05-50-03 Sudden Stoppage Inspection .................................................................................. 9
05-50-04 Propeller Strike ...................................................................................................... 9
05-50-05 Lightning Strike ..................................................................................................... 9
05-50-06 High Oil Consumption Inspection ...........................................................................10
05-50-07 Oil System Contaminated ......................................................................................10
05-50-08 Oil Pressure Loss Inspection ..................................................................................10
05-50-09 Inability to Start the Engine ..................................................................................10
Chapter 12-00-00 Servicing ........................................................................................................1
12-20-00 Engine Oil Servicing ............................................................................................... 1
12-20-01 Check the Oil Level ................................................................................................ 1
12-20-10 Gearbox Oil ........................................................................................................... 2
12-20-11 Check the Gearbox Oil Level................................................................................... 2
12-40-00 Engine Coolant Servicing ........................................................................................ 2
Chapter 24-00-00 Electrical Power ..............................................................................................1
24-00-01 General ................................................................................................................. 1
24-00-10 Alternator ............................................................................................................. 1
24-00-11 Removal of the Alternator ...................................................................................... 1
24-00-12 Installation of the Alternator .................................................................................. 1
24-00-13 Alternator/Regulator Adjustment E4A-91-100-000 ................................................... 3
24-00-14 Adjustment procedure of voltage regulation E4A-91-100-000 ................................... 4
24-00-15 Adjustment of alternator balancing E4A-91-100-000 (only for twin-engine ............
applications) ......................................................................................................... 4
24-00-16 Alternator/Regulator Adjustment E4A-91-200-000 ................................................... 5
24-00-17 Paralleling for twin engine system E4A-91-200-000 ................................................. 5
24-00-18 Replacing Alternator Regulator E4A-91-100-000 ...................................................... 5
24-00-20 Inspection of the Carbon Brushes ........................................................................... 6
24-00-21 Maintenance/Inspection of Carbon Brushes ............................................................. 6
24-00-22 Brush Holder Replacement in Field ......................................................................... 6
24-00-23 Inspection of Carbon Brushes and Alternator .......................................................... 6
24-00-24 Tools necessary ..................................................................................................... 6
24-00-25 Removal of the Alternator ...................................................................................... 6
24-00-26 Removal of the Brush Holder.................................................................................. 7
24-00-27 Visual Inspection of Alternator Housing................................................................... 8
24-00-28 Inspection of Contact Ring and Brushes .................................................................11
24-00-29 Disassembly of Brush Holder .................................................................................12
24-00-30 Measuring the Length of Carbon Brushes ...............................................................14
24-00-31 Evaluation Criteria ................................................................................................15
24-00-32 Completion of Brush Holder ..................................................................................16
24-00-33 Completion of Generator (Integration of Brush Holder) ...........................................18
24-00-34 Functionality Check ..............................................................................................20
24-00-35 Marking of Reworked Alternator ............................................................................21
24-00-36 Installation of the Alternator .................................................................................22
24-00-37 General ................................................................................................................22

Revision no: 24
Page: Intro-19
24-00-38 Maintenance / Inspection of Carbon Brushes ..........................................................22

24-00-39 Brush Holder Replacement in Field ........................................................................22
24-00-40 General Information .............................................................................................22
24-00-41 Inspection of Carbon Brushes and Alternator .........................................................23
24-00-42 Tool necessary .....................................................................................................23
24-00-43 Removal of Alternator ...........................................................................................23
24-00-44 Removal of Assy Brush Holder ...............................................................................24
24-00-45 Visual Inspection of Alternator Housing ..................................................................26
24-00-46 Inspection of Contact Ring and Brushes .................................................................29
24-00-47 Disassembly of ASSY Brush Holder ........................................................................30
24-00-48 Measuring the Length of Carbon Brushes ...............................................................31
24-00-49 Evaluation Criteria ................................................................................................32
24-00-50 Completion of Alternator (Installation of ASSY Brush Holder) ..................................33
24-00-51 Functionality Check ..............................................................................................36
24-00-52 Marking of Reworked Alternator ............................................................................37
24-00-53 Installation of the Alternator .................................................................................38
Chapter 51-00-00 Standard Practices ..........................................................................................1
51-00-10 Safety Wiring ........................................................................................................ 1
51-00-11 The following Alternator rules apply to safety wiring ................................................ 1
51-00-12 Single Wire Safe Tying ........................................................................................... 2
51-00-13 Double Wire Safety Wiring By Hand ........................................................................ 2
51-00-14 Double Wire Safety Wiring Using Pliers ................................................................... 3
51-00-15 Samples of Safety Wiring ....................................................................................... 4
51-00-20 Torque Standards .................................................................................................. 7
Chapter 71-00-00 Power Plant ...................................................................................................1
71-00-01 General ................................................................................................................. 1
71-00-02 Instruction ............................................................................................................ 1
71-00-03 Engine Ground Run ............................................................................................... 2
71-50-00 Electrical Harness .................................................................................................. 4
71-50-01 General ................................................................................................................. 4
71-50-02 General Information -> Wiring Harness .................................................................. 4
71-50-10 Engine Wiring Harness E4A-90-000-000 .................................................................. 5
71-50-20 Sensor – Check ..................................................................................................... 6
71-50-30 Description Plug Connector Wiring Harness ............................................................. 6
71-50-40 Material and saving material for the Engine Wiring Harness ..................................... 7
71-50-60 Mounting Backbones.............................................................................................. 8
71-50-70 Intake Air Manifold ................................................................................................ 9
71-50-80 Alternator ............................................................................................................16
71-50-90 GPC .....................................................................................................................17
71-50-100 CRS 1 & 2 ............................................................................................................18
71-50-110 Mechanical protection (Mesh tube) ........................................................................19
71-50-120 Engine Wiring Harness E4A-95-000-000 and E4B-95-000-000 .................................23
71-50-130 Sensor – Check ....................................................................................................25
71-50-140 Description Plug Connector Wiring Harness ............................................................25
71-50-150 Material and saving material for the E4A Engine Wiring Harness..............................26
71-50-160 Material and saving material for the E4B Engine Wiring Harness ..............................26
71-50-170 E4 Engine Wiring Harness mounting instruction ......................................................27
71-50-180 Fastening point in the aircraft (E4A-90-000-000) ....................................................43
71-50-190 Remove the Wiring Harness ..................................................................................45
71-50-800 Repair of the Engine Wiring Harness E4A-90-000-000 .............................................47
71-50-801 Exchange of Connector to “Intake Air Temperature”-Sensors ..................................47
71-50-802 Exchange of Connector to Fuel Pressure Sensor (FPS) ............................................49
71-50-803 Exchange of Connector to Boost Pressure Actuator (BPA) .......................................51
71-50-804 Exchange of Connector for Alternator E4A-91-400-000 ...........................................53

Revision no: 24
Page: Intro-20

71-50-900 Repair of the Engine Wiring Harness E4A-95-000-000 und E4B-95-000-000 .............58
71-50-901 Exchange of Connector of Gearbox Temperature Sensor (GBTS) .............................58
Chapter 73-00-00 Engine Fuel and Control ..................................................................................1
73-00-01 General ................................................................................................................. 1
73-00-10 Injector ................................................................................................................ 1
73-00-11 Removal of the Injector ......................................................................................... 1
73-00-12 Installation of the Injector ..................................................................................... 1
73-00-20 Injector Seals ........................................................................................................ 3
73-00-21 Removal of the Injectors Seals ............................................................................... 3
73-00-22 Installation of the Injectors Seals ........................................................................... 3
73-00-30 Fuel Return Line .................................................................................................... 4
73-00-31 Removal of the Fuel Return Line ............................................................................ 4
73-00-32 Installation of the Fuel Return Line ......................................................................... 4
73-00-40 High Pressure Pump .............................................................................................. 6
73-00-41 Removal of the High Pressure Pump ....................................................................... 6
73-00-42 Removal of the spur gear from High Pressure Pump ................................................ 7
73-00-43 Installation of the spur gear onto High Pressure Pump ............................................. 8
73-00-44 Installation of the High Pressure Pump ................................................................... 8
73-00-50 Low Fuel pressure sensor ....................................................................................... 9
73-00-51 Removal of the Fuel pressure sensor ...................................................................... 9
73-00-52 Installation of the Fuel pressure sensor................................................................... 9
73-00-60 Rail Pressure Sensor .............................................................................................10
73-00-61 Removal of the Rail Pressure Sensor ......................................................................10
73-00-62 Installation of the Rail Pressure Sensor ..................................................................10
73-00-70 Rail Pressure Control valve ....................................................................................10
Chapter 76-00-00 Engine Control ...............................................................................................1
76-00-01 General ................................................................................................................. 1
76-00-10 Engine Electronic Control Unit (EECU) ..................................................................... 1
76-00-11 Software Updates .................................................................................................. 1
76-00-20 Glow Plug Control .................................................................................................. 3
76-00-21 Removal of the Glow Plug Control .......................................................................... 3
76-00-22 Installation of the Glow Plug Control ....................................................................... 3
76-00-30 Crankshaft Sensor ................................................................................................. 4
76-00-31 Removal of the Crankshaft Sensor .......................................................................... 4
76-00-32 Installation of the Crankshaft Sensor ...................................................................... 4
76-00-40 Camshaft Sensor CAS 1 ......................................................................................... 5
76-00-41 Removal of the Camshaft Sensor CAS 1 .................................................................. 5
76-00-42 Installation of the Camshaft Sensor CAS 1 .............................................................. 5
76-00-50 Camshaft Sensor CAS 2 ......................................................................................... 6
76-00-51 Removal of the Camshaft Sensor CAS 2 .................................................................. 6
76-00-52 Installation of the Camshaft Sensor CAS 2 .............................................................. 6
Chapter 77-00-00 Engine Indicating ...........................................................................................1
77-00-01 General ................................................................................................................. 1
77-00-10 Gearbox Temperature Sensor ................................................................................. 1
Chapter 78-00-00 Engine Exhaust ..............................................................................................1
78-00-01 General ................................................................................................................. 1
78-00-10 Exhaust Manifold ................................................................................................... 1
78-00-11 Removal of the Exhaust Manifold ............................................................................ 1
78-00-12 Installation of the Exhaust Manifold ........................................................................ 1
78-00-20 Exhaust Manifold Gasket Exchange ......................................................................... 2
Chapter 79-00-00 Engine Oil ......................................................................................................1

Revision no: 24
Page: Intro-21
79-00-01 General ................................................................................................................. 1

79-00-10 Oil-Filter Housing Draining Line .............................................................................. 1
79-00-11 Removal of the Oil-Filter Housing drain line ............................................................. 1
79-00-12 Installation of the Oil-Filter Housing drain line ......................................................... 1
79-00-20 Drain of Engine Oil ................................................................................................ 3
79-00-30 Refill of Engine Oil ................................................................................................. 3
79-00-40 Oil Sump ............................................................................................................... 4
79-00-41 Removal of the Oil Sump ....................................................................................... 4
79-00-42 Installation of the Oil Sump .................................................................................... 4
79-00-50 Oil Sump Gasket Exchange .................................................................................... 5
79-00-60 Oil-Filter Housing ................................................................................................... 7
79-00-61 Removal of the Oil-Filter Housing ........................................................................... 7
79-00-62 Installation of the Oil-Filter Housing........................................................................ 7
79-00-70 Oil-Filter ............................................................................................................... 8
79-00-71 Remove and discard of the Oil-Filter ....................................................................... 8
79-00-72 Installation of the Oil-Filter .................................................................................... 8
79-00-80 Oil Separator ......................................................................................................... 9
79-00-81 Removal of the Oil Separator ................................................................................. 9
79-00-82 Installation of the Oil Separator .............................................................................. 9
79-00-83 Removal of the Oil Separator By-Pass Valve ............................................................ 9
79-00-84 Installation of the Oil Separator By-Pass Valve .......................................................10
79-00-90 Oil Separator Return Line ......................................................................................11
79-00-91 Removal of the Oil Separator Return Line ..............................................................11
79-00-92 Installation of the Oil Separator Return Line ...........................................................11
79-00-100 Lubricant Line ......................................................................................................12
79-00-101 Removal of the Lubricant Line ...............................................................................12
79-00-102 Installation of the Lubricant Line ...........................................................................12
79-00-103 Removal of the Lubricant Line Sealing Ring ............................................................13
79-00-104 Installation Lubricant Line Sealing Ring ..................................................................13
79-00-110 Oil Return Line .....................................................................................................14
79-00-111 Removal of the Oil Return Line ..............................................................................14
79-00-112 Installation of the Oil Return Line ..........................................................................14
79-00-113 Removal of the Oil Return Line Gasket ...................................................................15
79-00-114 Installation of the Oil Return Line Gasket ...............................................................15
79-00-120 Oil Level Sensor ...................................................................................................16
79-00-121 Removal of the Oil Level Sensor ............................................................................16
79-00-122 Installation of the Oil Level Sensor ........................................................................16
79-00-130 Oil Pressure Sensor ..............................................................................................17
79-00-131 Removal of the Oil Pressure Sensor .......................................................................17
79-00-132 Installation of the Oil Pressure Sensor ...................................................................17
79-00-140 Governor .............................................................................................................18
79-00-141 Removal of the Governor ......................................................................................18
79-00-142 Installation of the Governor ..................................................................................18
Chapter 80-00-00 Starting .........................................................................................................1
80-00-01 General ................................................................................................................. 1
80-00-10 Starter .................................................................................................................. 1
80-00-11 Removal of the Starter ........................................................................................... 1
80-00-12 Installation of the Starter ....................................................................................... 1
80-00-20 Glow Plugs ............................................................................................................ 3
80-00-21 Removal of the Glow Plugs .................................................................................... 3
80-00-22 Installation of the Glow Plugs ................................................................................. 3
Chapter 81-00-00 Turbocharging ................................................................................................1
81-00-01 General ................................................................................................................. 1
81-00-10 Turbo Charger Complete ........................................................................................ 1

Revision no: 24
Page: Intro-22
81-00-11 Removal of the Turbo Charger ............................................................................... 1

81-00-12 Installation of the Turbo Charger ............................................................................ 1
81-00-13 Removal of the Waste Gate Controller .................................................................... 1
81-00-14 Install new Waste Gate Controller .......................................................................... 1
81-00-20 Boost Pressure Actuator ......................................................................................... 3
81-00-21 Removal of the Boost Pressure Actuator (BPA) ........................................................ 3
81-00-22 Installation of the Boost Pressure Actuator .............................................................. 3
81-00-30 Waste Gate Controller ............................................................................................ 5
81-00-31 Inspection ............................................................................................................. 5
81-00-32 Check /Adjust of the Waste Gate Controller............................................................. 5
Chapter 85-00-00 Reciprocating Engine ......................................................................................1
85-00-10 Injector Cover ....................................................................................................... 1
85-00-11 Removal of the Injector Cover ................................................................................ 1
85-00-12 Installation of the Injector Cover without maintenance lid ........................................ 1
85-00-13 Removal of the Maintenance Lid ............................................................................. 3
85-00-14 Installation of the Injector Cover with maintenance lid ............................................ 3
85-00-15 Installation of the Maintenance Lid ......................................................................... 4
85-10-00 Reciprocating Engine Front System ......................................................................... 6
85-10-10 Gearbox ................................................................................................................ 6
85-10-11 Removal of the Gearbox ........................................................................................ 6
85-10-12 Installation of the Gearbox ..................................................................................... 6
85-10-20 Gearbox Magnet-Drain Plug ................................................................................... 9
85-10-21 Removal of the Gearbox Magnet-Drain Plug ............................................................ 9
85-10-22 Installation of the Gearbox Magnet-Drain Plug .......................................................10
85-10-30 Gearbox Oil Filter (Gearbox Rev. 70 or higher) .......................................................11
85-10-31 Removal of the Gearbox Oil Filter ..........................................................................11
85-10-32 Installation of the Gearbox Oil Filter ......................................................................12
85-10-40 Gearbox Temperature Sensor ................................................................................13
85-10-41 Removal of the Gearbox Temperature Sensor ........................................................13
85-10-42 Installation of the Gearbox Temperature Sensor .....................................................13
85-10-50 Gearbox Oil ..........................................................................................................14
85-10-51 General ................................................................................................................14
85-10-52 Exchange of the Gearbox Oil .................................................................................14
85-10-53 Refill of the Gearbox Oil ........................................................................................14
85-10-60 Two-Mass-Flywheel ..............................................................................................15
85-10-61 Removal of the Two-Mass-Flywheel .......................................................................15
85-10-62 Installation of the Two-Mass-Flywheel ...................................................................15
85-10-63 Removal and Disassembly .....................................................................................16
85-10-64 Cleaning ..............................................................................................................16
85-10-65 Inspection ............................................................................................................18
85-10-66 Repair and Replacement .......................................................................................32
85-10-67 Marking of Inspected Two-Mass-Flywheel ..............................................................32
85-10-68 Reassembly..........................................................................................................33
85-10-69 Special Tools ........................................................................................................33
85-10-70 Packing and Shipping............................................................................................34
85-20-00 Reciprocating Engine Power Section ......................................................................35
85-20-10 Crankshaft Cover ..................................................................................................35
85-20-11 Removal of the Crankshaft Cover ..........................................................................35
85-20-12 Installation of the Crankshaft Cover .......................................................................35
85-30-00 Reciprocating Engine Cylinder Section ...................................................................37
85-30-10 Intake Air.............................................................................................................37
85-30-11 Removal of the Intake Air Manifold ........................................................................37
85-30-12 Installation of the Intake Air Manifold ....................................................................37
85-30-20 Boost Pressure Sensor ..........................................................................................40

Revision no: 24
Page: Intro-23
85-30-21 Removal of the Boost Pressure Sensor ...................................................................40

85-30-22 Installation of the Boost Pressure Sensor ...............................................................40
85-30-30 Intake Air Temperature Sensor..............................................................................40
85-30-31 Removal of the Intake Air Temperature Sensor ......................................................40
85-30-32 Installation of the Intake Air Temperature Sensor ..................................................40
85-40-00 Reciprocating Engine Rear Section .........................................................................41
85-40-10 V-Ribbed Belt .......................................................................................................41
85-40-11 Removal of the V-Ribbed Belt ................................................................................41
85-40-12 Installation of the V-Ribbed Belt ............................................................................41
85-40-20 Belt Tensioner ......................................................................................................42
85-40-21 Removal of the Belt Tensioner...............................................................................42
85-40-22 Installation of the Belt Tensioner ...........................................................................42
85-40-30 Belt Tensioner – Roller ..........................................................................................43
85-40-31 Removal of the Belt Tensioner – Roller ..................................................................43
85-40-32 Installation of the Belt Tensioner – Roller ...............................................................43
85-40-40 Check of timing chain ...........................................................................................44
85-40-41 Preparations prior check of timing chain ................................................................44
85-40-42 Timing Chain Measuring tool (TCMT) .....................................................................45
85-40-43 Checking procedure of timing chain .......................................................................46
85-40-44 Results of the timing chain check ..........................................................................47
85-40-45 Assembly of engine after timing chain check ..........................................................48
85-40-50 Exposure of timing chain and camshaft chain wheel ...............................................49
85-40-51 Exchange of timing chain ......................................................................................51
85-40-52 Replacing of timing chain wheel ............................................................................57
85-40-53 Check of engine timing .........................................................................................59
85-40-54 Reassembly of engine ...........................................................................................60
85-70-00 Reciprocating Engine Liquid Cooling ......................................................................62
85-70-10 Coolant Temperature Sensor .................................................................................62
85-70-11 Removal of the Coolant Temperature Sensor .........................................................62
85-70-12 Installation of the Coolant Temperature Sensor ......................................................62
85-70-20 Water Pump .........................................................................................................63
85-70-21 Removal of the Water Pump .................................................................................63
85-70-22 Installation of the Water Pump ..............................................................................63
85-70-30 Heat Exchanger ....................................................................................................64
85-70-31 Removal of the Heat Exchanger ............................................................................64
85-70-32 Installation of the Heat Exchanger .........................................................................64
85-70-40 Coolant Thermostat ..............................................................................................65
85-70-41 Removal of the Coolant Thermostat .......................................................................65
85-70-42 Installation of the Coolant Thermostat ...................................................................65
Chapter 92-00-00 Additional Information ....................................................................................1
Engine Wiring Diagrams for E4A-90-000-000 .............................................................................. 1
Engine Wiring Diagrams for E4A-95-000-000 und E4B-95-000-000 .............................................. 3
Aircraft Interface Wiring ............................................................................................................ 5
Propeller Self Test (Automatic Run-Up Test) ............................................................................... 8
Harness Routing ......................................................................................................................13
List of Tools ...........................................................................................................................14

Revision no: 24
Page: Intro-24
Chapter 01-00-00 General
This Maintenance Manual contains all instructions necessary for continued airworthiness.
In addition this Maintenance Manual contains repair procedures for certain engine components, which
are detailed in a separate section of the chapter related to the engine component.
The engine installation instructions for the engine are given in the engine
Installation Manual E4.02.01.
The engine operating information and the description of the engine are given in the engine
Operation Manual E4.01.01.
For special removal and installation procedures from the aircraft manufacturer refer to the applicable
Aircraft Maintenance Manual.
Unless otherwise stated only new or overhauled parts, if applicable, shall be used in case of
exchange acc. to this manual.

Revision no: 19
Page: 01-1
01-10-00 General Engine Description

Designation:
Brand Name: AE 300

TC-Designation: E4 for the engine followed by a letter, which indicates installation
specific configuration changes. .
E4-A .................................. Basic Design
For detailed information refer to MSB E4-002
Brief Description:
The AE 300 is a liquid-cooled, in-line four-stroke four cylinder engine with a double overhead
camshaft (DOHC). Every cylinder has four valves which are actuated by the cam follower.
The direct fuel injection is realized with a common rail technique and the engine is turbo charged.
The whole engine operation is controlled by an Electronic Engine Control System.
The engine is equipped with an electrical starter, an alternator, a water pump, an oil pump, a coolant
system and an oil cooler. The propeller is driven by a directly integrated gearbox with an integral
torsional vibration damper
Power: 123,5 KW (165,6 hp) with a torque of 513 Nm (4540.43 Lbin) at 2300 PropRPM
Displacement: 1991 cm³ (121,5 cu in³)
Bore: 83 mm (3,26 in)
Stroke: 92 mm (3,62 in)
Weight (dry): 185 kg (408 lbs)
Gear Ratio: 1,69
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.
The EECU consists of two similar ECUs (Engine control Units).

A voter is integrated in the EECU and proposes an ECU to control the engine regarding the ECU
operating hours or in case of a failure the ECU with better engine control capability.
 This engine is not capable for aerobatics use.

 This engine is not approved for rotor craft.
 The engine should not be operated without propeller.
 This engine is only designed for pull propeller installations.

Revision no: 11
Page: 01-2
Scope of Supply:
The following components and assemblies are included as part in the Type Design of the
AE 300:
 Core engine
 Turbocharger
 Thermostat
 Water Pump
 Fuel injection system
 Starter
 Alternator with Alternator regulator
 EECU
 All actuators and sensors required for engine operation
 Wiring harness
 Gearbox
 Power Lever Sensor
 Glow Plug Control
Additional:
The following components are not part of the Type Design of the AE 300. These parts are provided by
the airframe manufacturer.
 Governor
 Fuel pumps
 Fuel Filter Housing
 Fuel Filter
 Engine shock mounts
For detailed specifications see corresponding chapters.

Revision no: 9
Page: 01-3
Engine Front View:
Fig. 01 - 1 Engine Front View

Revision no: 11
Page: 01-4
Engine Top View:
Fig. 01 - 2 Engine Top View

Revision no: 11
Page: 01-5
Engine Left Side View:
Fig. 01 - 3 Engine Left Side View

Revision no: 11
Page: 01-6
Engine Right Side View:
Fig. 01 - 4 Engine Right Side View

Revision no: 11
Page: 01-7
Engine Top View with removed Injector Cover:
Fig. 01 - 5 Detailed Top View with removed Injector Cover

Revision no: 11
Page: 01-8
Dimensions:
Bore: 83 mm
(3.268 in)
Stroke: 92 mm
(3.622 in)
Cylinder spacing (center to center): 90 mm

(3.543 in)
Displacement total: 1991 cm³

(121,5 in³)
Displacement (per cylinder): 498 cm³

(30,4 in³)
Compression ratio: 17.5:1
Gearbox ratio: 1,69
Weight (dry): 185 kg
Characteristics:
Manifold pressure max. 2660 mbar
Fuel pressure: max. 1650 bar
Firing order: 1:3:4:2

Revision no: 11
Page: 01-9
Gearbox:
The AE300 is equipped with a gearbox to reduce RPM from the 3880 RPM maximum of the engine to
2300 RPM at the propeller. The reduction ratio of the gearbox is 1.69:1. The figure shows the gearbox
case and the gearbox case cape of the disassembled gearbox.
The gearbox contains three gears. The gearbox housing itself is casted, while the gears are forged
steel.
The governor is attached to the top of the gearbox and controls the pitch of the propeller.
Fig. 01 - 6 Gearbox

Revision no: 11
Page: 01-10
Torsion Vibration Damper (TVD)

Between gearbox and crankshaft a torsion vibration damper is implemented to reduce torsion
vibration. On one hand the crankshaft is protected from vibrations coming from the propeller, on the
other hand the gearbox is protect from vibrations coming from the crankshaft and the combustion
process. The damper is composed of two elements, a mass and an energy dissipating element. The
mass resists the acceleration of the vibration and the energy dissipating element absorbs the
vibrations.
Crankshaft
The crankshaft of the AE 300 is made of vacuum remolded, forged steel. The crankshaft has 5 main
bearings.
Fig. 01 - 7 Crankshaft with Two Mass Flywheel attached

Revision no: 11
Page: 01-11
Crank Case
The AE300 Crankcase is a single piece, squeeze casted part. Based on this design ( cast iron)
separate cylinder liners are not necessary. The cast iron design of the crank case has good failsafe
running functions and also a reduced noise emission. The design of the AE300 is an inline, liquid
cooled engine, the crankcase incorporates the cylinders as well as the coolant passages.
The bore of the cylinder is 83 mm (3,268in). The displacement per cylinder is 498cm³ (30,4 cu in)
which results in a total displacement of 1991 cm³ (121,5 cu in) of the engine. The stroke per piston is
92 mm (3,622 in).
The crankcase also includes provisions for an internal oil pump and a water pump that is mounted on
the engine crank case and driven by the rip belt. The crankcase includes a wet oil sump and contains
the oil supply of the engine.
Cylinder Head
The cylinder head is made of high strength aluminum alloy. The cylinder head is equipped with two
camshafts. Each camshaft drives one intake and one exhaust valve per cylinder. One camshaft is
driven by chain directly from the crankshaft. The other camshaft is driven off the first by direct gear.
The chain drive consists of a double steel chain. Chain tensioning is automatic, and the system is
maintenance free for the life of the engine. The camshafts operate 16 valves, 8 intake and 8 exhaust
valves actuated by roller levers with hydraulic valve- clearance compensation.
The combustion chamber shape of the AE300 is defined mainly by the shape of the piston The valves
are arranged such that the intake air enters the combustion chamber in a swirling pattern to improve
combustion efficiency.
The location of the fuel injector is central to the four valves. The hole immediately next to the injector
hole is the hole for the glow plugs, which are used during pre-heating. The remaining openings in the
cylinder head are coolant passageways. The compression ratio of the engine is 17,5:1.
V-Ripped Belt
The engine is equipped with a V-ribbed belt at the rear end, which drives the coolant pump and the
alternator driven by the crankshaft pulley. The belt is self-tensioning by a spring-loaded pulley.

Revision no: 11
Page: 01-12
01-10-10 Intake/Exhaust System Description

General:
For operation the engine has to be supplied by the intake system with compressed air at manifold
pressures up to 2660 mbar (38,57 psi), which varies with altitude and power setting. The increased
manifold pressure is accomplished with an exhaust driven turbo charger. After the turbocharger, the
air passes through the intercooler, through the engine to the turbine side of the turbocharger before
exhausting to the atmosphere.
The intake air is cleaned by an air filter and then compressed by the turbo charger. During
compression the intake air gets hot. An intercooler between turbo charger and engine is provided to
cool the intake air down thus the desired engine performance can be obtained.
At the intake manifold the intake air temperature and intake air pressure are measured. For the
temperature and pressure readings there are two sensors for each value installed. To provide the
intake air pressure corresponding to the desired engine power and ambient EECU pressure a waste
gate valve is directly mounted at the turbo charger.
Turbo Charger
The EECU controls the turbocharger by using RPM, measured manifold pressure and barometric
pressure to determine a target value for manifold pressure. The EECU then sends an output signal
corresponding to this target value to a boost pressure actuator, which actuates the waste gate.
The boost pressure actuator uses air pressure from the compressor side of the turbocharger to control
a diaphragm box. This diaphragm box is mechanically linked to the turbo charger waste gate and
regulates the amount of exhaust gas that bypasses the turbocharger turbine and therefore manifold
pressure.
The figure shows the turbocharger with the boost pressure actuator, air filter for the boost pressure
actuator and the waste gate controller which is attached to the turbo charger.
Fig. 01 - 8 Turbo Charger Operation

Revision no: 11
Page: 01-13
Components of the A/C System:

(For installation and maintenance details refer to the applicable Aircraft Maintenance
Manual)
 Air filter
 Intercooler
 Hoses
 Alternate Air intake if required
Part of the engine TDD:
 Turbocharger
 Intake manifold
 Exhaust manifold
Example for acceptable Air Intake system:

(For particular installation refer to the applicable Aircraft Maintenance Manual)
Intake Manifold Intercooler
Exhaust Manifold
Alternate
Air Intake
Air Filter
Turbo Charger
Exhaust Pipe
Included in Engine TC Muffler

Fig. 01 - 9

Revision no: 11
Page: 01-14
01-10-20 Fuel System Description

General:
The AE 300 is equipped with a common rail fuel injection system. In such a system the common rail is
a high-pressure fuel reservoir that supplies fuel to solenoid type injectors. Fuel enters the common rail
directly from the high-pressure pump which compresses the fuel up to 1680 bar. The amount of
required fuel is regulated by a fuel metering unit which is attached direct to the high pressure pump.
The actual fuel pressure in the rail (and therefore to the injectors) is measured by the rail pressure
sensor. The EECU interprets the rail pressure, compares it to a target value, and adjust the rail
pressure control valve to reach the correct pressure. Return fuel flows back to the fuel tank. Fuel is
supplied to the injectors through the injector supply ports. Excess fuel (not depicted) is also returned.
The fuel pressure supplied to the injectors is varied continuously. A higher fuel pressure ensures
better vaporization and therefore better combustion, as well as shorter injection duration, allowing
delivering the desired fuel volume at the optimal time. By varying the fuel pressure, the injection
duration can be varied for a given desired fuel injection volume per cycle, allowing for better
combustion at lower RPM.
Injector #1
Injector #2
Injector #3 Rail Pressure Sensor
Injector #4
Common Rail
High Pressure
Pump Rail Pressure Control Valve
Fuel metering unit
Fig. 01 - 10 Common Rail fuel System

Revision no: 11
Page: 01-15

Manual)
 Feed pump
 Fuel feed line
 Fuel filter
 Fuel return line
 Fuel shut off valve
Part of the engine TDD:
 High pressure pump (HPP)

 High pressure fuel rail
 Low fuel pressure sensor
 High fuel pressure sensor
 Fuel temperature sensor
 Fuel control pressure valve

Revision no: 11
Page: 01-16
Fuel Distribution System:
There must be a shut-off valve on the feed line. In case of an emergency it must be
possible for the pilot to shut of the fuel flow.
In the return line a provision must be provided to cut off fuel flowing back to engine in
case of an engine fire (e.g. check valve).
Protection of the intake line to the fuel pump against vibration and other additional
forces is necessary.
Example for acceptable Fuel distribution system:

Fig. 01 - 11 Fuel circuit

Revision no: 11
Page: 01-17
01-10-30 Exhaust System Description

General:
The exhaust system is necessary to release the exhaust fumes in a safe and proper way into the
environment. Wrong installation and maintenance can lead to vibrations, which can cause serious
damage in the exhaust system.
Excessive tension at exhaust system mounting points could cause cracks and be a
potential fire hazard.

Manual)
 Exhaust pipe (including optionally exhaust muffler)
Example for acceptable Exhaust System is given under 01-10-10

01-10-40 Coolant System Description

General:
The internal engine cooling circuit consists of coolant pump, which is driven by the belt, the integrated
coolant/oil heat exchanger, coolant ducts within crank case, cylinder head and intake manifold, where
the coolant temperature sensors are located, and the coolant thermostat.
Coolant enters the engine, driven by the coolant pump. Depending on coolant temperature the
coolant passes at the coolant thermostat through the short circuit direct back to the engine, or
through the radiator, where it is cooled before returning to the engine by passing the oil/coolant heat
exchanger.
At the thermostat there are two circuits connected, the small circuit, which is flown through as long as
the engine is cold and the radiator circuit, which starts to be opened as soon as a coolant temperature
measured direct at the thermostat is above 80 °C (176 °F).
Above 95 °C (203 °F) coolant temperature the radiator circuit is fully open and the small circuit totally
closed. The Heating circuit is always open and aids in cooling.
An expansion tank is provided which contains a silica reservoir to provide the necessary corrosion
protection. The expansion tank has an overpressure valve installed which limits the relative pressure
in the coolant system to max. 2,3 bar (33,36 psi). In addition a low pressure valve is installed to
protect the coolant system from negative pressure
The coolant reservoir allows the coolant to expand when cold, or allows the cooling system to draw
additional coolant as needed. The coolant reservoir also contains a low coolant level indicator

Revision no: 11
Page: 01-18

Manual)
 Coolant radiator
 Cabin Air Heat Exchanger
 Coolant expansion Tank
 Overpressure Valve
 Low pressure Valve
 Silica Reservoir
 Coolant hoses
Cooling Circuit:
Example for acceptable cooling circuit:

Expansion Tank
(incl. Overpressure and low pressure valve)
D3 Part of certified
engine
D1
D2
D5
D4
Fig. 01 - 12 Cooling Circuit

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Page: 01-19
Thermostat Opening Temperature:
Small Cooling Circuit without Radiator: <80 °C

(<176 °F)
Mixed Operation: 80 °C – 95 °C
(176 °F – 203°F)
Radiator Through-Flow >95 °C

(>203°F)
To prevent the system from to much coolant flowing through the vent line an orifice is
installed with an inner diameter of 2 mm (0.079 in) within the line between expansion tank
and radiator. If the line is small enough no orifices are necessary.

Revision no: 11
Page: 01-20
01-10-50 Lubricating System Description

General:
The lubricating system of the AE300 consists of an internal chain driven oil pump, which pumps the
engine oil through the oil filter, the coolant/oil heat exchanger and the lubrication ports of the engine.
The lubricating system is part of the engine. A coolant/oil heat exchanger as part of the engine
provides the oil cooling. Dependant on the coolant temperature the oil temperature is obtained. If
necessary the cooling capacity can be increased by an airstream over the oil sump.
Below the injector cover an oil separator is installed. The breather air out of the crankcase is guided
through an oil separator. Downstream the oil separator the crankcase air is released through the
breather line into the environment. The outlet of the oil separator at the injector cover has to be
connected to a breather line provided by the OEM. The oil separator is protected with an overpressure
relief valve.
In front of the oil filter the oil pressure is measured. The oil temperature is measured in the oil sump
next to the oil filler neck.
Fig. 01 - 13 Lubrication System

Revision no: 11
Page: 01-21
01-10-60 Electrical System Description

The Electrical System consists of the following major Components:
– Starter
– Generator
– GPC – Glow Plug Control Unit
– EECU – Electronic Engine Control Unit
– Sensors & Actuators
The EECS Block Diagram shows the connection between the EECS components which are used in the
AE 300 Engine and displays also the Interface from the Airframe to the EECS of the AE 300.
Engine Sensors Actuators
EECU
Glow Generator
Plug Starter
Control
EECS
A/C
Power Engine
3way Cockpit
A/C Interface Lever Monitoring A/C Power
Switch
System
Fig. 01 - 14 EECS Block Diagram

Revision no: 11
Page: 01-22
The starter is manually controlled by the pilot. The EECU will detect a running engine at 600rpm
(Propeller) and further activation is not necessary.
The Generator is a 28V/70A power supply which consists of an alternator mounted to the engine and
an external regulator. This power supply is used to supply the EECS and the airframe.
The Glow Plug Control Unit is only used to enhance the cold starting behavior of the engine on
ground. It controls the power which is dissipated by glow plugs. These quick start glow plugs help to
ignite the compressed fuel/air mixture because of their hot surface temperature.
The EECU is a 28V supplied device which consists of two similar parts, called ECU A and ECU B. Each
ECU is able to control the engine itself. At each self test both ECU channels will be tested.
Depending on the operating hours count the active ECU will be selected. The other ECU channel is in
hot standby that means active, evaluating sensor values but not operating actuators.
In case of a detected failure on one ECU an internal voter can switch over to the alternate channel.
If different kinds of failures are active at the same time, the switch over decision is based on failure
priorities.
This switch over decision can be overruled by the pilot by manually forcing one channel.
The interface to the engine indications in the A/C is realized via a serial Bus (CAN-Bus).
The pilot interface is realized over Power Lever Sensors. Each ECU has it´s own sensor. Each sensor
has two outputs which are used to perform plausibility checks of the sensor.

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Page: 01-23
EECU Functions
Sensors and Actuators
Sensors ECU A
Camshaft Sensor
EECU
Crankshaft Sensor
Intake Air Temperature

Sensor
Boost Pressure Sensor
Power Lever Sensor
ECU A Actuators
Shared Sensors
Gearbox Temperature Injectors (4)
Sensor Boost Pressure
Acutator
Oil Temperature Sensor
Relay Rail Pressure
Fuel Pressure Sensor Shared Sensor
Signal Matrix Control Valve
Rail Pressure Sensor Conditioning
Oil Pressure Sensor Governor Actuator

Coolant Temperature
Fuel Metering Unit
Sensor
Fuel Temperature Sensor Fuel Pump A
ECU B Fuel Pump B

Sensors ECU B
Caution Lamp A
Camshaft Sensor
Crankshaft Sensor Caution Lamp B
Intake Air Temperature

Sensor
Boost Pressure Sensor
Power Lever Sensor
Fig. 01 - 15 Sensors and Actuators

Revision no: 11
Page: 01-24
Sensors
o Power Lever Sensor
o Power Lever Sensor position evaluation
o Hall Effect Sensor with dual output
o Crank Shaft Sensor
o Engine speed evaluation
o Cam Shaft Sensor
o Engine position evaluation
o Fuel Pressure Sensor
o Used for evaluation of the fuel pressure after the pre-supply pump
o Oil Pressure Sensor
o Used for evaluation of the engine oil pressure
o Rail Pressure Sensor
o Used to evaluate the rail pressure
o Boost Pressure Sensor
o Boost (Intake Air) Pressure evaluation
o Coolant Temperature Sensor
o Used for coolant temperature evaluation
o Fuel Temperature Sensor
o Used for fuel temperature evaluation
o Gearbox Oil Temperature Sensor
o Used for gearbox temperature evaluation
o Engine Oil Temperature Sensor
o Combinant Sensor used for engine oil temperature evaluation
o Intake Air Temperature Sensor
o Intake Air Temperature evaluation
Actuators
o Injectors
o Boost Pressure Actuator
o Rail Pressure Control Valve
o Fuel Metering Unit
o Pre-Supply (electrical) Fuel Pump
o Governor Set Point Actuator
o Caution Lamps

Revision no: 11
Page: 01-25
EECU
Power Supply
ECU A ECU A
Sensors ECU A
Relay
Shared Sensors Voter Actuators
Matrix
Sensors ECU B
Power Supply ECU B

ECU B
A/C
3way Cockpit
Engine Switch
Power
Sensor A Sensor B Indications /
Lever
Annunciations ECU A ECU B Voter
Fig. 01 - 16 EECU
 Electrical Interfaces
o Outputs protected against
 Short Circuit Ubatt
 Short Circuit GND
o Diagnosis on Outputs and Sensor Inputs
 Short Circuit Ubatt
 Short Circuit GND
 Open Load
o Sensor Inputs
 Linearization of the input voltage
 According to the sensor characteristics
 Monitoring of external interfaces

o External interfaces are monitored (sensors, actuators)
o A recognised failure (e.g. electrical) is internally reported
o Reported failures may inhibit other functions/monitoring
 SW Function Montoring
o Separately calculated Values are used for monitoring the main Engine Control
Functions (e.g. Engine Speed Calculation, Injection Quantity Calculation)
 EECU Hardware Monitoring provided
o Internal Supplies
o Internal Memories
o Internal communication

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Page: 01-26
 Failure monitoring / Fault Code Memory

o Reported Failures
 are stored in the Fault Code Memory
 Up to 20 entries
 Can lead in an ECU switch over
 Can activate the ECU caution
 Can cause a substitute function (e.g. substitute value)
 ECU Switch Over

o 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
 The magnitude of power change can be up to 10%
 The typical switch over time is 10 ms.
 Diagnosis via defined CAN- Protocol possible
o AE diagnostic tool (AE 300 wizard)
 Eventrecorder and Datarecorder provided

o Eventrecorder stores defined „Events“ (e.g. reported failures, crossed limits)
o Datarecorder stores cyclically predefined values
 Time stamp based on a Real Time Clock
 Statistics
o Records statistics of 8 physical parameters
o Engine and ECU uptimes are recorded

Revision no: 11
Page: 01-27
Engine Speed and Power Regulation
The desired propeller speed set point is calculated depending on the power lever sensor position. The
current engine speed is used to compute the deviation of the actual propeller speed from the set
point.
The deviation is converted into an output ratio for the set point actuator. The propeller speed set
point is set by an electric motor (actuator) in the governor system. This electric motor substitutes the
conventionally used Bowden Cable.
The governor itself controls the propeller speed via the propeller blade pitch angle adjustment. The
actuator control ensures together with the monitoring a safe and correct actuation.
If the set point is reached the actuator is deactivated (hysteresis provided).
The requested engine torque is calculated depending on the power lever position and the engine-
speed.
- Depending on the requested torque the resulting injection quantity (fuel mass) is calculated.
- Depending on the calculated injection quantity the required boost pressure (air mass) is calculated.

Revision no: 11
Page: 01-28
Page: 01-29
ECU Governor
Propeller Propeller
Left Right
Endstop Endstop
Pitch Speed
Fig. 01 - 17 EECU and Covernor

R1 R2
Propeller
Desired Actuator Set Point Propeller
Actuator End Stop Actuator Speed Speed
Propeller Set Point Set Point Gear
Control Monitoring (Motor) Control
Speed Calculation
Box
Power Engine
Power Lever
Lever Sensor Engine
Sensor Signal Speed
Evaluation Engine Speed Information
Demanded Injection Actuator Injection

Maintenance Manual
Actuator Injectors
Torque Quantity Control
Calculation Calculation Calculation Control Quantity
Engine
Torque
Boost Actuator Boost Boost
Actuator
Pressure Control Pressure
Control Pressure
Calculation Calculation Actuator
E4.08.04
Revision no: 11
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. The self test button in the cockpit has to be released once before a new
(subsequent) self test can be initiated by pressing the button again.
Release Criteria:
The propeller governor self test will only be released if the following release conditions have been
met:
 Aircraft on the ground.
 Prop speed = idle (below 1000rpm).
 Prop speed = idle (below 1000rpm).
 Power lever = idle (below 5% power lever position).
 No errors pending
 Self test button active (and pressed during the whole test run).
The EECU will increase the prop speed to about 1900 rpm producing thrust. Therefore
the brakes have to be applied during the whole test run to prevent the A/C from
moving.
The engine oil temperature and gearbox oil temperature shall be within the green
range of the respective engine indicators before initiating the self test.
Test Abortion:
The propeller governor self test will abort immediately and the prop speed will be reduced to idle for
the following reasons:
 “Self test”-button has been released by the pilot.

 “Weight on wheels”-switch has been released for more than 1 sec.
 Power lever has been moved above the 5% position
 An error has been detected by the EECU (see “Diagnosing Self Test Failures”
for failure analysis).
Cockpit Indications:
For the proper sequence of cockpit indications and possible caution alerts during the self test, refer to
the applicable Aircraft Flight Manual.

Revision no: 11
Page: 01-30
Error Handling
For the list of engine control system errors and their error handling refer to chapter 7 of Operation
Manual E4.01.01. Three different types errors are known:
 Errors which lead to a latched caution indication

 Errors which lead to a non-latched caution indication
 Not indicated errors
In case of a latched caution an unscheduled maintenance is necessary and Austro

Engine GmbH has to be informed.

Revision no: 24
Page: 01-31
Electrical System Installation Requirements:
The following requirements have to be observed to ensure a proper performance of the AE 300 in the
installation environment.
Pay attention that the entire electrical system and wiring harness is protected against
chafing at hot parts or sharp edges.
The source of electric power of the aircraft is the main battery as defined in 14.5.5.14. The engine is
equipped with an alternator, which is the electrical power system dedicated to the engine. An
excitation battery as defined in 14.5.2.3 has to be provided for alternator start up. Thereafter the
alternator is self-exciting.
The following basic rules apply for a proper electrical system.
The EECU, alternator and batteries must be wired that in a case of battery failure a voltage supply for
the EECU and fuel feed pumps is still granted.
It must always be possible to separate the engine electrical system (EECU, associated systems and
alternator) from the battery and the rest of the aircraft electrical system.
It must be ensured, that the electric power supply to the EECS is always in compliance with the
requirements defined in RTCA DO160D, Section 16, Cat B.
The required minimum reliability of the EECS electric power supply is depended on the class airplane.
Consult AC 23.1309-1C for determination. If this requires the installation of an EECS backup electric
power system, it must be ensured, that this system is independent and isolated from the airplane bus
system or systems so that electric power from the backup system is supplied to the EECS solely.
An example below gives an overview about a possible installation with isolated supply-Buses showing
the possibility of separating the Alternator from the Main Bus.
Alternator
Relay
MAIN ECU BUS

Switch BUS
Signal
EECU
Regulator Excitation G Main Battery

Current Excitation & Backup
Source (Battery)
Engine
Alternator
Fig. 01 - 18 Power Supply Installation

Revision no: 24
Page: 01-32
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.
The EECU consists of two similar ECUs (Engine control Units).

A voter is integrated in the EECU and proposes an ECU to control the engine regarding the ECU
operating hours or in case of a failure the ECU with better engine control capability.
In Installations using the caution indication via CAN, the caution lamp shall be substituted by a
resistor. If the substitute load is not installed, a Caution Lamp Circuit failure will be detected.
If applicable for the installation, lightning protection bonding of the EECU housing to airframe GND
shall be with AWG 4 wire with a maximum length of 0.5m.
Fig. 01 - 19 EECU Dimensions (in mm)

Revision no: 24
Page: 01-33
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.

CAN-termination resistors 60R (2x 120R in parallel, 120R in EECU included)
(CAN Bus according to ISO 11898)
For Example:
CAN CAN
nodes nodes
EECU
CAN
termination
CAN High CAN Termination in
120R 120R Installation
CAN Low
Fig. 01 - 20 CAN Bus Termination
Make sure that the terminating connector is installed in a save position that in any event a
disconnection is impossible.
According to the CAN BUS Protocol each ECU of the EECU sends its own engine information.
Any device connected to the EECU CAN BUS must not transmit any data on the EECU CAN BUS!
It is part of the installer’s responsibility to verify that the information displayed in the
engine instruments conform to the information provided by the CAN BUS.

Revision no: 24
Page: 01-34
Alternator:
The alternator system consists of an alternator and an alternator-regulator device.
The alternator provides the following main properties:
 Air-cooled synchronous three-phase alternator with a claw-pole rotor

 Built-in semiconductor rectifier
 Stator winding circuit: delta connection
 External alternator regulator (mounted on the aircraft)
 Belt-driven by the engine
There are three external terminal points on the alternator:
 Power output (connected with battery)

 Excitation current input
 Ground (housing)
The output voltage of the alternator has to be constant, independent from engine speed and actual
load current. This requires a regulation of the output voltage by a variation of the excitation current
(implemented in the alternator-regulator device).
To avoid damage of the alternator the regulator must be deactivated when the engine
is not running.

Revision no: 24
Page: 01-35
Electrical starter:
The main power supply to the starter cannot be protected with a fuse. Thus the routing
must ensure that there is no increased risk of fire in the event of a short circuit.
The electrical connection of the starter is shown in Chapter 92-00-00 Wiring diagrams.
Fig. 01 - 21 Starter Wiring Diagram
Function Description
Terminal T30 Power supply starter <200A*
Terminal T50 Power supply on T50 ACTIVATES the starter

Pull-in current <30A
Hold-in current <7,5A
Ground GND Connect starter housing on GND (engine block)
Starter Connector
*Depends on different terms (temperature, mounted propeller, etc.) the current through the supply
line can reach a value up to 200A.
Glow Plug Control Unit:
The glow system is designed to be only active, if the aircraft is on ground.

This is provided by an “A/C on ground indication”, which must be implemented into the aircraft
design. This needs to be low if active (switch to GND if active).
These lamps are not essential for flight operation. Therefore they can be seen as optional for
installation. Replace Annunciation Lamp GPC and Caution Lamp GPC with a pull-down resistor
(5kOhm), if the lamps are not used.
But it is recommended to install the indication lamps to ease failure analysis for maintenance actions
e.g. if problems with cold start performance occur.

Revision no: 24
Page: 01-36
Governor Interface:
This EECU is able to actuate the electric motor which changes the governor-set point.
According to power lever position the related propeller speed is controlled by the EECU see Fig. 01-11.
A more detailed description can be found in section Governor Functional description.
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.
The desired engine speed for low power is only reachable in flight.
Propeller Setpoint Curve
VC31 Baseline 01
2400
2350
100%
2300
2250
2200
2150 0%
Propeller Speed [rpm]
2100
92%
2050
2000
1950
1900
1850
1800
20%
1750
1700
1650
1600
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Power Lever [%]
Fig. 01 - 22 Propeller Setpoint Curve
Max Take Off Power: 100 %

Max Continuous Power: 92 %
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. The EECU also detects
mechanical jamming of the electrical motor. In case of a e.g. a defect motor or mechanical stop
sensing the motor will not be overheat because of excessive current consumption.

Revision no: 24
Page: 01-37
The connector equipped on the harness is a Deutsch AS 008 35 PN. Each compatible
connector can be used on a governor.
Pin Description
1 Feather Valve
2 Feather Valve
3 Motor +
4 Motor -
5 Governor Stop Sensing
6 GND
Governor Pin Assignment
Electrical Drawing Example
EECU E4
Input Circuit Ubatt
2K56
Governor
Stop Propeller Governor – Actuator Circuit
Feedback
180R 560R
Curent 390R
330R
Feedback Current M
H-Bridge Left Right
Measurement Stop Stop
GND
Possible
Governor
Fig. 01 - 23 Electrical Drawing Governor System System
EECU Caution Lamp:
Each ECU has its own caution lamp output. The lamp will be supplied with bus voltage via the ECU.
These display lamps are used to inform the flight crew of a detected EECU or Engine failure.
Power Lever Sensor:
The Power Lever Sensor is a sensor using the Hall-Effect.

It has two independent outputs with different output characteristics which are verified inside the ECU.
Each ECU requires its own sensor. E.g. in a twin engine installation, 4 sensors are necessary.
The installation of the two power lever sensors for the EECU shall ensure that the output signals are
within 5% to each other (e.g. Signal A 85%, Signal B 87%).

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Page: 01-38
Engine Selftest Pushbutton:
The engine is able to perform a Selftest. For this a normally open closer pushbutton is installed.
Activation of the Selftest via the Selftest Pushbutton is only be possible if the VOTER Switch is in
AUTO Position (logical AND relation).
During the whole Selftest the Pushbutton must remain pressed.
Fig. 01 - 24 Self Test Wiring

Revision no: 24
Page: 01-39
Engine Display if installed:
Description:
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.
The display is approved as part of the engine installation by the airframe manufacture.
Installation, Operation and Maintenance Information:
The instructions for installing, operating and maintaining the engine displays are given in the
document A1.04.01 Revision 3 “Design Specification”. In this document the definition of the physical
and functional interfaces to the aircraft and aircraft equipment is given.
Display Layout, Limits and Indication:
MED Layout SED Layout

Revision no: 24
Page: 01-40
01-10-70 Governor Description

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.01-11)
Governor drive:
Flange of the backside of the gearbox: AND 20010

Prop/Governor drive ratio: 1:1,22
Direction of rotation : CCW (facing gearbox pad)
Overhang moment max. 3 Nm
Break away torque: max. 40 Nm
An adequate filter, mesh or other appropriate measure to prevent governor damage

due to contaminants in the gearbox oil has to be installed.

Revision no: 24
Page: 01-41
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.
The desired propeller speed set point is calculated depending on the power lever sensor position.
(refer to Governor Interface)
The current engine speed divided by the gear box ratio is used to compute the propeller speed
deviation which is then converted into an output ratio for the actuator
The propeller speed set point is set by an electric motor (actuator) in the governor system.
The governor controls the propeller speed via the propeller blade pitch angle
The actuator control ensures together with the monitoring a safe and correct actuation
If the set point is reached the actuator is deactivated and the governor controls the engine speed to
the set point.
Overview of propeller speed control:
ECU Governor
Propeller
Pitch
Desired Actuator
Propeller Set Point Set Point Propeller
Speed Calc Actuator End Stop End Actuator Speed
Control Feedback Stops (Motor) Control Propeller
Speed
Power
Lever
Engine Speed Information
Sensor Gear
Box
Injection Quantity Injection Engine

Demanded Calculation Quantity
Torque Engine Engine
Calculation Torque Speed
Boost Pressure Boost
Calculation Pressure
Fig. 01 - 25 Propeller Speed Control

Revision no: 24
Page: 01-42
Chapter 02-00-00 Transport and Packaging
02-00-10 Packaging
The engine is packed in a wooden crate and will be shipped attached to the corresponding mountings.
If not declared otherwise the engine is shipped without any liquids.
Fig.02 - 1
The box containing the supplied parts is filled with filler material and closed with adhesive tape.
Fig.02 - 2
On the box an envelope with the papers belonging to the motor is attached.

Revision no: 9
Page: 02-1
Fig.02 - 3
This box is positioned in the slope below the injector cover.
Fig.02 - 4
Then the engine is covered by a special VCI foil.

Revision no: 9
Page: 02-2
Fig.02 - 5 Fig.02 - 6
The whole engine is enclosed by a wooden box.

Revision no: 9
Page: 02-3
02-00-20 Transport
The engine has to be lifted with the transport eyelets.
The used hoisting device must be suitable for the weight of the engine.
Lifting eyelet
Fig.02 - 7 Lifting eyelet 1
Lifting eyelet
Fig.02 - 8 Lifting eyelet 2
The lifting eyelet at the cylinder head must be dismounted after installing the engine.

Revision no: 9
Page: 02-4
02-00-30 Protective Covers
To protect the engine of corrosion it should be stored and transported in a package appropriate for
corrosion protection. Suitable corrosion protection is available at Austro Engine GmbH.
All engine openings have to be protected against ingress of dirt and moisture.
All protective covers and mountings have to be removed before taking the engine into
operation.
To avoid contamination during the installation process, the covers should be removed step
by step with installing the lines and hoses.
02-00-40 Storage
During transport and afterwards storage, following terms must be observed:
Storage temperature -25°C to 70°C

(-13°F to 158°F)
Humidity max. 60%
Storage time 8 weeks
The engine has to be stored in suitable workplaces in a horizontal position, the cylinder axis must
have an angle of 34°, always covered against environmental influences and never outside. For further
information refer to the Installation Manual E4.02.01 Chapter 6 “Installation Position”.
For storage requirements refer to the Operation Manual E4.01.01. of the AE 300 engine.
02-00-50 Return Parts Shipping Instruction
If you have to return parts to Austro Engine, please follow these instructions:
 Clean the part, especially oil contaminated arts like Governors

 Tag the part with an unserviceable tag and fill all required information
 Put the part in an appropriate box together with shock absorbing material e.g. bubble foil,
foam etc.
 Make the box ready for shipment
 If the whole engine has to be supplied back ensure that the appropriate box as described in
Chapter 02-00-10 is used

Revision no: 9
Page: 02-5

Revision no: 9
Page: 02-6
Chapter 03-00-00 Engine Installation
For detailed engine installation refer to the applicable Aircraft Maintenance Manual.

Revision no: 24
Page: 03-1

Revision no: 3
Page: 03-2
Chapter 04-00-00 Airworthiness Limitation
No 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.
FAA Approval Statement:
The Airworthiness Limitation Section is FAA approved and specifies maintenance required under Sec.
43.16 and Sec. 91.403 of Title 14 of the Code of Federal Regulations unless an alternative program
has been FAA approved.

Revision no: 3
Page: 04-1

Revision no: 1
Page: 04-2
Chapter 05-00-00 Time Limits and Maintenance Check
05-00-01 General
Work on the engine must be conducted by a certificated mechanic or otherwise authorized persons
under consideration of the applicable national requirements. For warranty reason all of the tasks
described in this manual must be performed by trained personnel only.
All applicable national and international regulation must be observed.
In the present Maintenance Manual the correct maintenance of the aircraft engine AE 300 is
documented.
With the publication of the Maintenance Manual, Austro Engine GmbH ensures the correctness of
the instruction. In case of changes Austro Engine GmbH will inform with Service Bulletins, Service
Letters or manual amendments, if it is necessary.
If there are any problems with the maintenance and repair or any further questions about the engine,
Austro Engine GmbH can be contacted.
The aircraft engine has to be maintained and repaired in accordance with the instructions given in this
manual unless otherwise approved under consideration of the applicable national requirements.
It is necessary to read this instructions attentive and carefully. To grant a proper engine work and to
obtain the maximum service life all work steps have to be done as shown.
For any further information Austro Engine GmbH can be contacted.
The following symbols and warning signs are used in this manual to point out important instruction.
They must be observed strictly to prevent personal injury and material damage, to insure operational
safety of the aircraft and to avoid any damage to the aircraft as a result of incorrect handling.
Disregarding these safety rules can cause personal injury or even death.
Disregarding these special instruction and safety measures can damage the engine or
other components.
The maintenance intervals must be strictly observed. When the service is not executed in accordance
to this manual Austro Engine GmbH will reject any warranty claims.
Additional note or instruction for better understanding of an instruction.

Revision no: 3
Page: 05-1
05-10-00 Time Limits
The time limits below must be followed to obtain the max. service life of the engine.
Every 600 operating hours:
 Replace the High Pressure pump – refer to Chapter 73-00-40
Every 1500 operating hours:
 Replace the V-Ribbed Belt all 5 years or after 1500 hours – refer to Chapter
85-40-10
 Replace the Gearbox – refer to Chapter 85-10-10
 Overhaul Engine - remove and reinstall engine in accordance with the
applicable Aircraft Maintenance Manual
 Replace the EECU all 5 years or after 1500 hours
Fuel filter recommended replace latest every 100 hours – refer to applicable Aircraft Maintenance
Manual.
05-10-01 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 ±5%
more than 1000 operating hours ± 50 operating hours
Maintenance Actions based on time
Time Intervals Claimable Exceed of the Basic Interval

up to and including 2 months ± 5 days
between 2 months and 1 year ± 15 days
more than 1 year ± 30 days
05-10-02 Engine Time between Overhaul
The maximum time between overhaul of the engine is 1500 hours or 12 years.
After this time the engine has to be overhauled by a certified mechanic or otherwise authorized
person under consideration of the applicable national requirements. For warranty reasons the
overhaul has to be conducted by trained personnel only in accordance with the instructions given in
the overhaul manual of Austro Engine GmbH.
The Shipment to an authorized overhaul facility must include the following:
 Engine log book

 Maintenance records of the engine (i.e. all maintenance check lists, and reports of operation,
of maintenance, of findings and of oil analyses)

Revision no: 21
Page: 05-2
 The engine assembly as per supply volume. Additionally all added-on parts as in the supply
volume such as turbo charger, sensors, actuators, glow plug control unit, electric starter,
engine wiring harness, EECU, alternator and the alternator regulator.
 Statement of total period of operation (TSN) and if applicable the period of operation after a
conducted general overhaul (TSO)
 Data about the type of aircraft used
 Useful remarks and observations concerning the engine

Revision no: 21
Page: 05-3
05-20-00 Schedule Maintenance Inspections and Checks
The following service intervals are mandatory to obtain the maximum service life of the engine.
If the engine has not been in operation for a certain time a service interval based on time become
effective. The time intervals are beneath the operating service interval.
100 h
Activities/Services Interval 300 h 600 h 1000 h Chapter
12 Months
Check Change Check Change Check Change Check Change refer to
TORSIONAL-VIB.DAMPER
Two Mass flywheel ● 05-20-01
ELECTRIC
Alternator ● 05-20-02
Engine Harness and Sensors ● 05-20-03
EECU read out ● 05-20-05
GEARBOX
Oil ● ● 05-20-06
(1)
Oil Filter ● ● 05-20-07
BELT DRIVE SYSTEM
V-Ribbed Belt ● 05-20-08
ENGINE OIL
Oil ● 05-20-09
Oil Filter ● 05-20-10
FUEL SYSTEM
HPP(High pressure pump) ● 05-20-11
Cylinder Head Drain ● 05-20-12
Fuel System ● 05-20-13
Fuel Filter ● 05-20-14
EXHAUST SYSTEM
Waste Gate Controller ● 05-20-15
Exhaust System ● 05-20-16
COOLING SYSTEM
Coolant ● 05-20-17
Cooling System ● 05-20-18
OIL SEPERATOR
Breather line ● 05-20-19
ENGINE
Zonal Inspection ● 05-20-20
Injector Cover ● 05-20-21
(2)
Timing chain ● 05-20-22
(1)
Only applicable if Gearbox E4A-70-000-000 Rev.70 or higher installed (refer to Engine Log)
(2)
on demand

Revision no: 24
Page: 05-4
05-20-01 Two Mass Flywheel
For Removal and Installation of the Two Mass Flywheel refer to Chapter 85-10-60.
05-20-02 Alternator
For Removal and Installation of the Alternator refer to Chapter 24-00-10.
05-20-03 Engine Harness and Sensors
Carry out a visual inspection of the wiring harness for signs of wear or damage.
Inspect the sensor connections for tight fit.
The parts of the harness which are located below the injector cover have to be
inspected every 300 hours.
To prevent any damage on cables and sensor, don’t apply forces on the cables!
In case of any significant wear or damage, contact Austro Engine GmbH.
05-20-04 EECU
Replace the EECU in accordance with the applicable Aircraft Maintenance Manual.
05-20-05 EECU Read Out
Read out EECU using the AE 300 Wizard and send data to Austro Engine GmbH.
For usage instructions of the AE 300 Wizard refer to the AE 300 Wizard User Guide E4.08.09.
Data to be sent:
 Engine log
 Event recorder
(Exception: If not otherwise communicated/defined with AE)
05-20-06 Gearbox – Oil
For gearbox oil check conduct following steps:
 Gearbox oil level check according to Chapter 12-20-11

 Gearbox oil inspection according to Chapter 85-10-20
For gearbox oil change conduct following steps:
 Collect a sample of used Gearbox Oil using the oil container provided with the 300 h
Service Kit and send the oil sample to oil check directly (already pre-filled out envelope).
 For gearbox oil discard and refill refer to Chapter 85-10-50.

Revision no: 24
Page: 05-5
05-20-07 Gearbox Oil Filter

Check gearbox oil filter according to Chapter 85-10-30.
Replace gearbox oil filter according to Chapter 85-10-30.
05-20-08 V-Ribbed Belt

Conduct a detailed visual inspection of the V-ribbed belt.
Inspect V-Ribbed Belt for abrasion and signs of damage.
Inspect the belt pulley profiles and the tensioner for damage and dirt.
In case of dirt clean the v-ribbed belt using water only.

If one of the following damages occurs replace the v-ribbed belt:
 textile reinforcement visible between the ribs

 tapered ribs
 transverse cracks on the running surface
 dirt between the ribs
 transverse cracks in the ribs
 frayed textile reinforcement
For replace of the v-ribbed belt refer to Chapter 85-40-10.
Do not lubricate the v-ribbed belt.
05-20-09 Engine – Oil

Exchange Engine Oil according to Chapter 79-00-20 and Chapter 79-00-30.
Collect a sample of the used Engine Oil using the oil container provided with the 100 h Service Kit and
send the oil sample to oil check directly (already pre-filled out envelope)..
After Engine Oil exchange perform an engine ground run according to Chapter 71-00-03.
After the ground run inspect the oil system for leakage.
If leaks are found please contact Austro Engine GmbH for further instructions.
If necessary insert engine oil according to chapter 12-20-01
05-20-10 Engine Oil Filter

Replace Oil filter according to Chapter 79-00-70.
Use only original Austro Engine oil filter insert: E4A-52-100-802
Conduct a visual inspection of the used oil filter for contamination and metal abrasion. If unusual
contamination (metal shavings exceeding 1,5 mm; concentration of particles; clogged filter) is found,
or in case of doubt contact Austro Engine GmbH.
05-20-11 High Pressure Pump
Replace High Pressure Pump according to Chapter 73-00-40.

Revision no: 24
Page: 05-6
05-20-12 Cylinder Head Drain
Disconnect Cylinder Head Drain Line from cylinder head.

Blow through the drain hole using compressed air.
Blow through the Cylinder Head Drain line using compressed air to ensure an unobstructed line.
Connect Drain line.
Cylinder Head Drain line Cylinder Head Drain line

Fig. 05 - 1 Fig. 05 - 2
05-20-13 Fuel System
Conduct a visual inspection of the Fuel System.

Inspect especially for signs of wear and leakage.
Check if the fittings are tightened.
05-20-14 Fuel Filter
Replace fuel filter in accordance with the applicable Aircraft Maintenance Manual.
05-20-15 Waste Gate Controller
Check and adjust the waste gate controller according to Chapter 81-00-30
05-20-16 Exhaust System
Inspect the exhaust manifold for cracks using a flashlight and a mirror.
Inspect the exhaust manifold gaskets for signs of leakage.
In case of leakages replace the exhaust manifold gaskets according to Chapter 78-00-00.
If cracks have been found contact Austro Engine GmbH.
05-20-17 Coolant
For exchange of coolant refer to applicable Aircraft Maintenance Manual.
At each exchange of coolant the freezing point has to be checked. The freezing point
with a coolant mixture of 50/50 is -38 ºC (-36.4 ºF).
Recommended radiator protection type: Glysantin Protect plus / G 48 mixed at a ratio

of 50:50 with distilled water.

Revision no: 21
Page: 05-7
05-20-18 Cooling System
Conduct a visual inspection of the Cooling System.

Inspect especially for signs of wear and leakage.
If leakage is detected the affected connections have to be inspected for tight fit or damaged hoses
must be replaced.
05-20-19 Breather Line
Inspect the outlet of the Breather Line for abnormal quantity of oil (oil dust has to be expected).
In case of oil detection clean the Breather Outlet and conduct an engine ground run according to
Chapter 71-00-03.
After the ground run inspect the breather outlet again. If oil accumulation is obvious, contact Austro
Engine GmbH.
For inspection and replace of the breather line refer to the applicable Aircraft Maintenance Manual.
05-20-20 Zonal Inspection
Conduct a visual inspection of the whole engine surface using a flashlight and mirror.
Look especially for signs of wear and leakage at the oil sump gasket and the cylinder head gasket.
Inspect for loose parts or foreign objects.
If sign of wear, leaks, loosen parts or foreign objects could be found, contact Austro Engine GmbH
for further instructions.
05-20-21 Injector Cover
Remove Injector Cover according to 85-00-11.
 Conduct a visual inspection of the high pressure fuel lines. Inspect especially for signs of
wear and leakage.
 Carry out a visual inspection of the wiring harness for signs of wear or damage. Inspect
the cam shaft sensor connection and the injector connections for tight fit.
 Inspect the Oil Separator hoses for damage.
 Inspect the Oil Separator for signs of leakage.
 Clean the area below the injector cover using cleaning agent. To assure an unobstructed
cylinder head drain the cleaning agent should drain off through the cylinder head drain
line.
Do not apply cleaning agent on opened sensor connections.
Install Injector Cover according to Chapter 85-00-12.
05-20-22 Timing Chain
Conduct an inspection of the timing chain according to Chapter 85-40-40.

Revision no: 24
Page: 05-8
05-50-00 Unscheduled Maintenance Checks
05-50-01 Performance Deterioration
Read out the EECU data using the AE 300 Wizard and send data to Austro Engine GmbH for
analysis and further instructions.
Data to be sent:
 Engine log
 Data log (min. 3 hrs.).
(Exception: If not otherwise communicated/defined with AE)
05-50-02 Over Temperature
 Inspect the fluid level for leakage.

 Read out the EECU data using the AE 300 Wizard and send data to Austro
Engine GmbH for analysis and further instructions.
05-50-03 Sudden Stoppage Inspection
 Remove the engine in accordance with the applicable Aircraft Maintenance

Manual and send it to Austro Engine GmbH.
05-50-04 Propeller Strike
In case a propeller strike occurred send the following data to Austro Engine GmbH for analysis and
further instructions.
 Engine log, event recorder and data log (using the AE 300 Wizard).
 Pictures from damage of the propeller.
 Statement from person operating the aircraft at the time of the occurrence
including details about the engine parameters and power lever position during
the propeller strike.
05-50-05 Lightning Strike
Direct: Remove the engine in accordance with the applicable Aircraft Maintenance Manual
and send it to Austro Engine GmbH.
Indirect: Visually inspect the sensor for signs of damage.
Visually inspect all electric engine components for signs of damage. (Sensors,
Actuators, EECU, Harness, GPC, Starter, Alternator)
Perform a ground run according to Chapter 71-00-03, read out the data using the AE 300 Wizard and
send data to Austro Engine GmbH and further instructions.

Revision no: 21
Page: 05-9
05-50-06 High Oil Consumption Inspection
 Inspect engine for oil leakage.

 Inspect the compression.
 Send Data to Austro Engine GmbH for analysis and further instructions.
05-50-07 Oil System Contaminated
 Send an oil sample to Austro Engine GmbH for further investigation.
05-50-08 Oil Pressure Loss Inspection
 Check Oil quantity.

 Inspect if “neg. g” flights have been conducted. (Visual inspection of the
breather outlet for oil contamination).
 Read out the EECU data using the AE 300 Wizard and send data to Austro
Engine GmbH for analysis and further instructions.
05-50-09 Inability to Start the Engine
 Check voltage.
 Check battery condition.
 Check fuel supply.
 Check for EECU cautions.
 Read out EECU data using the AE 300 Wizard and send data to Austro
Engine GmbH and further instructions.

Revision no: 21
Page: 05-10
Chapter 12-00-00 Servicing
12-20-00 Engine Oil Servicing
12-20-01 Check the Oil Level
1. For checking the oil level the oil dipstick has to be taken out.
2. For optimum run, the oil level should be in the middle of the min / max mark.
3. Otherwise the right quantity of engine oil has to be refilled according to the
requirements specified under Chapter 79-00-00 Engine Oil.
4. Afterwards the oil dipstick has to be inserted and closed.
Oil dipstick
Fig. 12 - 1
Fig. 12 - 2

Revision no: 5
Page: 12-1
12-20-10 Gearbox Oil
12-20-11 Check the Gearbox Oil Level
The quantity of the gearbox oil has to be checked.
Oil Level
Oil inspection window
Fig. 12 - 3
In case gearbox E4A-70-000-000 Rev. 60 or lower is installed (refer to Engine Log)

gearbox oil has to be refilled (refer to Chapter 85-10-53) if the oil level is visible in the
inspection window.
For details acc. to the Prop Regulation System refer to the applicable Aircraft Maintenance Manual.
12-40-00 Engine Coolant Servicing
For the Servicing of the Engine Coolant Fluid refer to the applicable Aircraft Manufacture Manual.

Revision no: 15
Page: 12-2
Chapter 24-00-00 Electrical Power
24-00-01 General
For general description of the Electrical Power refer to the AE 300 Operation Manual E4.01.01 -
Chapter 7.
The following chapters (24-00-20 to 24-00-36) are only applicable for alternator E4A-91-000-000.
24-00-10 Alternator
An Alternator replacement from type E4A-91-000-000 to E4A-91-400-000 is only
allowed once on the used engine harness. For the replacement only an approved
repair Kit as is allowed to be used.
An Exchange from alternator E4A-91-400-000 back to its predecessor E4A-91-000-000
is not permitted.
24-00-11 Removal of the Alternator
1. Disconnect the battery according to the applicable Aircraft Maintenance Manual.
First disconnect the negative pole and second the positive pole.
Remove the power line from the B+ terminal according to the applicable Aircraft
Maintenance Manual.
2. Remove the v-belt - refer to Chapter 85-40-11.

3. Alternator E4A-91-000-000: Remove the electrical line [1] marked with “GEN/G2”
Alternator E4A-91-400-000: Remove the electrical line marked with “GEN/G2”. The
lock nut [6] and the plastic cover lock nut [7] will be needed for installation again.
Remove the screws [2] and [4].
24-00-12 Installation of the Alternator
1. Carefully install the Alternator [5] and install the mounting screws [4].
2. Torque the screws [2] and [4] with 20 Nm.
3. Alternator E4A-91-400-000: Connect the electrical cable marked with “GEN/G2” the
fastening torque for the lock [6] nut is 2,7 Nm – 3,8 nm. Make sure that the black
plastic cover [6] is placed on the lock nut. Connect the power line to the B+ terminal
(fastening torque 11-13 Nm). Put the white dust seal [8] of the electrical cable over
the black plastic cover of the lock nut.
If the connection is wrong a serious damage to engine is possible.
4. Install the v-ribbed belt according to Chapter 85-40-12.
Inspect the V-ribbed Belt for correct installation.
5. Connect the main battery according to the applicable Aircraft Maintenance Manual.
6. Perform an engine ground run according to the Chapter 71-00-03.

Revision no: 24
Page: 24-1
Figures for Chapter 24-00-11 and 24-00-12
Fig. 24 - 1 Fig. 24 - 2
3 2
4 5
Fig. 24 - 3
7
6
Fig. 24 - 4
Fig. 24 - 5
Fig. 24 - 6

Revision no: 24
Page: 24-2
24-00-13 Alternator/Regulator Adjustment E4A-91-100-000
Fig. 24 - 7

Revision no: 24
Page: 24-3
24-00-14 Adjustment procedure of voltage regulation E4A-91-100-000
The engines should be brought up to full operation coolant temperatures prior to adjustment.
With one engine at cruising speed, the voltage on the operating system is adjusted to 28 volts at a
typical electrical load by a replace of the set screw (see Fig. 24 – 4).The first engine is switched off
and the next engine is switched on. The second system has to be adjusted to the same voltage at the
same load and engine speed (only for twin-engine applications).
24-00-15 Adjustment of alternator balancing E4A-91-100-000

(only for twin-engine applications)
Both systems are switches on and the loads have to be compared for the operation point of the
voltage regulation adjustment.
If it is desired to pull the load division closer together, the regulator of the heavier loaded alternator
has to be adjusted lower respectively the regulator of the lower loaded alternator has to be adjusted
higher.
A test of the adjustment results shall be conducted by turning on the heaviest loads available and
varying of the engine speeds.
For not having significant brush wear difference on both alternators the alternator load current should
be as equal as possible. A difference of less than 25A is strongly recommended.
After completion of the regulator adjustment, the regulator set screws have to be fixed with torque
seal.

Revision no: 11
Page: 24-4
24-00-16 Alternator/Regulator Adjustment E4A-91-200-000
There is no regulator adjustment (e.g.: by potentiometer) required to establish a stable voltage

regulation.
24-00-17 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. The set point of this current regulator is generated dynamically as averaged
load current of both alternators.
The set point of one voltage regulator in the system is modified continuously to compensate static and
dynamic asymmetries of the system.
Graphic below show the basic installation in a twin engine system.
Excitation Excitation
Current Current
sensor 1 sensor 2
Engine 1 Alternator 1 Alternator 2 Engine 2
Electrical supply
system
actuation actuation
Voltage Actual value

Actual value Voltage
regulator regulator
Fig. 24 - 8
24-00-18 Replacing Alternator Regulator E4A-91-100-000
If it is necessary to replace the alternator regulator type E4A-91-100-000 with the alternator regulator
type E4A-91-200-000, it has to be mentioned that case the wiring harness needs to be replaced.

Revision no: 24
Page: 24-5
24-00-20 Inspection of the Carbon Brushes
This chapter shall be guidance for checking the carbon brushes of alternator E4A-91-000-000, and if
necessary for replacing Assy brush holder E4A-91-300-000.
This chapter describes in detail the steps how to disassemble the alternator and its components
(e.g.: brush holder) for checking the carbon brush length. The criteria of replacing ASSY brush holder
E4A-91-300-000 is also include in this chapter.
24-00-21 Maintenance/Inspection of Carbon Brushes
AE decided to introduce a maintenance action to measure the length of carbon brushes after a
specified time of operation. The maintenance interval can be found in Chapter 05-02-00 and the
evaluation criteria can be found in Chapter 24-00-31.
24-00-22 Brush Holder Replacement in Field
Additional to the maintenance action a procedure how to replace ASSY brush holder E4A-91-300-000
is introduced. This document describes in detail how to check the carbon brushes, and if necessary
how to replace ASSY brush holder E4A-91-300-000.
24-00-23 Inspection of Carbon Brushes and Alternator
24-00-24 Tools necessary
Number Description Dimensions Supplied by:

1 Screw Driver Slotted Screw Driver (~2mm) Operator
Thin Metal Austro Engine (if
2 ~0,3mm x ~8mm
Sheet requested)
3 Sliding Caliper --- Operator
4 Multimeter --- Operator
Wrench
5 Nr. 8 Operator
(hexagonal)
Wrench
6 Nr. 7 Operator
(hexagonal)
24-00-25 Removal of the Alternator
Remove the alternator according to Chapter 24-00-11.

Revision no: 14
Page: 24-6
24-00-26 Removal of the Brush Holder
Remove the two screws G and G2.

Remove the black plastic cover on the back side of the alternator with wrench nr. 8.
G
G2
Fig. 24 - 9 Alternator back side
Remove R1, R2 and R3 with wrench nr. 7.

Remove ASSY brush holder E4A-91-300-000 carefully.
R1
R3
R2
ASSY brush holder E4A-91-300-000
Fig. 24 - 10 Alternator with removed plastic cover

Revision no: 24
Page: 24-7
24-00-27 Visual Inspection of Alternator Housing
Check the black plastic cover on backside of the alternator if it is cracked or damaged in any kind.
Fig. 24 - 11 Damage of “B+” connector plastic
Fig. 24 - 12 Damage of excitation connector plastic

Revision no: 24
Page: 24-8
Check the cooling outlets of the plastic cover.
Fig. 24 - 13 Broken cooling outlet
Check the alternator housing.

If there are any damages on the housing visible please contact Austro Engine GmbH.
Fig. 24 - 14 Alternator housing
If any damage comparable to the ones described in the pictures above is visible, please contact
Austro Engine GmbH for further instructions.

Revision no: 24
Page: 24-9
Check the pulley of the alternator. If there is any kind of damage visible (cuts, chafing marks,…) the
alternator needs to be replaced.
Pulley
Fig. 24 - 15 Pulley

Revision no: 24
Page: 24-10
24-00-28 Inspection of Contact Ring and Brushes
When ASSY brush holder E4A-91-300-000 is removed the contact ring can be inspected.
Check for grooving (>0,5mm) on the contact ring. If grooving (>0,5mm) are visible the alternator
needs to be replaced.
Grooving (<0,5mm) caused by abrasion of carbon brushes are normal.
Clean the contact ring with a soft brush
Do not use a steal brush for cleaning to avoid any damage.
The diameter of the contact ring has to be 15mm (+0 / -2mm).
Contact ring
Fig. 24 - 16 Contact ring

Revision no: 24
Page: 24-11
24-00-29 Disassembly of Brush Holder
To check the length of carbon brushes further disassembly of ASSY brush holder E4A-91-300-000 is
necessary.
Push upper carbon brush with a small screw driver and hold them in end position below the cover rib.
Cover Rib
Upper Brush
Lower Brush
Cover
Fig. 24 - 17 Brush holder
Insert thin metal sheet between cover rib and brush holder E4A-91-300-801.
Push the metal sheet forward to hold down the upper brush.
Push Direction
Thin Metal Sheet
Cover Rib

Revision no: 24
Page: 24-12
Push lower carbon brush down with small screw driver.

Push the metal sheet forward to hold down the lower carbon brush.
When the lower and the upper brush are hold down the cover can be demounted.
Push the cover backwards out of the brush holder.
It can take a little effort to push down the cover. Ensure not to damage the cover or
the brushes!
Thin Metal Sheet
Push Direction
Cover
The picture below shows the released carbon brushes and the demounted cover.
Clean the brush holder and the brush rip with a soft brush.
Carbon Brush
Cover
Fig. 24 - 20 Brush holder with cover

Revision no: 24
Page: 24-13
24-00-30 Measuring the Length of Carbon Brushes
Measure the length of both carbon brushes with a calibre gauge.
Length
Carbon brush
Brush Holder
Fig. 24 - 21 Brush length
Ensure to measure the length of the carbon brushes at the points shown in the picture above.
The evaluation criteria can be found in chapter 24-00-31 Evaluation Criteria.

Revision no: 24
Page: 24-14
24-00-31 Evaluation Criteria
The table below gives information about the inspection time and minimum brush length.
Operation Time of
300 h
Alternator
Minimum length 7 mm
<7 mm
Brush change necessary if
replace ASSY
below minimum length
brush holder
If the brush length is <7 mm please order a new ASSY brush holder E4A-91-300-000.
For each inspection of ASSY brush holder E4A-91-300-000 an X (cross) has to be engraved into the
housing of alternator E4A-91-000-901. For the exact positioning of X (cross) see Chapter24-00-35
Marking of Alternator.
ASSY Brush Holder

E4A-91-300-000
Carbon Brushes
E4A-91-300-802
>7mm <7mm
Brush holder can be used for Order new brush holder from Austro
additonal 300h of operating time, Engine & continue with chapter 2.10
continue with chapter 2.9 Completion of Generator (Integration
Completion of Brush Holder of Brush Holder)
Fig. 24 - 22 Flow chart
It is not allowed to replace carbon brushes in field! Only ASSY brush holders
E4A-91-300-000 provided by Austro Engine GmbH is used for maintenance.

Revision no: 24
Page: 24-15
24-00-32 Completion of Brush Holder
Press down the brushes with metal sheet and place the cover into the brush holder.
Thin Metal Sheet
Push Direction
Upper Brush Position
Lower Brush Position
Cover
Don’t push the cover down to the end position. Cover rib must hold the brushes down in mounting
position.
End Position
Cover
Cover Rib
Fig. 24 - 24 ASSY Brush holder E4A-91-300-000

with brushes pushed back in mounting position

Revision no: 24
Page: 24-16
Assure the correct fitment of the cover (direction) as shown in the picture below.
Backside of Cover
Backside of ASSY Brush Holder

Fig. 24 - 25 Brush holder and hover

Revision no: 24
Page: 24-17
24-00-33 Completion of Generator (Integration of Brush Holder)
If the brushes are not pushed back into the assembly position, it is not possible to
assembly ASSY brush holder E4A-91-300-000.
Gap
Fig. 24 - 26 ASSY Brush holder assembled on the alternator

(brushes are not released)
Assemble the brush holder with screws R1; R2 and R3 using fastening torque 4Nm +/-0,5.
R1
R2
R3
Fig. 24 - 27 Reassembled Assy brush holder

Revision no: 24
Page: 24-18
Push down the cover to its end position.

Brushes are released only if the cover reaches the end position.
If the cover is not pushed down to its end position, the carbon brushes won’t be released.
Push Direction
Fig. 24 - 28 Cover at end position
Place the black plastic cover of the alternator on the alternator backside.
Screw down the hexagonal screws G and G2 using fastening torque 4Nm +/-0,5Nm.
G
G2
Fig. 24 - 29 Cover at end position
After reassembly the alternator has to be functional checked. Therefore continue with chapter
24-00-34 Functionality Check.

Revision no: 24
Page: 24-19
24-00-34 Functionality Check
After assembly the alternator has to be checked if the full functionality is given.
Excitation Winding
Fig. 24 - 30 Alternator
Measure the resistance of the excitation winding.
Test Case 1:
Adjustment Multimeter:
- Resistance
Measuring points:
- Excitation Winding
- Alternator housing
Nominal value:
- 2,5 – 5,0 Ohms
Hint:
If the value is above 5 Ohms rotate the pulley and repeat the measurement.
If the value is again above 5 Ohms please contact Austro Engine GmbH for further
instructions.
If the excitation winding resistance is above 10 Ohms, the brushes are defect or not
released. Check if the brush holder is assembled correct as stated in Chapter 24-00-32
Completion of brush holder.
If the brush holder is assembled correct an the excitation winding resistance is above
10 ohms please contact Austro Engine GmbH for further instructions.

Revision no: 24
Page: 24-20
24-00-35 Marking of Reworked Alternator
For each time when ASSY brush holder E4A-91-300-000 is checked an X (cross) has to be engraved
on the bottom of the alternator. The dimension of the marking is described in Fig. 24.-31.
~10 mm
~10 mm
Fig. 24 - 31 Dimension of marking
Fig. 24 - 29 shows the positioning where the marking has to be engraved on the alternator.
X (Cross)
Fig. 24 - 32 Alternator bottom side with marking
To increase the visibility of the cross, it can be additionally marked with a permanent marker.
It is not allowed to use stickers for marking!

Revision no: 24
Page: 24-21
Install the alternator as described in Chapter 24-00-12.
After the installation a ground run has to be conducted. During this ground run the
output voltage of the alternator has to be observed.
The output voltage of the alternator has to be in the typical operating range as
described in the E4 Installation Manual E4.02.01.
24-00-37 General
The following chapters (24-00-37 to 24-000-53) are only applicable for alternator E4A-91-400-000.
These chapters describes in detail the steps how to dissemble the alternator and its components (e.g.:
brush holder) for checking the carbon brush length. The criteria of replacing ASSY brush E4A-91-410-
000 is also include in this chapters.
24-00-38 Maintenance / Inspection of Carbon Brushes
Austro Engine decided to introduce a maintenance action to measure the length of carbon brushes
after a specified time of operation. The maintenance interval can be found in Chapter 05-20-00 and
the evaluation criteria can be found in Chapter 24-00-49.
24-00-39 Brush Holder Replacement in Field
Additional to the maintenance action a procedure how to replace ASSY brush holder E4A-91-410-000
is introduced. This document describes in detail how to check the carbon brushes, and if necessary
how to replace ASSY brush holder E4A-91-410-000.
24-00-40 General Information
The following symbols and warning signs are used in the manual to point out important instructions.
They must be heeded strictly to prevent personal injury and material damage, to insure operational
safety of the aircraft and to avoid any damage to the aircraft as a result of incorrect handling.
Warning: Disregarding these safety rules can cause personal injury or

even death.
Caution: Disregarding these special instructions and safety measures

can damage the engine or other components.
Note: Additional not or instruction for better understanding of an

instruction.

Revision no: 24
Page: 24-22
24-00-41 Inspection of Carbon Brushes and Alternator
24-00-42 Tool necessary
Number Description Dimensions Supplied by:

1 Screw Driver Slotted Screw Driver (~2mm) Operator
2 Sliding Caliper --- Operator
3 Multimeter --- Operator
4 Torx T20 Operator
5 Spanner 13 mm Operator
6 Spanner 8 mm Operator
24-00-43 Removal of Alternator
Remove the alternator as described in Chapter 24-00-11.

Revision no: 24
Page: 24-23
24-00-44 Removal of Assy Brush Holder
Remove the two screws G and G2.

Remove the black plastic cover on the back side of the alternator with Torx T20.
G2
Fig. 24 - 33..Alternator back side
Remove R1, R2 and R3 with wrench Torx T20, and Terminal Screw T2.
T2
R1
R3
R2
ASSY Brush Holder E4A-91-410-000
Fig. 24 - 34..Alternator with removed plastic cover

Revision no: 24
Page: 24-24
Remove ASSY Brush Holder E4A-91-410-000 carefully.
Remove Direction of ASSY Brush Holder

Revision no: 24
Page: 24-25
24-00-45 Visual Inspection of Alternator Housing
Check the black plastic cover on backside of the alternator if it is cracked or damaged in any kind.
Fig. 24 - 36..Damage of connector outlets
Fig. 24 - 37..Damage of cover

Revision no: 24
Page: 24-26
Check the cooling outlets of the plastic cover.
Fig. 24 - 38 Broken cooling outlet
Check the alternator housing.

If there are any damages on the housing visible please contact Austro Engine GmbH.
Fig. 24 - 39 Alternator housing
If any damage comparable to the ones described in the pictures above is visible, please contact
Austro Engine GmbH for further instructions.

Revision no: 24
Page: 24-27
Check the pulley of the alternator. If there is any kind of damage visible (cuts, chafing marks,…) the
alternator needs to be replaced.
Pulley
Fig. 24 - 40 Pulley

Revision no: 24
Page: 24-28
24-00-46 Inspection of Contact Ring and Brushes
When ASSY brush holder E4A-91-410-000 is removed the contact ring can be inspected.
Check for grooving (>0,5mm) on the contact ring. If grooving (>0,5mm) are visible the alternator
needs to be replaced.
Grooving (<0,5mm) caused by abrasion of carbon brushes are normal.
Clean the contact ring with a soft brush.
Contact ring
Fig. 24 - 41 Contact ring

Revision no: 24
Page: 24-29
24-00-47 Disassembly of ASSY Brush Holder
To check the length of carbon brushes no further disassembly of ASSY Brush Holder E4A-91-410-000
is necessary.
The picture below shows the released carbon brushes.

Clean the brush holder and the brush rip with a soft brush.
Carbon Brush
Fig. 24 - 42 ASSY Brush Holder

Revision no: 24
Page: 24-30
24-00-48 Measuring the Length of Carbon Brushes
Measure the length of both carbon brushes with a calibre gauge.
Length
Carbon brush
Brush Holder
Fig. 24 - 43 Brush length
Ensure to measure the length of the carbon brushes at the points shown in the picture above.
The evaluation criteria can be found in Chapter24-00-49.

Revision no: 24
Page: 24-31
24-00-49 Evaluation Criteria
The table below gives information about the inspection time and minimum brush length.
Operation Time of
300 h
Alternator
Minimum length 7 mm
<7 mm
Brush change necessary if
replace ASSY
below minimum length
brush holder
If the brush length is <7 mm please order a new ASSY brush holder E4A-91-410-000.
For each 300h inspection of the alternator an X (cross) has to be engraved into the housing of
alternator E4A-91-400-000. For the exact positioning of X (cross) please see Chapter 24-00-52
Marking of Alternator.
After an operation time of 2400 h the whole alternator E4A-91-400-000 has to be

replaced.
Brush Holder
E4A-91-410-000
Carbon Brushes
>7mm <7mm
Brush holder can be used for Order new brush holder from Austro
additonal 300h of operating time, Engine & continue with chapter 2.10
continue with chapter 2.9 Completion of Generator (Integration
Completion of Brush Holder of Brush Holder)
Fig. 24 - 44 Flow chart
Only ASSY brush holders E4A-91-410-000 provided by Austro Engine GmbH are used
for maintenance.

Revision no: 24
Page: 24-32
24-00-50 Completion of Alternator (Installation of ASSY Brush Holder)

Place ASSY Brush Holder E4A-91-410-000 carefully on the alternator.
Make sure that the Guide rail of alternator and brush holder E4A-91-410-000 are placed exactly!
Guide rail Guide rail
Fig. 24 - 45 Alternator with ASSY Brush Holder
Push the carbon brush into ASSY Brush Holder softly and move ASSY Brush Holder along the guide rail.
Push direction of ASSY brush holder
Guide rail
Push direction of carbon brush
Fig. 24 - 46 Alternator with ASSY Brush Holder

Revision no: 24
Page: 24-33
The picture below shows the correct placed ASSY Brush Holder on the alternator.
Fig. 24 - 47 Placed ASSY Brush Holder
Assemble the ASSY Brush Holder with screws R1; R2 and R3 using fastening torque 1,6 – 2,3 Nm, and
terminal screw T2 with fastening torque 9 - 13 Nm.
T2
R1
R3
R2
ASSY Brush Holder E4A-91-410-000

Revision no: 24
Page: 24-34
Place the black plastic cover of the alternator on the alternator backside.
Screw down the torx screws G and G2 using fastening torque 1,6 – 2,3 Nm.
Screw down the nut of W (mounted above R1) wit 2,7 – 3,8 Nm.
G W
G2
Fig. 24 - 49 Alternator back side
After reassembly the alternator has to be functionally checked. Therefore continue with
Chapter 24-00-51 Functionality Check.

Revision no: 24
Page: 24-35
24-00-51 Functionality Check

After assembly the alternator has to be checked if the full functionality is given.
Excitation
Winding
Fig. 24 - 50 Alternator
Measure the resistance of the excitation winding.
Test Case 1:
Adjustment Multimeter:
- Resistance
Measuring points:
- Excitation Winding
- Alternator housing
Nominal value:
- 2,5 – 9,0 Ohms
Hint:
If the value is above 9 Ohms rotate the pulley and repeat the measurement. If the
value is again above 9 Ohms please contact Austro Engine GmbH for further
instructions.
If the excitation winding resistance is above 10 Ohms, the brushes are defect or not
released. Check if the brush holder is assembled correct as stated in Chapter 24-00-50
Completion of Generator (Integration of Brush Holder).
If the brush holder is assembled correct an the excitation winding resistance is above
10 Ohms please contact Austro Engine GmbH for further instructions.

Revision no: 24
Page: 24-36
24-00-52 Marking of Reworked Alternator
For each time when ASSY brush holder E4A-91-410-000 is checked an X (cross) has to be engraved
on the bottom of the alternator. The dimension of the marking is described in Fig. 24 - 51
~10 mm
~10 mm
Fig. 24 - 51 Dimension of marking
Fig. 52 shows the positioning where the marking has to be engraved on the alternator.
X (Cross)
Fig. 24 - 52 Alternator bottom side with marking
To increase the visibility of the cross, it can be additionally marked with a permanent marker.
It is not allowed to use stickers for marking!

Revision no: 24
Page: 24-37
Install the alternator as described in Chapter 24-00-12.
After the installation a ground run has to be conducted. During this ground run the
output voltage of the alternator has to be observed.
The output voltage of the alternator has to be in the typical operating range as
described in the E4 Installation Manual E4.02.01.
Fig. 24 - 53 Alternator back side with covers
Do not forget to apply the black plastic covers on the electrical Terminals (W, Excitation L and B+).

Revision no: 24
Page: 24-38
Chapter 51-00-00 Standard Practices
51-00-10 Safety Wiring
Safety wire is used to secure fasteners to prevent them from coming lose. It's used a lot in aviation
and racing. To safety wire fasteners you will need safety wire, safety wire pliers, wire cutters (dykes),
and needle nose pliers. In a pinch, you can make do with the wire and needle-nose pliers with a
cutting edge. The hardest part of safety wiring is drilling the holes in the hardened fasteners. There
are jigs available to hold nuts and bolts so they can be drilled more easily. You may also be able to
purchase pre-drilled fasteners and save yourself some time. Safety wire comes in many types and
sizes. You must first select the correct type and size of wire for the job. Annealed corrosion-resistant
steel or stainless steel wire is used in race preparation.
51-00-11 The following Alternator rules apply to safety wiring
1. All safety wires must be tight after installation, but not under so much tension that
normal handling or vibration will break the wire.
2. The wire must be applied so that all pull exerted by the wire tends to tighten the nut.
3. Twists should be tight and even, and the wire between nuts as taut as possible
without over-twisting. Safety wire pliers can easily twist the wire too far, breaking or
weakening it.
4. Twist ends should routed so that no injured ours
For this reason, wire between nuts should be twisted with the hands. The use of pliers may damage
the wire. Pliers should be used only for final end twist before cutting excess wire
Fig. 51 - 1
Patterns
All critical nuts except the self-locking types must be safe tied; the method used depends upon the
particular installation. The illustration at left shows various methods commonly used in safety wiring
nuts, bolts, and screws. Examples 1, 2, and 7 show the proper method of safety wiring bolts, screws,
square head plugs, and similar parts when wired in pairs. Examples 4 and 5 show a single threaded
component wired to a housing or lug. Example 3 shows several components wired in series. Example
6 shows the proper method of wiring castellated nuts and studs. Note that there is no loop around the
nut. Example 8 shows several components in a closely spaced, closed geometrical pattern, using the
single-wire method.

Revision no: 5
Page: 51-1
51-00-12 Single Wire Safe Tying
Insert the wire through each part consecutively in the direction that will prevent the part from
loosening. Draw the wire tightly around each bend and twist the ends into a tight pigtail close to one
of the safe tied parts. Cut the pigtail square, leaving a minimum of three twists. Bend the pigtail over
against the part being safe tied to prevent snagging. You should not use safety wire longer than 24
inches for single wiring three or more parts as a group.
Fig. 51 - 2
51-00-13 Double Wire Safety Wiring By Hand
Pull the wire through the first bolt. Bend one end of the wire around the head of bolt #1 toward bolt
#2, in a direction such that a pull on the twisted wire toward bolt #2 would cause bolt #1 to tighten.
Twist the outer wire under the other wire close to bolt #1. Continue twisting the wire clockwise,
keeping the strands wide apart to ensure a tight even twist. When the twisted pair reaches bolt #2
without slack, insert the wire in the bolt hole in a direction so that bolt #2 cannot loosen without
pulling bolt #1 tight. Bend the free wire around the head of bolt #2, and twist the wires counter
clockwise. Continue twisting counter clockwise beyond the bolt to form a pigtail. Cut the pigtail
square, leaving a minimum of three twists. Bend the pigtail over against the part being safe tied, to
prevent snagging.
Fig. 51 - 3

Revision no: 5
Page: 51-2
Fig. 51 - 4
51-00-14 Double Wire Safety Wiring Using Pliers
Start by looping the wire through the fastener, using a little extra wire, because you don't want to be
short at the end. Loop the wire coming out of the bottom hole around the bolt head clockwise and
pull the wire tight with needle nose pliers in the direction of the second bolt. Start the twist by hand
(two to three turns) then bring the two wires together and clip the safety wire pliers on the wires next
to the hole it will go in on the second bolt, keep the two wires next to each other in the pliers jaws
(no gap between them). Pull the safety wire pliers twist-knob to twist the wire, hold the pliers to keep
it from twisting backwards and let the knob retract then repeat until the desired twist is reached. Do
not over-twist the wire, you can easily weaken or break it. Unclip the safety wire pliers, put one wire
through the second bolt (using needle nose pliers helps), loop the other wire around the bolt head,
start the twist by hand, clip on the safety wire pliers and twist. Now you're ready to cut the wire.
Leave about 1/4 inch of a tail (about 3 twists) Tuck it around the last fastener so it doesn't snag.
Fig. 51 - 5 Fig. 51 - 6
Assorted Odd Bolt Heads and Nuts
When various types of bolt heads and or nuts are safe tied to stationary parts, you can use either
right or left hand twists. Attach the safety wire in such a manner that if the bolt or nut should start to
loosen then the wire would be in the direction of tightening the fastener.

Revision no: 5
Page: 51-3
51-00-15 Samples of Safety Wiring
Fig. 51 - 7

Revision no: 5
Page: 51-4
Fig. 51 - 8

Revision no: 5
Page: 51-5
Fig. 51 - 9

Revision no: 5
Page: 51-6
51-00-20 Torque Standards
The importance of correct torque application cannot be overemphasized. Under torque can result in
unnecessary wear of nuts and bolts, as well as the parts they secure. Over torque can cause failure of
a bolt or nut from overstressing the threaded areas. Uneven or additional loads that are applied to the
assembly may result in wear or premature failure. The following are a few simple, but important
procedures, which should be followed to ensure that correct torque is applied.
Be sure that the torque applied is for the size of the bolt shank not the wrench size.
a. Calibrate the torque wrench at least once a year, or immediately after it has been abused or
dropped, to ensure continued accuracy.
b. Be sure the bolt and nut threads are clean and dry, unless otherwise specified by the manufacturer.
c. Run the nut down to near contact with the washer or bearing surface and check the friction drag
torque required to turn the nut. Whenever possible, apply the torque to the nut and not the bolt.
This will reduce rotation of the bolt in the hole and reduce wear.
d. Add the friction drag torque to the desired torque. This is referred to as “final torque,” which should
register on the indicator or setting for a snap-over type torque wrench.
e. Apply a smooth even pull when applying torque pressure. If chattering or a jerking motion occurs
during final torque, back off the nut and retorque.
Many applications of bolts in aircraft/engines require stretch checks prior to reuse.

This requirement is due primarily to bolt stretching caused by over torque.
f. When installing a castle nut, start alignment with the cotter pin hole at the minimum recommended
torque plus friction drag torque.
Do not exceed the maximum torque plus the friction drag. If the hole and nut
castellation do not align, change washer or nut and try again.
Exceeding the maximum recommended torque is not recommended.
g. When torque is applied to bolt heads or cap screws, apply the recommended torque plus friction
drag torque.
h. If special adapters are used which will change the effective length of the torque wrench, the final
torque indication or wrench setting must be adjusted accordingly. Determine the torque wrench
indication or setting with adapter installed as shown in figure

Revision no: 1
Page: 51-7
Torque wrench with various adapters.
Fig. 51 - 10
Elimination of friction in interference fit applications may sometimes be attained by

placing the bolt in a freezer prior to installation. When this procedure is used, the bolt
should be allowed to warm up to ambient temperature before torque.

Revision no: 5
Page: 51-8
Chapter 71-00-00 Power Plant
71-00-01 General
For description see Chapter 01-10-00 General Engine Description
71-00-02 Instruction
An engine ground test run should be conducted after any work on the engine. After running the test,
the engine has to be inspected visually, especially the replaced and repaired engine parts.
Some work steps have to be performed when the engine is warm.

These work steps must be taken with utmost care.
Wrong maintenance of the engine can cause heavy engine damage even to engine
stop during aviation.
To award the warranty approved parts from the Austro Engine GmbH must be
used. For further information of maintenance Austro Engine GmbH can be
contacted.

Revision no: 9
Page: 71-1
71-00-03 Engine Ground Run
After work on the engine it is recommended to perform a ground run following this procedure:
For starting, warm up and shut down refer to the applicable Aircraft Flight Manual (AFM).
Aircraft engine ground run must be performed in a secure and save area protected
against movements of unauthorised persons.
Accidents can cause severe injury or even death.
Aircraft engine ground run must be performed by authorised persons only.
The area of the propeller must be kept clear. If objects get into the propeller,
propeller and engine can be seriously damaged.
To execute the Engine Ground Test Run, following steps have to be performed consecutive:
For engine start and warm up refer to the applicable Aircraft Flight Manual (AFM)
Conduct EECU self test (Refer to the applicable Aircraft Flight Manual)
Start engine test
1. Ensure that the Voter switch is on the ECU A position.

2 Move power lever quickly to the full-load position. The propeller must accelerate
smoothly and steadily up to the propeller speed of 2300 rpm. The load indicator must
show more than 95%. Maintain this status for 30 seconds, and then return the load
selector to the idle position.
3. Move the Voter switch to the ECU B position. Move the power lever to the
full-load position. The propeller must accelerate smoothly and steadily up to the
propeller speed of 2300 rpm. The load indicator must show more than 95%.
Maintain this status for more than 30 seconds, and then return the load selector to
the idle position.
4. Return the Voter switch to the Auto position.
Shut off engine in accordance to the applicable Aircraft Flight Manual (AFM).
In case of failure indications read out data using the AE 300-Wizard.
After the Engine Ground Run perform a visual inspection of the engine. Look especially for leakage
and chafing.

Revision no: 11
Page: 71-2
In case of any maintenance on the camshaft sensor, conduct the following procedure:
Switch ECU-Voter
to ECU_A
Crank the engine
No
Check engine
Engine start‘s mechanical /
electrical System
Yes
Turn off engine
Switch ECU-Voter
to ECU_B
Crank the engine
No
Check ECU_B sensor

Engine start‘s Target wheel and/or
System
Yes
Test OK

Revision no: 24
Page: 71-3
71-50-00 Electrical Harness
71-50-01 General
The harness provides electrical interconnection between all system components. Also it is an
important part for HIRF & lightning protection.
71-50-02 General Information -> Wiring Harness
The wiring harness has to be fixed at several points to avoid harness damage caused by normal
engine operation (e.g.: due to vibration). Fixing points are marked in „ Fig. 71 - 41, Fig. 71 - 42 and
Fig. 71 - 43“.
Bend radius : min. 100 mm

Unsupported distance : max. 150 mm
All connectors must be plugged in a way to avoid forces applied to the connector.
No tension on the harness is allowed at all.
Pay attention for correct interlocking of the plug and socket

connections. Inspect the correct locking of ALL connectors.
All shielding wires must be attached via electrically conducting connections to the engine block
at the actuator and sensor ends of the wiring harness. It is not allowed to shorten or to
extend the shielding wires.
No changes are allowed of the delivered wiring harness.

Only the delivered configuration is tested (EMI, lightning protection) and approved.
Exception: To avoid abrasion, mounting of protective tube is allowed.

Revision no: 24
Page: 71-4
71-50-10 Engine Wiring Harness E4A-90-000-000
Inspect the engine harness for chafing, damage or missing clamps.

In case of signs of wear or damage contact Austro Engine GmbH for further instructions.
FPS
FTS
PCV
INJ 4
FMU
GP 4
INJ 3 CAS 1
GPC GP 3
INJ 2
GBTS GP 2
INJ 1
CAS 2
GP 1
CRS 1
GOV
RPS BPA
CTS_GPC
CTS
OPS
BPS2
IAT 2 IAT 1
BPS1
CRS 2
MOK
Connection Cockpit
GEN
Connection EECU
Fig. 71 - 1
Pay attention for correct interlocking and snapping of the plug and socket connections
(e.g. ECU connector or Injector connector)

Revision no: 24
Page: 71-5
71-50-20 Sensor – Check
The sensors have to be inspected for loosened, chafed or damaged connectors according to the
attached list and schematic. Be aware of, that some connectors have interlocks which need to be
checked.
In case of signs of damage contact Austro Engine GmbH for further instructions.
71-50-30 Description Plug Connector Wiring Harness

Wiring Description long version German description Abbr.
diagram
B1/1 Fuel Pressure Sensor Kraftstoffdrucksensor FPS
B4/6 Rail Pressure Sensor Raildrucksensor RPS
B40 Oil Combinant Sensor Temperature Kombinierter Ölsensor Temperatur MOK
B5/1 Boost Pressure Sensor 1 Ladedrucksensor BPS1
B5/2 Boost Pressure Sensor 2 Ladedrucksensor BPS2
B5/3 Oil Pressure Sensor Öldrucksensor OPS
B50/1 Intake Air Temperature 1 Ladelufttemperatursensor IAT 1
B50/2 Intake Air Temperature 2 Ladelufttemperatursensor IAT 2
B50/3 Coolant Temperature Sensor Kühlwassertemperatur CTS
B50/5 Gearbox Temperatur Sensor Getriebetemperatursensor GBTS
B50/6 GPC Coolant Temperature Kühlwassertemperatursensor GPC CTS_GPC
B50/7 Fuel Temperature Sensor Kraftstofftemperatursensor FTS
B6/1 Camshaft Sensor 1 Nockenwellensensor CAS 1 X)
B6/2 Camshaft Sensor 2 Nockenwellensensor CAS 2
G115 ECU A
G121 ECU Power
G116 ECU B
G2 Alternator Plug Alternator Stecker GEN
GPC A/C Interface 6
L5/1 Crankshaft Sensor 1 Kurbelwellensensor 1 CRS 1
L5/2 Crankshaft Sensor 2 Kurbelwellensensor 2 CRS 2
M55 Governor Actuator Governor GOV
N14/2 Glow Plug Control GPC Glow Plug Control GPC
R9/1 Glow Plug 1 Glühkerze 1 GP 1
W11
X1/1 A/C Interface 1
Y31/5 Boost Pressure Actuator EPW BPA
Y74 Pressure Control Valve Druckregelventil Rail PCV
Y76/1 Fuel Injector 1 Injektor INJ 1 X)
Y94 Fuel Metering Unit Zumesseinheit FMU
X) This Sensor can only be checked all 300 h if the Injector cover is removed.

Revision no: 24
Page: 71-6
71-50-40 Material and saving material for the Engine Wiring Harness
Pos Part number Description St Torque specification Tool

01 E4A-90-000-000 Engine wiring harness 1
02 E4A-90-000-801 Hex-head screw with 1 6 Nm
tooth lock M6x10
03 DIN3016-W1-DM Clamp 1 12 Nm
12x15
04 DIN3016-W1-DM Clamp 2 5 Nm
6x15
05 DIN3016-W1- Clamp 2 6 Nm
DM8x15
tooth lock M6x16
tooth lock M8x16
08 E4A-90-100-801 Cable strap 100 x 2,5 mm 60
09 DIN3016-W1- Clamp 1
DM15x15
10 E4A-90-100-808 Cable strap with 1
EdgeCLip
11 DIN3016-W1- Clamp 2
DM10x20
12 DIN3016-W1- Clamp 1 12 Nm
DM13x20
13 E4A-90-100-805 Cable strap 340x4,5 2
14 E4A-90-100-810 Mesh tube
ø 8 mm x195 cm
15 E4A-90-100-811 Mesh tube
ø 13 mm x 100 cm
Mounting of mesh tube pos.14 and pos.15 is shown on several Figures.

Revision no: 24
Page: 71-7
71-50-60 Mounting Backbones
09
06
Fig. 71 - 2
Use the screw 06 to fix the clamp 09 and torque it with 10 Nm (see Fig. 71-3)
12
Fig. 71 - 3
Use the screw of the engine fastener to fix the clamp 12 and torque it with 12 Nm
(see Fig.71-3).

Revision no: 24
Page: 71-8
71-50-70 Intake Air Manifold
03
Fig. 71 - 4
03
Fig. 71 - 5
Use Clamp 03 to fix the sub-backbone (intake air manifold) and the wire for glow-plug 4 and torque it
with 12 Nm.

Revision no: 24
Page: 71-9
Fig. 71 - 6
07
11
Fig. 71 - 7
Use the screw 07 and torque it with 12 Nm to fix the clamp 11 .

(see Fig. 71-7).

Revision no: 24
Page: 71-10
Fig. 71 - 8
Fig. 71 - 9

Revision no: 24
Page: 71-11
Fig. 71 - 10
Fig. 71 - 11

Revision no: 24
Page: 71-12
11
Fig. 71 - 12
Fig. 71 - 13
Clamp 11 is screwed on the fastener of the alternator (see Fig. 71 – 13).

Revision no: 24
Page: 71-13
05
Fig. 71 - 14
Use the screw (Pos. 02) to fix the clamp 05 and torque it with 6 Nm (see Fig. 71 - 14).
11
04
Fig. 71 - 15
Clamp 04 is screwed on the Oil level sensor.

Revision no: 24
Page: 71-14
04
02
Fig. 71 - 16
Use the screw 02 to fix the Clamp 04 and torque it with 6 Nm (see Fig. 71 - 16).
Fig. 71 - 17
Fix the clamp on the oil filter housing. The clamp-bow is orientated to the engine block
(see Fig. 71 – 17).

Revision no: 24
Page: 71-15
71-50-80 Alternator
Fig. 71 - 18
Fig. 71 - 19

Revision no: 24
Page: 71-16
71-50-90 GPC
Fig. 71 - 20

Revision no: 24
Page: 71-17
71-50-100 CRS 1 & 2
Fig. 71 - 21
Fig. 71 - 22

Revision no: 24
Page: 71-18
71-50-110 Mechanical protection (Mesh tube)
Fig. 71 - 23
Fig. 71 - 24

Revision no: 24
Page: 71-19
Fig. 71 - 25

Revision no: 24
Page: 71-20
Fig. 71 - 26
Fig. 71 - 27
Fig. 71 - 27 shows the CORRECT mounting of the EPW wire.

Fix the cable by the usage of cable strap and mind a sufficient distance between cable and turbo
charger case.

Revision no: 24
Page: 71-21
Fig. 71 - 28
Fig. 71 – 28 shows the WRONG mounting of the EPW wire.

Caution: The wire must not touch the turbo charger housing!
Fig. 71 - 29
Fig. 71 – 29 shows the laying and the fixing point of the shielding cable.

Revision no: 24
Page: 71-22
71-50-120 Engine Wiring Harness E4A-95-000-000 and E4B-95-000-000
Inspect the engine wiring harness for chafing, damage or missing clamps.
In case of signs of wear or damage contact Austro Engine GmbH for further instructions.
Block diagram E4A
Fig. 71 - 30

Revision no: 24
Page: 71-23
Block diagram E4B
Fig. 71 - 31
Pay attention for correct interlocking and snapping of the plug and socket connections
(e.g. ECU connector or Injector connector).

Revision no: 24
Page: 71-24
71-50-130 Sensor – Check
The sensors have to be inspected for loosened, chafed or damaged connectors according to the
attached list and schematic.
In case of signs of damage contact Austro Engine GmbH for further instructions.
71-50-140 Description Plug Connector Wiring Harness

Wiring Description long version German description
diagram
FPS Fuel Pressure Sensor Kraftstoffdrucksensor
RPS Rail Pressure Sensor Raildrucksensor
MOK Oil Combinant Sensor Kombinierter Ölsensor Temperatur
Temperature
BPS1 Boost Pressure Sensor 1 Ladedrucksensor
BPS2 Boost Pressure Sensor 2 Ladedrucksensor
OPS Oil Pressure Sensor Öldrucksensor
IAT 1 Intake Air Temperature 1 Ladelufttemperatursensor
IAT 2 Intake Air Temperature 2 Ladelufttemperatursensor
CTS Coolant Temperature Sensor Kühlwassertemperatur
GBTS Gearbox Temperatur Sensor Getriebetemperatursensor
CTS_GPC GPC Coolant Temperature Kühlwassertemperatursensor GPC
FTS Fuel Temperature Sensor Kraftstofftemperatursensor
CAS 1 Camshaft Sensor 1 Nockenwellensensor X)
CAS 2 Camshaft Sensor 2 Nockenwellensensor
ECU A ECU A ECU A Stecker
ECU PWR ECU Power ECU Power Stecker
ECU B ECU B ECU B Stecker
GEN Alternator Plug Alternator Stecker
GPC GPC Connector GPC Stecker
CRS 1 Crankshaft Sensor 1 Kurbelwellensensor 1
CRS 2 Crankshaft Sensor 2 Kurbelwellensensor 2
GOV Governor Actuator Governor
GPC Glow Plug Control GPC Glow Plug Control
GP 1 Glow Plug 1 Glühkerze 1
W11 / 1 Ground Connection GPC Masse Verbindung für GPC
W11 / 2 Ground Connection Governor Masse Verbindung für Governor
X1/1 CPC 1 A/C Interface 1 CPC 1
X1/2 CPC 2 A/C Interface 2 CPC 2
BPA Boost Pressure Actuator EPW
PCV Pressure Control Valve Druckregelventil Rail
INJ 1 Fuel Injector 1 Injektor X)
FMU Fuel Metering Unit Zumesseinheit
X) This Sensors can only be checked all 300h if the Injector cover is removed.

Revision no: 24
Page: 71-25
71-50-150 Material and saving material for the E4A Engine Wiring Harness
Pos Teilenummer Bezeichnung St Drehmoment in Nm Werkzeug Sicherung

01 E4A-95-000-000 LU Kabelbaum 1
02 DIN3016-W1- Schelle 28 1
DM28-20
03 DIN3016-W1-DM Schelle 22 2
22x15
8x15
05 PLT4S-M30 Kabelbinder 25
06 E4A-90-100-808 Edge Clip 3
07 E4A-90-000-809 Edge Clip 5
08 50266513 Edge Clip 3
09 E4A-90-100-801 Schraube 2 5
10 E4A-95-100-000 Assy Shielding Fuel Pressure 1
71-50-160 Material and saving material for the E4B Engine Wiring Harness
Pos Teilenummer Bezeichnung St Drehmoment in Nm Werkzeug Sicherung

01 E4B-95-000-000 LU Kabelbaum 1
02 DIN3016-W1- Schelle 28 1
DM28-20
22x15
8x15
05 PLT4S-M30 Kabelbinder 25
06 E4A-90-100-808 Edge Clip 3
07 E4A-90-000-809 Edge Clip 5
08 50266513 Edge Clip 3
09 E4A-90-100-801 Schraube 2 5

Revision no: 24
Page: 71-26
71-50-170 E4 Engine Wiring Harness mounting instruction
For Harness Routing see Chapter 92-00-00 Additional Information.
On the following pages the mounting of the engine wiring harness is described in detail. The mounting
instruction is identical for both versions of E4 wiring harness (E4A-95-000-000 and E4B-95-000-000).
RPS
Pigtail RPS
02
Fig. 71 - 32
Ensure sufficient space between the wiring harness and the engine block as shown
below to avoid chafing of the engine harness.
Fig. 71 - 33

Revision no: 24
Page: 71-27
Fig. 71 - 34
A clamp which is mounted to the lifting eyelet (12 Nm) is used for fixation wiring harness and RPS
pigtail as shown at Fig. 71 -32.
CAS1
03
Fig. 71 - 35
The wiring harness has to be placed above the pipes for each injector. CAS1 pigtail has to be
connected to the fastening screw (14 Nm) of CAS1.
The wiring harness has to be fixed with cable ties 03 in the near of injector plug.

Revision no: 24
Page: 71-28
Fig. 71 - 36
Fig. 71 - 37

Revision no: 24
Page: 71-29
Fig. 71 - 38
The branch for the glow plugs shall be placed behind the thermostat as shown at Fig. 71 - 36,
Fig. 71 – 37 and Fig. 71 – 38.
Rail
05
Fig. 71 - 39
The wiring harness has to be placed on the rail and fixed with 3 cable ties 05 .
It has to be ensured that the branches and cable ties do not constrain the mounting of the
injector cover.

Revision no: 24
Page: 71-30
Pigtails BPS1 & IAT2 Pigtails BPS2 & IAT2
Fig. 71 - 40
The mounting screws (5 Nm) of sensors, BPS 1 and BPS 2 shall be used to connect the pigtails of
IAT 1, IAT 2, BPS 1 and BPS 2 with the intake air manifold.
Fig. 71 - 41
It has to be insured that the engine wiring branch hat to be placed as shown at Fig. 71 – 41.

Revision no: 24
Page: 71-31
Fig. 71 - 42
The pigtails of FTS and PCV have to be screwed (12 Nm) as shown at Fig. 71 – 42.
Fig. 71 - 43
The pigtails of FMU and CTS have to be screwed (12 Nm) to the lifting eyelet shown at Fig. 71 – 43.

Revision no: 24
Page: 71-32
For the engine harness E4A-95-000-000 and E4B-95-000-000 the fuel pressure sensor
(FPS) and fuel pressure sensor cable have to be covered by an additional shielding (E4A-
95-100-000), which is provided with the engine if applicable.
If the engine harness E4A-90-000-000 is installed this procedure is not applicable.
10
05
11
Fig. 71 - 44
Fuel pressure sensor and the fuel pressure sensor cable have to be equipped with an additional
shielding as shown in picture Fig. 14. 2. Therefore cover the fuel pressure sensor and fuel pressure
sensor cable with a netting 10 , RAY-90-25.0 with the length of 180mm. At each end of the netting a
cable tie 05 is used to fix the netting. At each end of the netting a tape 11 can be used to avoid
splicing.
FMU
Pigtail FPS
Branch FPS
Fig. 71 - 45
The pigtail connector of FPS has to be connected to the mounting screw of the FMU as shown at Fig. 71 – 45

Revision no: 24
Page: 71-33
08
Fig. 71 - 46
For fixation the branch of CRS1 sensor the edge clips 08 has to be placed as shown at Fig. 71 – 46.
Pigtail CRS1
Pigtail CRS1
Fig. 71 - 47
The pigtail of CRS1 (crankshaft sensor) has to be connected to the screw of EGR cover (21 Nm).
The edge clips shall be used to fix the branch of CRS1.

Revision no: 24
Page: 71-34
EGR Cover
03
Fig. 71 - 48
The engine harness has to be fixed (9 Nm) with a clamp 03 to the EGR cover. The rest of the branch
located in that area are fixed after starter, gearbox and GPC are mounted.
Fig. 71 - 49

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Page: 71-35
Pigtail BPA
Pigtail CAS 2
Fig. 71 - 50
Pigtail of CAS2 has to be connected sensor mounting screw (12 Nm), pigtail of BPA has to be
connected to injector cover plate (9Nm), as shown at Fig. 71 -50.
Branch of CRS2 has to be placed as shown on picture above. Ensure that the branch is not in contact
with the turbo charger.
05
06
Fig. 71 - 51
The branch of EPW and CAS2 has to be fixed with edge clip 06 and cable tie 05 as shown at
Fig. 71 – 51.

Revision no: 24
Page: 71-36
BPA
05
BPA Filter
Fig. 71 - 52
BPA filter has to be fixed with a cable tie 05 as shown at Fig. 71 – 52.
Only the connector adapter (of PBA filter) is allowed to be used for fixation with the cable tie.
03
Oil filter housing
GPC
Alternator
MOK
Fig. 71 - 53
The branch of GPC, MOK and GEN, CRS2 has to be fixed with a clamp 03 to the oil filter housing
screws (8 Nm).

Revision no: 24
Page: 71-37
Heat exchanger
Pigtail OPS
OPS
05
Fig. 71 - 54
The pigtail of OPS has to be connected to the heat exchanger (9 Nm). The engine harness has to be
fixed with cable tie 05 to the starter.
Pigtail MOK
Pigtail GEN
04
W11/1
Oil sump
09
Fig. 71 - 55
Clamp 04 is used for fixation the branch of GEN. The screw of MOK which is used for mounting the
clamp shall also be used to connect the pigtail of GEN (5 Nm). W11/1 loop and pigtail of MOK have to
be connected to the screw of the oil sump (5 Nm).

Revision no: 24
Page: 71-38
GBTS
W11/2
09 07
Fig. 71 - 56
2 edge clips have to be mounted to the GPC holder. The edge clips shall be used for fixation the
branch of GBTS and W11/2 as shown at Fig. 71 – 56.
GBTS Pigtail
GPC
Fig. 71 - 57
The pigtail of GBTS has to be connected to the GPC holder screw (10 Nm) as shown at Fig. 71 – 57.

Revision no: 24
Page: 71-39
Branch CRS2
08
Fig. 71 - 58
One edge clip 08 has to be mounted as shown at Fig. 71 – 58.

It shall be used to fix the branch of CRS2.
Branch CRS2
07
GPC Holder
Fig. 71 - 59
One edge clip 07 has to be mounted as shown at Fig. 71 – 59.

It shall be used to fix the branch of CRS2.

Revision no: 24
Page: 71-40
Branch CRS2
Pigtail CRS2
07
CRS2
Fig. 71 - 60
One edge clip 07 has to be mounted as shown at Fig. 71 – 60. It shall be used to fix the branch of
CRS2. The pigtail of CRS2 has to be connected to the screw (11 Nm) of CRS2.
Governor
Fig. 71 - 61
The governor pigtail is included to the bayonet connector GOV. No additional screwing of pigtail is
therefore needed.

Revision no: 24
Page: 71-41
Fig. 71 - 62
The installer of the engine harness is allowed to use the same cable tie type for additional fixation, if
the described fixation points are not sufficient. It has to be ensured by installer that the additional
cable ties are not directly mounted to driven or hot parts of the engine.
If it is required the installer is allowed to use cable ties 05 and Edge Clips (06; 07; 08) to fix the
engine harness additional. In such a case of an additional fixation with the described materials it has
to be ensured that the branches with the used materials are not attached to hot areas.

Revision no: 24
Page: 71-42
71-50-180 Fastening point in the aircraft (E4A-90-000-000)
The wiring harness has to be fixed at several points to avoid harness damage.
Fixing points are marked in Fig 71.-.63, Fig. 71.-.64 and Fig. 7 - 65.
Fig. 71 - 63
Fig. 71 - 64

Revision no: 24
Page: 71-43
Fig. 71 - 65

Revision no: 24
Page: 71-44
71-50-190 Remove the Wiring Harness
DISCONNECT the power source prior to the remove of the wiring harness.
 Remove the Injector Cover – refer to Chapter 85-00-11 Removal of the Injector Cover
 Remove all clamps. (Pos. 03, 04, 05, 09, 11, 12).
 Remove the cable strap from the Edge Clip (Pos.10) and the starter motor.
 Disconnect the shielding cable.
 Disconnect the wiring harness from all electrical equipment which is connected to the harness.
Start on the right gearbox side.
 The harness can be removed.
Each connector is locked. Release the lock before disconnect the plugs.
For example some locking-systems are shown.
Connectors locked Connectors unlocked
Fig. 71 - 66
Fig. 71 - 67

Revision no: 24
Page: 71-45
Connectors locked Connectors unlocked
Fig. 71 - 68

Revision no: 24
Page: 71-46
71-50-800 Repair of the Engine Wiring Harness E4A-90-000-000
Herein described repair procedures for exchange of connectors can only be conducted once.
71-50-801 Exchange of Connector to “Intake Air Temperature”-Sensors
Pos. Partnumber Description Qty.

1 E4A-90-R16-000 Assy Repair Kit Cable 1
2 - Cutter 1
3 - Hot Air Gun 1
4 - Crimp Tool for 1
TE (Tyco) D-436-36 crimp
5 - Multimeter 1
Step 1: Step 2:
Remove the protective sleeve. Cut off the “damaged” part at the solder sleeve. The
old connector will not be used for repair.
Protective Sleeve
Solder Sleeve
Step 3: Step 4:
Remove approx. 10mm (± 2mm) of the insulation The inline crimp shall be used to connect the single
with shielding of the remaining wire. Put the solder wire (2) of the remaining engine harness, and the
sleeve over the cable of the remaining engine white single (1) wire of the repair kit cable E4A-90-
harness. The solder sleeve will be needed for R16-000.
2
electrical connection as described at step 6. 1
10mm
Inline Crimp
Solder Sleeve

Revision no: 24
Page: 71-47
Step 5: Step 6
Strip the insulation behind the inline crimp (5mm Move the solder sleeve, which was putted over the
± 2mm) which was mounted as described in Step4. wire of the reaming harness (see Step 3), over the
Ensure not to cut off the shielding below the shielding that was exposed at step 5. The red
insulation. marking of the solder sleeve should be placed over
the exposed shielding.
Put the white / black wire (3) of repair kit cable E4A-
Inline Crimp 90-R16-000 into the solder sleeve (expose wire
should connect the shielding).
Heat the solder sleeve (300°C – 350°C) with a hot
air gun until the solder sleeve is connected with the
Shielding cable and the shielding.
Solder Sleeve
3
Step 7: Step 8:
Put the smaller ROUNDIT over the cable as shown The bigger ROUNDIT can be placed in addition over
below. The cable ties or / and the tape of the the smaller ROUNDIT for improved chafing
repair kit can be used for fixation of the ROUNDIT protection.
as necessary. The cable ties or / and the tape of the repair kit can
be used for fixation of the ROUNDIT as necessary.
ROUNDIT
Tape
Step 9:
Check with a Multimeter the connection between the pins as stated below:
Connector Pin Connector Pin

s B50/1 (IAT1) 2
ECU A
t B50/1 (IAT1) 1
s B50/2 (IAT2) 2
ECU B
t B50/2 (IAT2) 1

Revision no: 24
Page: 71-48
71-50-802 Exchange of Connector to Fuel Pressure Sensor (FPS)

3 - Cutter 1
4 - Hot Air Gun 1
TE (Tyco)D-436-36 crimp
Step 1: Step 2:
Cut off the old connecter Remove the black and white cable insulation.
Remaining
engine wiring
harness
50 mm (±5)
20 mm (+5mm)
Step 3: Step 4:
Remove the shielding as shown below. Put the solder sleeve over the engine harness cable
and place it above the shielding.
10 mm (+5mm) Heat the solder sleeve (300°C – 350°C) with a hot air
gun until the solder sleeve is connected with the
cable and the shielding
Solder Sleeve

Revision no: 24
Page: 71-49
Step 5: Step 6:
Remove the isolation of all single wires on the end The inline crimp consists of the splice crimp and the
of the engine harness and the repair kit cable E4A- isolation sleeve. Put the isolation sleeve of the inline
90-R18-000 as shown below. crimp over the single wire of engine harness.
Place the splice crimp at the end of the single wires
of the repair kit cable E4A-90-R18-000.
5mm (±1) Crimps

Isolation sleeves
Step 7: Step 8:
Connect the singles wires of the engine harness Put the isolation sleeve of the inline crimp over the
with the repair kit cable of E4A-90-R18-000 by inline crimp sleeve. Heat the isolation sleeve (300°C
usage of the inline crimp. – 350°C) with a hot air gun until the isolation sleeve
seals the splice crimp and the single wires.
Pinning list for FPS connector is shown in
the table below.

ECU A n B1/1 (FPS) 2
ECU A m B1/1 (FPS) 3
ECU A k B1/1 (FPS) 1
Inline crimp
Step 9: Step 10:

Put the chafing protection ROUNDIT over the Install the additional shielding E4A-95-100-000 as
repair kit cable and the engine wiring harness. The described in the Installation Manual E4.02.01. The
length of the chafing protection ROUNDIT can be shielding shall be used as an additional caving
reduced if necessary. protection.
ROUNDIT Cable Ties
Pig Tail
Ensure that the Cable ties as provided in the repair kit can be used
pig tail is not covered with ROUNDIT and a ring for fixation.
termination is mounted on it.

Revision no: 24
Page: 71-50
71-50-803 Exchange of Connector to Boost Pressure Actuator (BPA)

2 - Cutter 1
3 - Hot Air Gun 1
Step 1: Step 2:
Cut off the old solder sleeve of the BPA branch. Remove the black and white cable insulation.
Old Solder Sleeve
50 mm (+5mm)
10 mm (+5mm)
Step 3: Step 4:
Remove the shielding as shown below. Put the solder sleeve over the wiring harness cable
and place it above the shielding.
Heat the solder sleeve (300°C – 350°C) with a hot air
gun until the solder sleeve is connected with the
cable and the shielding
Solder Sleeve
10 mm (+5mm)
Step 5: Step 6:
Remove the isolation of single wire on the end of The inline crimp consists of the splice crimp and the
the engine wiring harness and the cable of the isolation sleeve. Put the isolation sleeve of the inline
repair kit as shown below. crimp over the single wire of engine harness.
Place the splice crimp at the end of the single wires
of the repair kit cable E4A-90-R17-000.
See also picture of step 6 of chapter 71-50-802.
5 mm (±1)

Revision no: 24
Page: 71-51
Step 7: Step 8:
Connect the singles wires of the engine wiring Put the isolation sleeve of the inline crimp over the
harness with the repair kit cable by use of the inline crimp sleeve. Heat the isolation sleeve (300°C
inline crimp sleeve. – 350°C) with a hot air gun until the isolation sleeve
seals the splice crimp and the single wires.
Pinning list for BPA connector is shown in
the table below.

ECU PWR M Y31/5 (BPA) 1
ECU PWR a Y31/5 (BPA) 2
Isolation Sleeve
Step 9: Step 10:

Put the chafing protection ROUNDIT over the Cable ties as provided in the repair kit can be used
repair kit cable and the engine wiring harness. The for fixation onto the engine.
length of the chafing protection ROUNDIT can be
reduced if necessary.

Revision no: 24
Page: 71-52
71-50-804 Exchange of Connector for Alternator E4A-91-400-000

1 E4A-90-R21-000- Assy Repair Kit Cable 1
000
2 - Cutter 1
3 - Hot Air Gun 1
Step 1: Step 2:
The black backsheel needs to be removed. Cut off the connector G2/Gen as close as possible at
the connector housing.
Backshell Reamining Harness
The old connector will not be needed any more.
Step 3: Step 4:
Remove the insulation of the remaining harness The part number of the inline crimp is D-436-37. This
and the repair kit cable. number includes the splice crimp and the (blue)
isolation sleeve.
Put the blue isolation sleeve of the inline crimp D-
436-37 over the single wire of the repair kit cable.
Place the splice crimp at the end of the single wire of
the repair kit cable. Connect the crimp with the
repair kit cable by usage of the crimp tool Mil
Standard Part Number: M22520/37-01
5mm (+/-2)
Crimp Gasket

Revision no: 24
Page: 71-53
Step 5:
Use the crimp tool Mil Standard Part Number: Step 6:
M22520/37-01 to connect the repair kit cable (A) and Put the blue isolation sleeve of the inline crimp
the remaining engine harness (B). D-436-37 directly over the splice crimp.
Heat the inline crimp isolation sleeve (300°C –

350°C) with a “hot air gun” until the inline crimp
isolation seals the inline crimp barrel and the
single wires.
A Isolation sleeve
Step 7: Step 8:
If necessary the green roundit 2000NX5-5 which is part Use a Multimeter to check connection between
of the repair kit can be put over inline crimp and the the pins stated below:
black expando of the repair kit cable.
If the green roundit of the remaining harness is long X1/2 4 G2 / GEN 1
enough to cover the inline crimp and the black expando

this step will not be needed.
Roundit Expando
Pig Tail
Ensure that the pig tail is not covered by the roundit.
Step 9:
Cable ties PLT1M-M30 and PLT4S-M30 can be used for
fixation of repair kit cable.

Revision no: 24
Page: 71-54

1 E4A-90-R22-000-000 Assy Repair Kit Cable 1
2 - Cutter 1
3 - Hot Air Gun 1
Step1: Step2:
Cut off the “damaged” part at the solder sleeve of the (The following pictures are example pictures, to
engine harness. The old connector will not be used for detail the repair instruction)
repair.
Remove the black insulation as shown in the
picture below. (~50mm from remaining
harness).
Solder Sleeve
50mm (+5)

Revision no: 24
Page: 71-55
Step3: Step4:
Remove the white cable insulation down to the shielding Put the solder sleeve over the cable of the
of the cable as shown in the picture below. remaining engine harness.
Heat the solder sleeve (300°C – 350°C) with a
“hot air gun”.
50mm (+5)
Solder Sleeve
10mm (+5)
Step5:
Remove the insulation with shielding of the remaining Step 6:
wire. The part number of the inline crimp is D-436-37.
This number includes the splice crimp and the
isolation sleeve.
10mm (+/-2)
Put the blue isolation sleeve of the inline crimp
D-436-37 over the single wire of engine harness.
Place the splice crimp at the end of the single
wires of the repair kit cable E4A-90-R22-000-
000.
Gasket
Crimp
Step 7: Step 8:
The inline crimp shall be used to connect the single wire Put the blue isolation sleeve of the inline crimp
(A) of the remaining engine harness, and the white D-436-37 directly over the splice crimp.
single (B) wire of the repair kit cable E4A-90-R22-000-
000. Heat the inline crimp isolation sleeve (300°C –
B 350°C) with a “hot air gun” until the inline crimp
A
single wires.
Isolation sleeve
Inline Crimp (5)

Revision no: 24
Page: 71-56
Step 9: Step10:
Put the chafing protection ROUNDIT 2000NX5-5 over the Use a Multimeter to check connection between
repair kit cable and the engine harness. The length of the pins stated below:
the chafing protection ROUNDIT 2000NX5-5 can be
reduced if necessary.
X1/2 4 G2 / GEN 1
Roundit
Pig Tail
Step11:
fixation of repair kit cable E4A-90-R22-000-000.

Revision no: 24
Page: 71-57
71-50-900 Repair of the Engine Wiring Harness E4A-95-000-000 und E4B-95-000-000
Herein described repair procedures for exchange of connectors can only be conducted once.
71-50-901 Exchange of Connector of Gearbox Temperature Sensor (GBTS)

2 - Cutter 1
3 - Hot Air Gun 1
Step 1: Step 2:
Cut off the GBTS connector as close as possible at Strip the insulation of the remaining single wires of
the end of the wiring branch. the engine wiring harness as shown below.
5mm (±1mm)
Step 3: Step 4:
Strip the insulation of the repair kit cable as shown Place the isolation sleeve over the single wires of the
below. repair kit cable.
5mm (±1mm)

Revision no: 24
Page: 71-58
Step 5: Step 6:
Connect the single wires of the repair kit cable Move the blue isolation sleeve over the inline crimps and
E4B-95-R10-000 with the remaining engine wiring heat them with a hot air gun (300 °C).
harness as shown in the table below using the
inline crimps and crimp tool.
ECU A v GBTS 1
ECU A u GBTS 2
Step 7: Step 8:
Put the ROUNDIT over the cable as shown below. The cable ties and the fusion tape can be used for fixation
ROUNDIT and the cable harness as shown below.

Revision no: 24
Page: 71-59

1 E4A-95-R11-000- Assy Repair Kit Cable 1
000
2 - Cutter 1
3 - Hot Air Gun 1
Step 1: Step 2:
The black backsheel needs to be removed. Cut off the connector G2/Gen as close as possible at
the connector housing.
Backshell Reamining Harness
The old connector will not be needed any more.
Step 3: Step 4:
Remove the insulation of the remaining harness The part number of the inline crimp is D-436-37. This
and the repair kit cable. number includes the splice crimp and the (blue)
isolation sleeve.
Put the blue isolation sleeve of the inline crimp D-
436-37 over the single wire of the repair kit cable.
Place the splice crimp at the end of the single wire of
the repair kit cable. Connect the crimp with the
repair kit cable by usage of the crimp tool Mil
Standard Part Number: M22520/37-01
5mm (+/-2)
Crimp Gasket

Revision no: 24
Page: 71-60
Step 5:
Use the crimp tool Mil Standard Part Number: Step 6:
M22520/37-01 to connect the repair kit cable (A) and Put the blue isolation sleeve of the inline crimp
the remaining engine harness (B). D-436-37 directly over the splice crimp.
Heat the inline crimp isolation sleeve (300°C –

350°C) with a “hot air gun” until the inline crimp
single wires.
A Isolation sleeve
Step 7: Step 8:
If necessary the green roundit 2000NX5-5 which is part Use a Multimeter to check connection between
of the repair kit can be put over inline crimp and the the pins stated below:
black expando of the repair kit cable.
If the green roundit of the remaining harness is long X1/2 4 G2 / GEN 1
enough to cover the inline crimp and the black expando

this step will not be needed.
Roundit Expando
Pig Tail
Step 9:
fixation of repair kit cable.

Revision no: 24
Page: 71-61
Chapter 73-00-00 Engine Fuel and Control
73-00-01 General
For detailed description refer to the AE 300 Operation Manual E4.01.01 – Chapter System Description.
For approved fuels refer to the AE 300 Operation Manual E4.01.01 Chapter Fuel Grade.
73-00-10 Injector
73-00-11 Removal of the Injector
1. Remove the injector cover - refer to Chapter 85-00-11.

2. Disconnect the injector 1-4 connectors [6] from the injector head.
3. Remove the circlip [7] from the injector fuel return line [8].
4. Open the flare nuts [9] of the high pressure fuel line on the injector side.
5. Loose the flare nuts [10] on the common rail to give more space during removal of
the injector.
6. Remove the screw [4] off and the clamping shoe [5] of the injector (for picture see
next page).
7. Carefully remove the injectors (if necessary use the “Dismount Tool for Injectors”, see
List of Tools).
Mark each injector for correct position. Do not swap injector IQA-Codes!
73-00-12 Installation of the Injector
Two different types of injectors are used on the AE 300 engine (see picture below)
Make sure that all 4 injectors of the same type are installed.
Standard injector:
E4A-34-000-000 LU Injector for common rail
corresponds no. of Daimler A 640 070 07 87
Anti wear injector:

E4A-35-000-000 LU Injector f. common rail
corresponds no. of Daimler A 640 070 11 87

Revision no: 14
Page: 73-1
If a new injector is installed, record IQA-code given at the top of the injector.
The IQA-code has to be programmed into the EECU with the AE 300-Wizard.
1. Put on the new gasket rings [1] of the injectors - refer to Chapter 73-00-22.
2. Lubricate the cleaned injectors [2] with special grease [3] refer to Chapter 73-00-22.
3. Insert the injectors according to the marking sequence during the removal Chapter.
4. Use only new (!) screws [4] for clamping shoe [5].
5. Starting torque for clamping shoe:
Level 1: 7 Nm
Level 2: 90º
Level 3: 90º
6. Install the fuel line [9] to the injector with 22 Nm.

7. Screw on the nut on the common rail with 27 Nm
8. Install the fuel return line to each injector.
9. Install on each injector the circlip on the fuel return line.
10. Install on the injector the electrical cable (injector 1 – 4).
11. Install the injector cover - refer to Chapter 85-00-12.
12. Program the IQA-code into the EECU with the AE 300-Wizard (if new injectors
installed).
13. Perform an engine ground run according to Chapter 71-00-03.
14. After the ground run inspect fuel system for leakage.
For picture see Chapter 73-00-20 - Injector seal.
10 4x 6 4x
Fig. 73 - 1
7 4x 8 9 4x

Revision no: 14
Page: 73-2
73-00-20 Injector Seals
73-00-21 Removal of the Injectors Seals
1. Remove of the injector cover - refer to Chapter 85-00-11.

2. Remove the injector - refer to Chapter 73-00-11.
3. Remove gasket rings [1] and clean injector shaft.
73-00-22 Installation of the Injectors Seals
1. Install new gasket rings [1].

2. Install the injectors - refer to Chapter 73-00-12.
4
3
Fig. 73 - 2 Fig. 73 - 3
Fig. 73 - 4
Injector grease [3] is available at Austro Engine GmbH.

Revision no: 11
Page: 73-3
73-00-30 Fuel Return Line
73-00-31 Removal of the Fuel Return Line

2. Remove the clips [1] from the 4 injectors.
3. Pull down the return line assy.
4. Remove the safety wire [2] and the banjo bolt [3].
5. Remove the clamps [4] from the rail return line [5].
6. Pull down the two return lines [5], [8] from the fitting [6].
73-00-32 Installation of the Fuel Return Line
1. Push the new return line assy into the 4 injectors.

2. Safe it with the clip [1].
Do not scratch the IQA-Code (see picture)
3. Pull the fire sleeve over the return line [8].

4. Push the return line [8] on the fitting [6].
5. Pull the fire sleeve over the rail return line [5].
6. Install new rail return line [5] between common rail and fitting [6] and safe it with a
new clamp.
7. Use heat resistant sealant (see Consumable List) to cover all fire sleeve ends.
8. Install the banjo bolt [3], torque it with 27 Nm and safe it with a safety wire (use only
new sealing rings [7]).
11. After the ground run inspect the fuel system for leakage.

Revision no: 13
Page: 73-4
4 3
5 6
7
8
Fig. 73 - 5
Fig. 73 - 6 Fig. 73 - 7
2 3 4 2x

Revision no: 13
Page: 73-5
73-00-40 High Pressure Pump
73-00-41 Removal of the High Pressure Pump
1. Disconnect the cable plug connection [8] (FPS).

2. Disconnect the cable plug connection [7] (FTS).
3. Disconnect the cable plug connection [1] (FMU).
4. Unscrew the fuel connection [2] - refer to the applicable Aircraft Maintenance Manual.
5. Remove the safety wire [3].
6. Remove the banjo bolt [4].
7. Screw on the coupling nut [5].
8. Remove the banjo bolt [9] with the fuel pressure sensor.
9. Disconnect the screws [6].
10. Remove the high pressure pump assy.
11. Clean the sealing face.
12. Ensure that the rubber gasket [10] is removed from the engine properly. Correct
position as shown in figure 73-10.
7 8 2
5 9 3 4
1
6 3x
x
Fig. 73 - 8 Fig. 73 - 9
10
Fig. 73 - 10
Whenever loosening or tightening hose connections fitted with a twin nipple, always hold
the twin nipple steady.

Revision no: 24
Page: 73-6
73-00-42 Removal of the spur gear from High Pressure Pump
1. Unscrew hexagon nut [1]. Use the special tool AE300T-012-1 as counter torque
wrench.
2. Remove the spur gear [2] from the High Pressure Pump.
4 2
Fig. 73 - 11
3. Conduct an inspection of the spur gear according to the following:
Perform a visual inspection of the spur gear. If one of the following damages is identified
during the visual inspection replace the spur gear:
 Tooth missing (broken)

 Visible cracks (use magnifying glass)
 Pitting (use magnifying glass)
 other visual damages
The teeth flanks may show slight wear (polished surfaces) and sporadic traces of oil
lacquer. An example of a polished tooth flank surface can be seen in Fig. 73 – 8b.
Nevertheless these spur gears are acceptable for re-use. In case of doubt contact Austro
Engine GmbH.
Fig. 73 - 12

Revision no: 24
Page: 73-7
73-00-43 Installation of the spur gear onto High Pressure Pump
For references refer to figure of Chapter 73-00-42 – Removal of the spur gear.
1. Put the spur gear [2] onto the High Pressure Pump [3].
2. Screw on the hexagon nut M14x1.5 [1]. Check the fit of the spur gear.
3. Use the special tool AE300T-012-1 as counter torque wrench.
4. Tighten the nut with a torque of 70 Nm.
5. Check if the sealing [4] ring is installed at the High Pressure Pump.
6. Install the High Pressure Pump according to chapter 73-00-44.
73-00-44 Installation of the High Pressure Pump
1. Slightly lubricate the rubber gasket with engine oil.

2. Fit on the high pressure pump assy.
Fill the pump with fuel before installing (if not already filled)
3. Screw down the screws [6] with 12 Nm.
4. Screw on the coupling nut [5] with 22 Nm.
5. Install the banjo bolt [4] with new sealing rings and torque that with 25 Nm.
6. Install the banjo bolt [9] with the FPS, use Loctite 243 and new sealing rings and
torque that with 22 Nm.
When using Loctite, make sure, that the thread is free of grease and apply only a thin
film of Loctite.
7. Mount the fuel line - refer to the applicable Aircraft Maintenance Manual.
8. Fit on the connector [1] (FMU).
9. Fit on the connector [7] (FTS).
10. Fit on the connector [8] (FPS).
11. Clean working area.
13. After the ground run the engine must be cooled down (40°C-50°C / 104°F-122°F) for
a further tighten of the banjo bolt [4] with 25 Nm.
14. Install a safety wire [3].
For picture see Chapter 73-00-50 – Low Fuel pressure sensor.

Revision no: 24
Page: 73-8
73-00-50 Low Fuel pressure sensor
73-00-51 Removal of the Fuel pressure sensor
1. Disconnect the cable plug connection [8] (FPS).

2. Screw out the FPS.
73-00-52 Installation of the Fuel pressure sensor
1. Use only a new sealing ring.

2. Screw on the FPS with 20 Nm.
3. Fit on the connector (FPS).
4. Perform an engine ground run according to Chapter 71-00-03

Revision no: 24
Page: 73-9
73-00-60 Rail Pressure Sensor
73-00-61 Removal of the Rail Pressure Sensor
1. Remove the connectors (RPS), (PCV).

3. Open the coupling nuts [1].
4. Loose the coupling nuts [2] at the injectors to have more space during removal the
common rail.
5. Remove the screws [3].
6. Remove the common rail assy [4].
73-00-62 Installation of the Rail Pressure Sensor
1. Install the new common rail assy [4] and screw it down with 16 Nm.
2. Screw on the fuel lines on the common rail.
3. Torque the coupling nuts at the common rail with 27 Nm.
4. Torque the coupling nuts at the injectors with 22 Nm.
6. Attach the connectors (RPS), (PCV).
7. Clean the working area.
1
4
3 3
Fig. 73 - 13
73-00-70 Rail Pressure Control valve
Use the same procedure from Chapter 73-00-60.

Revision no: 24
Page: 73-10
Chapter 76-00-00 Engine Control
76-00-01 General
For detailed description refer to the Chapter 01-10-60 Electrical System Description.
76-00-10 Engine Electronic Control Unit (EECU)
For removal and installation of the EECU refer to the applicable Aircraft Maintenance Manual.
76-00-11 Software Updates
To perform an EECU Software Update you have to follow the instructions given below.
The intention of this procedure is to document the current status of the EECU, update the
EECU Software (SW) acc. to the MSB-E4-003 using the AE Wizard and document the updated
status of the EECU.
For detailed instructions on the Software Updates Process itself refer to the AE 300 Wizard User
GuideE4.08.09 at least revision 7.
The Software-file for updating the EECU will be part of a Flash Container (FCT) which is used by the
AE300-Wizard.This FCT is available at the Austro Engine Homepage / Client Area.
Use the appendix of MSB E4-003 “Execution Report” to document the performed update.
The EECU Software Update Procedure below will also guide you through a Software Update procedure
by use of references to AE300 Wizard.
EECU
SW to be updated
Engine Log
Flash Container
Update EECU AE300 Wizard Load Flash Container with new SW
into Wizard (downloaded from
Software AE-Homepage)
Acc. „AE300 SW Update

Check-Sheet“ Flash Log
Flash Autosave
Engine Log
EECU
updated
Engine Log

Revision no: 11
Page: 76-1
Refer to MSB E4-003 for current software versions. Software updates may only be performed by an
Austro Engine GmbH service partner.
EECU Software Update Procedure
1. Connect AE 300 Wizard to EECU

a. AE300 Wizard at least version 1.2.0.0 required.
b. For reference use AE300 Wizard User guide"
2. Check Software-Version on ECU A and ECU B
3. Compare Software-Version on ECU A and ECU B to latest valid Software-Version (according to
MSB E4-003)
4. If SW version is obsolete and/or not the latest valid version available perform further steps as
described below
5. Load latest valid "Flash Container" into AE300 Wizard

a. "Latest valid Version” according to MSB-E4-003
6. EECU SW Update according to AE-300 Wizard User Guide section "EECU Software update”
7. Perform "EECU SW Update" according to AE-300 Wizard User Guide
a. Wizard User Guide section "EECU Software update"
8. Check if "GREEN MESSAGE BOX appeared
a. Update Process successful;
9. Check Software Version on ECU A and ECU B
10. Compare Software Version in ECU A and ECU B
11. ECU A and ECU B have same SW
a. According to AE300 Wizard User Guide
12. Read out "Engine Log" and compare to latest valid SW Version.
a. In case of doubt contact Austro Engine and provide "Engine Log"
13. Check function and connection to Engine Display
a. Start Engine
b. Switch manually to ECU A
c. Check if Engine Data is displayed correctly
d. Check that no Engine Caution Indication is generated or active
e. Switch manually to ECU B
f. Check if Engine Data is displayed correctly
g. Check that no Engine Caution Indication is generated or active
h. Stop Engine
14. Disconnect AE 300 Wizard

Revision no: 5
Page: 76-2
76-00-20 Glow Plug Control
76-00-21 Removal of the Glow Plug Control
1. Remove the plug connection [1] (GPC).

3. Remove the glow control box [3].
76-00-22 Installation of the Glow Plug Control
1. Use only new stop nuts.

2. Fit on the glow control box [3].
3. Torque the nuts with 4 Nm.
4. Fit the connector (GPC) [1]
2 4x 3 1
Fig. 76 - 1

Revision no: 20
Page: 76-3
76-00-30 Crankshaft Sensor
76-00-31 Removal of the Crankshaft Sensor
1. Remove the electrical lines [1].”CRS1 or CRS2”.

2. Remove the screw [2].
3. Remove the crankshaft-sensors [3].
76-00-32 Installation of the Crankshaft Sensor
1. Install the crankshaft-sensors.

2. The distance between the sensor and the two mass flywheel must be 0,8 mm +/- 0,5
mm.
3. Screw down the fixing screws with 11 Nm.
4. Inspect the correctly seat from the sensors.
5. To clip the electrical line [1] “CRS1 or CRS2”.
1
1
5
3
1
5
2
1
5
Fig. 76 - 2
3 1 2
1 1 1
5 5 5

Revision no: 11
Page: 76-4
76-00-40 Camshaft Sensor CAS 1
76-00-41 Removal of the Camshaft Sensor CAS 1

2. Pull down the electrical connector CAS 1.
3. Remove the locking screw from the sensor [1].
4. Pull the camshaft sensor out.
76-00-42 Installation of the Camshaft Sensor CAS 1
1. Lubricate the new o-ring with acid free lubrication.

2. Push the sensor into the cylinder head cover and inspect the correctly seat of the
o-ring.
3. Tighten up the camshaft sensor screw with 14 Nm.
4. Inspect the correctly seat of the sensor.
5. Attach the electrical connector CAS 1.
Fig. 76 - 3

Revision no: 11
Page: 76-5
76-00-50 Camshaft Sensor CAS 2
76-00-51 Removal of the Camshaft Sensor CAS 2
1. Pull down the electrical connector CAS 2.

2. Remove the locking screw from the sensor [1].
3. Pull the camshaft sensor out.
76-00-52 Installation of the Camshaft Sensor CAS 2
1. Lubricate the new o-ring with acid free lubrication.

2. Push the sensor into the sensor housing and inspect the correctly seat of the o-ring.
3. Tighten up the camshaft sensor screw with 12 Nm.
4. Inspect the correctly seat of the sensor.
5. Attach the electrical connector CAS 2.
Fig. 76 - 4

Revision no: 11
Page: 76-6
Chapter 77-00-00 Engine Indicating
77-00-01 General
The engine indicating is realized by the EECU. The EECU gathers the required information from engine
sensors and passes it through the CAN-Bus to an engine display.
If a failure in indication is suspected maintain the relevant sensor (Rely on EECU sensor failure
detection to identify electrically defect sensors.)
77-00-10 Gearbox Temperature Sensor

Refer to Chapter 85-10-40.

Revision no: 15
Page: 77-1

Revision no: 1
Page: 77-2
Chapter 78-00-00 Engine Exhaust
78-00-01 General
For detailed description refer to Chapter 01-10-10 Intake/Exhaust System Description.
78-00-10 Exhaust Manifold
78-00-11 Removal of the Exhaust Manifold
1. Remove the exhaust pipe from the turbo charger - refer to the applicable Aircraft
Maintenance Manual.
2. Remove the intake air hose from the turbo charger - refer to the applicable Aircraft
Maintenance Manual.
3. Remove the oil return line from the turbo charger - refer to Chapter 79-00-111.
4. Remove the lubricate line from the turbo charger - refer to Chapter 79-00-101.
5. Remove the clip [1] from the waste gate controller [2] and pull down the hose.
7. Open the nuts [4] from the exhaust manifold [8].
8. Remove the exhaust manifold with the turbo charger.
10. Remove the turbo charger [6].
78-00-12 Installation of the Exhaust Manifold
1. Attach the turbo charger with new gasket [7] to the exhaust manifold [8].
2. Insert the screws [5] with new nuts.
3. Tighten the screws equally with 35 Nm.
4. Install the exhaust manifold [8] with the turbo charger [6].
5. Use only new gaskets [9].
6. Screw the exhaust manifold with new nuts [4] with 30 Nm.
7. Put on the hose on the waste gate controller and fix it with the clip [1].
8. Install the banjo bolt [3] with new sealing rings and torque it with 7 Nm.
9. Before install the oil line fill in approximately 1 cm³ engine oil (see Fig. 78 - 1).
10. Install the oil lubricate line - refer to Chapter 79-00-102.
11. Install the return line - refer to Chapter 79-00-112.
12. Install the intake air hose - refer to the applicable Aircraft Maintenance Manual.
13. Install the exhaust pipe - refer to the applicable Aircraft Maintenance Manual.
16. After the ground run inspect exhaust system for leakage.
Fill with appr. 1 cm³ engine oil.
Fig. 78 - 1

Revision no: 11
Page: 78-1
1 2 6
5 4x
3
5
8
4 8x
5
Fig. 78 - 2 Fig. 78 - 3
7 5 4x
8
4 8x
9
Fig. 78 - 4
78-00-20 Exhaust Manifold Gasket Exchange
For Removal and Installation refer to Chapter 78-00-00.

Revision no: 5
Page: 78-2
Chapter 79-00-00 Engine Oil
79-00-01 General
Engine Oil Information:
For approved engine oils see Operation Manual E4.01.01 – Chapter 3.5.6.1.
Oil volume (initial filling) 7.5 l

Oil volume (continuously) min. 5l
max. 7l
Only engine oils conforming to MB 229.5 specification are approved by
Austro Engine GmbH to be used for operation. Austro Engine GmbH will not
assume any liabilities if other types of oil are used.
79-00-10 Oil-Filter Housing Draining Line
79-00-11 Removal of the Oil-Filter Housing drain line
1. Open the sleeve nut [1] of the drain line [2] on the upper end (Oil filter housing) first.
2. Remove the safety wire from the banjo bolt [3].
3. Open the sleeve nut [4] on the lower end of the drain line [2].
4. Open the banjo bolt [5] at the oil sump [6].
5. Carefully remove the drain line.
6. Remove the gasket rings from the banjo bolt [5].
79-00-12 Installation of the Oil-Filter Housing drain line
1. Put on new gasket rings on the banjo bolt [5].

2. Connect the lower end of the drain line [2] to the banjo bolt [5].
3. Connect the banjo bolt [5] to the oil sump [6].
4. Connect to upper end of the oil drain line [2] to the fitting of the oil filter housing [7].
5. Torque the banjo bolt [5] with 20 Nm.
Do not over torque the banjo bolt – serious damage of the oil sump is possible.
6. Torque the lower sleeve nut of the oil drain line [2] with 16 Nm.
7. Torque the upper sleeve nut of the oil drain line [2] with 16 Nm.
8. Apply safety wire on banjo bolt [5] according to the standard practices on Chapter
51-00-00.
11. After the ground run inspect oil system for leakage.

Revision no: 11
Page: 79-1
Figure for Chapter 79-00-11 and 79-00-12
5 3 4 2 1 7
Fig. 79 - 1

Revision no: 5
Page: 79-2
79-00-20 Drain of Engine Oil

2. Put a container (min. 8,5 l) below the drain plug.
3. Open the oil drain plug [2].
4. Open the Oil Dip Stick
5. Let the oil drain off.
2 1
Fig. 79 - 2
79-00-30 Refill of Engine Oil
6. Turn in the oil drain plug [2] with a new sealing ring and torque it with 30 Nm.
7. Save it with a safety wire Ø 0,81 mm.
8. Refill Engine Oil at the Oil Dip Stick Opening
9. Install Oil Dip Stick and check oil level (refer to Chapter 12-20-01)
Only use recommended engine oil according to 79-00-01 General

Revision no: 5
Page: 79-3
79-00-40 Oil Sump
79-00-41 Removal of the Oil Sump
1. Remove the engine - refer to the applicable Aircraft Maintenance Manual.

2. Remove the gearbox - refer to Chapter 85-10-11.
3. Remove the belt tensioner - refer to Chapter 85-40-21.
4. Drain the engine oil from the oil sump - refer to Chapter 79-00-20.
5. Remove the oil return line - refer to Chapter 79-00-11.
6. Remove the oil filter housing drain line - refer to Chapter 79-00-111.
7. Remove the screws from the oil sump [11], [12], [13] and [14].
8. Remove carefully the oil sump [1].
9. Remove the crankshaft sensor - refer to Chapter 76-00-31.
10. Remove the oil dipstick.
11. Remove the oil level sensor – refer to Chapter 79-00-121.
12. Replace the oil drain plug to the new oil sump according to chapter 79-00-20 and refill
the engine oil according to Chapter 79-00-30.
13. Remove the engine bracket – refer to the applicable Aircraft Maintenance Manual.
14. Remove the screws [3] and the washers.
The washers are not shown in Fig. 79 – 3. Some oil baffle panels have
washers already soldered onto the oil baffle panel. In this case no additional
washers have to be removed.
15. Remove the oil baffle panel [2].
79-00-42 Installation of the Oil Sump
1. Install the oil oil baffle panel [2]

2. Place between [2] and [3] a single washer and fix the oil baffle panel screws with 5
Nm ± 0,5 (use Loctite 243).
The washers are not shown in Fig. 79 – 3. Some oil baffle panels have
washers already soldered onto the oil baffle panel. In this case no additional
washers have to be mounted.
film of Loctite.
3. Install the engine bracket – refer to the applicable Aircraft Maintenance Manual.
4. Install the oil drain plug – refer to Chapter 79-00-30.
5. Install the oil level sensor – refer to Chapter 79-00-120.
6. Install the oil dipstick.
7. Install the crankshaft sensor - refer to Chapter 76-00-32.
8. Put on carefully a new gasket [15] on the oil sump [1] and then put the oil sump on the
engine.
Use a small amount of sealant near the joint of the crankshaft cover.
9. Screw down the oil sump according to the tightening diagram:

(Figure 74) 1st step: 6 Nm , 2nd step 13 Nm.

Revision no: 24
Page: 79-4
10. Install the oil filter housing drain line – refer to Chapter 79-00-12.
11. Install the return line – refer to Chapter 79-00-112 Installation of the Oil Return
Line.
12. Install the belt tensioner – refer to Chapter 85-40-22.
13. Install the gearbox – refer to Chapter 85-10-12.
14. Install the engine to the aircraft – refer to the applicable Aircraft Maintenance Manual.
15. Fill in engine oil – refer to the Chapter 79-00-30.
16. Clean the working areas.
18. After the ground run inspect fluid systems for leakage.
79-00-50 Oil Sump Gasket Exchange
For Removal and Installation refer to Chapter 79-00-40.

Revision no: 24
Page: 79-5
3 6x
15
2 7 6
11 14x
13
16 *
09
13
12
13 5 4 8 10 2x
14
Fig. 79 - 3
17 *
Fig. 79 - 4 Tighting Diagram

Revision no: 5
Page: 79-6
79-00-60 Oil-Filter Housing
79-00-61 Removal of the Oil-Filter Housing
1. Remove the oil filter housing drain line – refer to Chapter 79-00-11.
2. Remove the fitting [9] from the oil filter housing drain line.
3. Remove the oil filter – refer to Chapter 79-00-71.
4. Remove the (OPS) Oil pressure sensor [3] – refer to Chapter 79-00-131
5. Remove the screws [5], [6] and the screw [7] with the clamp [8] of the wiring
harness.
6. Remove the oil filter housing.
79-00-62 Installation of the Oil-Filter Housing
1. Use new o-rings [4], lubricate it with acid free lubrication.

2. Install the oil filter housing carefully.
3. Screw it down with the screws [5], [6] and [7) and torque them with 9 Nm.
(do not forget the claps from the wiring harness)
4. Install the (OPS) Oil pressure sensor [3] – refer to Chapter 79-00 132
5. Install the oil filter – refer to Chapter 79-00-72.
6. Install the fitting [9] from the draining line with a new sealing ring and torque with
18 Nm.
7. Install the oil filter housing drain line – refer to Chapter 79-00-12.
For picture see Chapter 79-00-72.

Revision no: 11
Page: 79-7
79-00-70 Oil-Filter
79-00-71 Remove and discard of the Oil-Filter
1. Remove oil filter by unscrewing of the oil filter cover [1].

2. Detach the oil filter from the oil filter cover by pulling them off.
3. Discard the oil filter [2].
79-00-72 Installation of the Oil-Filter
1. Use only new o-rings at the oil-filter.

2. Put on the new filter on the cover.
3. Screw down the oil filter cover with 25 Nm.
4
2
Fig. 79 - 5 Fig. 79 - 6
3 7
9
5
Fig. 79 - 7

Revision no: 12
Page: 79-8
79-00-80 Oil Separator
79-00-81 Removal of the Oil Separator

3. Remove the oil separator [1].
4. Open the steel tape clamp and pull down the hose [6].
5. Pull down the hose [5].
6. Pull down the oil pipe [3].
7. Remove the By-Pass Valve [2] - refer to Chapter 79-00-83.
79-00-82 Installation of the Oil Separator

1. Install the by-pass valve [2] – refer to Chapter 79-00-84.
2. Install the hose [6] using the steel tape clamps (lubricate the connecting tube with
acid free lubrication)
The hose need to be installed stressless - see Fig. 79 -8.
3. Push on the hose [5] (lubricate the connecting tube with acid free lubrication).
4. Push on the oil pipe [3].
5. Use only new sealing rings [4] (lubricate the rings with acid free lubrication).
6. Install the oil separator on the injector cover.
7. Push on the tube to the injector cover [9].
8. Push on the oil pipe into the injector cover [10].
9. Inspect the correct position of the o-rings [4].
10. Screw on the oil separator with 5 Nm using Loctite 243.
film of Loctite.
11. Install the injector cover – refer to Chapter 85-00-12.

Fig. 79 - 8
79-00-83 Removal of the Oil Separator By-Pass Valve

1. Remove the injector cover – refer to Chapter 85-00-11.
2. Remove the oil separator - refer to Chapter 79-00-81.
3. Remove the by-pass valve [2].
4. Clean and inspect the thread.

Revision no: 11
Page: 79-9
79-00-84 Installation of the Oil Separator By-Pass Valve
1. Install the new by-pass valve.

2. Screw it down carefully by hand torque.
3. Use Loctite 243.
film of Loctite.
4. Install the oil separator – refer to Chapter 79-00-82.

5. Install the injector cover – refer to Chapter 85-00-12.
5 7 6
4
3
Fig. 79 - 9
10
Fig. 79 - 10

Revision no: 11
Page: 79-10
79-00-90 Oil Separator Return Line
79-00-91 Removal of the Oil Separator Return Line

2. Remove the banjo bolt [1] at the camshaft sensor housing.
3. Remove the screw from the injector cover.
4. Remove the oil line [4].
79-00-92 Installation of the Oil Separator Return Line
1. Use new o-ring [5] and lubricate it with acid free lubrication.
2. Push the oil-line in the injector cover and fixed it with the screw.
3. Install the banjo bolt in the camshaft sensor housing with new sealing rings and
torque it with 15 Nm.
4. Secure the banjo bolt with a safety wire.
5
1 2
Fig. 79 - 11 Fig. 79 - 12

Revision no: 11
Page: 79-11
79-00-100 Lubricant Line
79-00-101 Removal of the Lubricant Line

3. Remove the screw [3] with the clip [4].
5. Dismount the oil lubricant line [6].
79-00-102 Installation of the Lubricant Line
1. Use new sealing rings – refer to Chapter 79-00-104.

2. Fit on the new pipe [6].
3. Screw down the screw [5] and torque it with 12 Nm.
4. Screw down the banjo bolt [2] and torque it with 35 Nm.
5. Screw down the screw [3] with the clip [4] with 12 Nm.
9. The lubricant line banjo bolt has to be torqued again with 35 Nm after cooling down
the engine.
10. Secure the banjo bolt with safety wire.
2 1
3
Fig. 79 - 13 Fig. 79 - 14

Revision no: 22
Page: 79-12
79-00-103 Removal of the Lubricant Line Sealing Ring
1. Remove the lubricant line [1] – refer to Chapter 79-00-101.

2. Remove the sealing ring [3] at the banjo bolt [4].
3. Remove the o-ring. [2].
79-00-104 Installation Lubricant Line Sealing Ring
1. Install the new o-ring and lubricate it with acid free lubrication.
2. Install the new sealing rings [3].
3. Install the lubricant line [1] – refer to Chapter 79-00-102.
6. The lubricant line banjo bolt has to be torqued again after cooling down the engine.
Fig. 79 - 15

Revision no: 11
Page: 79-13
79-00-110 Oil Return Line
79-00-111 Removal of the Oil Return Line
1. Drain engine oil – refer to Chapter 79-00-20

2. Remove the wire protection [1].
3. Remove the banjo bolt [2] at the oil sump.
4. Remove the screw [2] at the turbo charger.
5. Remove the screw [4] with the clamp [5].
6. Remove the oil return line [6] (pull the line carefully from the adapter [7]).
79-00-112 Installation of the Oil Return Line

7. Fit on the new gaskets – refer to Chapter 79-00-114.
8. Push the line back to the adapter [7].
9. Screw down the banjo bolt [2] (don’t tighten the banjo bolt)
10. Put on the screw [4] with the clip [5] (don’t tighten the screw).
11. Screw down the screw [3] with 9 Nm.
12. Tighten the banjo bolt [2] with 50 Nm and save it with safety wire.
13. Screw down the screw [4] with 21 Nm.
15. Refill engine oil – refer to Chapter 79-00-30.
17. After the ground run the engine must be cooled down, then inspect for leakage of oil
and tightened the banjo bolt [2] again with 50 Nm and saved with safety wire.
Fig. 79 - 16

Revision no: 11
Page: 79-14
79-00-113 Removal of the Oil Return Line Gasket
1. Remove the oil return line – refer to Chapter 79-00-111.

2. Remove the o-ring [1]
3. Remove the gasket [2]
4. Remove the sealing rings [3].
79-00-114 Installation of the Oil Return Line Gasket
1. Install the new o-ring [1] and lubricate with acid free lubrication.
2. Install the new sealing rings [3].
3. Install the new gasket [2].
4. Install the oil return line – refer to Chapter 79-00-112.
Fig. 79 - 17

Revision no: 5
Page: 79-15
79-00-120 Oil Level Sensor
79-00-121 Removal of the Oil Level Sensor
1. Disconnect the electrical connector (MOK).

2. Disconnect the screws.
3. Remove the cover and the oil-level sensor.
4. Remove and fit the oil-level-sensor.
79-00-122 Installation of the Oil Level Sensor
1. Use a new o-ring.

2. Lubricate the o-ring with oil.
3. Insert the oil-level-sensor.
4. Push down the sensor with light pressure in the oil sump [1].
5. Put the cover in place above the oil level sensor.
6. Screw the oil level sensor together with the cover down with 5 Nm using Loctite 243.
film of Loctite.
7. Connect the cable (MOK).

Oil Level Sensor
Fig. 79 - 18

Revision no: 11
Page: 79-16
79-00-130 Oil Pressure Sensor
79-00-131 Removal of the Oil Pressure Sensor
1. Disconnect the electrical connector (OPS) [1].

2. Remove the sensor [2].
79-00-132 Installation of the Oil Pressure Sensor
1. Put on a new sealing ring.

2. Screw down the new oil pressure sensor [2] with 20 Nm using Loctite 542.
film of Loctite.
3. Connect the electrical connector (OPS) [1].

Fig. 79 - 19

Revision no: 11
Page: 79-17
79-00-140 Governor
The Governor is not part of the engine. For detailed information refer to the applicable
79-00-141 Removal of the Governor
1. Remove the electrical connector (GOV) [1].

2. Remove the oil hose [2] (if installed) – refer to the applicable Aircraft Maintenance
Manual.
3. Remove the four nuts [3].
4. Pull down carefully the governor.
5. Remove the gasket and clean the sealing face.
79-00-142 Installation of the Governor
1. Use a new gasket.
Inspect the correct seat of the gasket.

Take care, that the curved side of the gasket metal sieve must be assembled in
direction to the governor (see Fig. 79 – 22).
2. Push on carefully the governor.

3. Fixed the governor with new stop nuts and torque them crosswise with 20 Nm.
4. Connect the electrical connector (GOV) [1].
5. Connect the oil hose [2] (if installed) – refer to the applicable Aircraft Maintenance
Manual.
8. After the ground run inspect gearbox oil system for leakage.
9. Inspect gearbox oil level, if necessary adjust the oil level – refer to Chapter 85-10-50
3 1
Fig. 79 - 20 Fig. 79 - 21
Fig. 79 - 22

Revision no: 15
Page: 79-18

Revision no: 11
Page: 79-19
Chapter 80-00-00 Starting
80-00-01 General
For detailed description refer to the AE 300 Operation Manual E4.01.01 - Chapter Operating
Instructions.
80-00-10 Starter
80-00-11 Removal of the Starter
1. Disconnect the battery – refer to the applicable Aircraft Maintenance Manual.
First disconnect the negative pole and second the positive pole.
2. Disconnect the electrical cables from the starter – refer to the applicable Aircraft
Maintenance Manual.
3. Remove the tie rap [1].
4. Remove the screws [2] from the GPC-bracket.
6. Place the GPC side wards.
7. Do not lose the spacer [4].
8. Remove the second screw at the starter.
9. Remove carefully the starter.
80-00-12 Installation of the Starter
1. Install carefully the starter.

2. Put the GPC-bracket in the correct position.
3. Screw on the screws [2] with the spacer [4].
4. Screw on the screws on the starter.
5. Torque the screws on the starter with 22 Nm.
6. Torque the screws [2] with 13 Nm.
7. Install a new tie rap [1].
8. Connect the electrical cables – refer to the applicable Aircraft Maintenance Manual.
9. Connect the battery – refer to the applicable Aircraft Maintenance Manual.

Revision no: 11
Page: 80-1
Figure for Chapter 80-00-11 and 80-00-12.
1
2
4 2x
Fig. 80 - 1

Revision no: 5
Page: 80-2
80-00-20 Glow Plugs
80-00-21 Removal of the Glow Plugs
1. Remove the cable connector [1] carefully with a gripper (GP1/GP2/GP3/GP4).

2. Remove the glow plugs.
80-00-22 Installation of the Glow Plugs
1. Screw in the glow plugs and torque them with 11 Nm.

2. Clip on the cable connector [1] again.
Fig. 80 - 2

Revision no: 5
Page: 80-3

Revision no: 1
Page: 80-4
Chapter 81-00-00 Turbocharging
81-00-01 General
For description refer to Chapter 01-10-10 Intake/Exhaust System Description.
81-00-10 Turbo Charger Complete
81-00-11 Removal of the Turbo Charger

1. Remove the exhaust manifold including turbo charger – refer to Chapter 78-00-11.
2. Remove turbo charger from exhaust manifold – refer to Chapter 78-00-11.
81-00-12 Installation of the Turbo Charger

1. Install turbo charger on exhaust manifold – refer to Chapter 78-00-12
2. Install exhaust manifold including turbo charger – refer to Chapter 78-00-12
For explosion picture see also Chapter 78-00-12.
81-00-13 Removal of the Waste Gate Controller

1. Disconnect hose at the top of the waste gate controller.
2. Remove three M6 bolts [2].
3. Remove circlip [1].
4. Disconnect rod from waste gate lever and remove waste gate controller [3].
81-00-14 Install new Waste Gate Controller
The following figure defines the Installation versions of the waste gate controller bracket.
Fig. 81 - 1 Waste Gate Controller – Installation Versions
Take care to install the waste gate controller according to your engine configuration
(E4A, E4B or E4C).

Revision no: 12
Page: 81-1
1. Install the bracket with the M6 bolts [2] and torque them with 7 Nm.
2. Chose a suitable air pressure device (see Fig. 81 – 4) as described in
Chapter 81-00-32.
3. Attach the chosen device to the top of the waste gate controller and apply pressure
till the rod starts to move. Do not excess a pressure level of 3,5 bar.
4. Connect rod to waste gate lever.
5. Adjust waste gate controller – refer to Chapter 81-00-32.
03
02
01
Fig. 81 - 2 E4A Turbo Charger
Note: For fixing of the rod on the waste gate lever use new circlip.

Revision no: 12
Page: 81-2
81-00-20 Boost Pressure Actuator
81-00-21 Removal of the Boost Pressure Actuator (BPA)
There are actually two different BPA installation versions on the E4 engine.
At the previous version the BPA inlet is connected to the turbocharger (see Fig. 81 – 3).
The BPA inlet of the latest version is connected to the Manifold and therefore the BPA is
installed twisted.
1. Remove the electrical connector [1] “BPA”.

2. Remove the clamps [2] as required.
3. Remove the hoses.
4. Loose the screws [3].
5. Remove the boost pressure actuator [4].
81-00-22 Installation of the Boost Pressure Actuator
In case of installation of the previous BPA versions (for explanations refer to chapter
81-00-21) please follow the steps 1, 3 (routing according to Fig. 81 – 4) 4, 5 and 7 of the
following installation instruction.
In case of installation of the latest BPA version (for explanation refer to chapter 81-00-21)
the following steps need to be followed.
If parts need to be replaced (e.g. bracket or hose) it is always required to install the latest
BPA version.
1. Install the boost pressure actuator [4] using existing screws [3], washers and new
counter nuts and torque them with 3 Nm.
2. Make sure that the spacer [5] is installed on the Manifold according to chapter
85-30-22.
3. Route the hoses according to Fig. 81 - 4.
4. Install hoses and secure them with the clamps [2].
5. Connect electric connector “BPA” [1].
6. If the previous disassembled EPW (according to chapter 81-00-21) was connected to
the Turbo Charger instead to the Manifold make sure that the Turbo Charger outlet is
plugged with a scrub screw [6]. Secure the scrub screw with Loctite 542 and torque
them with 5 Nm.
Fig. 81 - 3 Previous BPA installation version

Revision no: 13
Page: 81-3
03
04 01
02
02
05 02
Fig. 81 - 4 Latest BPA installation version
06
Fig. 81 - 5 Scrub screw installation

Revision no: 13
Page: 81-4
81-00-30 Waste Gate Controller
81-00-31 Inspection
If you have problems with the waste gate controller, remove the complete turbo charger (refer to
Chapter 81-00-11) and send it to an Austro Engine GmbH – Service Center.
81-00-32 Check /Adjust of the Waste Gate Controller
1. For checking the waste gate controller, remove the clip [1] and pull off the hose [2].
2. For the checking procedure use an air pressure device with the ability to stepwise
increase the pressure at the waste gate.
3. Apply the hose [3] from the chosen air pressure device [4] onto the port of the
controller and fix it with a clamp.
4. Slowly pump air in the controller by use of an air pressure device.
5. At 1,5 bar the pushrod must start to move.
6. If it is necessary to correct the adjustment, loosen the nut [5] and remove the circlip
[6].
Only apply an relative air pressure of 1,4 – 1,5 bar to the controller to move the
pushrod. Do not exceed the maximum allowable pressure of 3,5 bar.
7. To reduce the opening pressure, turn the fitting [7] out of the pushrod [8].
8. To increase the opening pressure, turn the fitting [7] into the pushrod [8].
9. Recapitulate this procedure until the pressure has 1,5 bar.
10. When the pressure is correct, mount the fitting [7] back onto the waste gate pin and
secure it with a circlip [6].
A new circlip has to be used for installation.
11. Torque the nut [5] with 6 Nm using Loctite 243.
film of Loctite.
Hold the pushrod [8] with a gripper.
12. Remove the hose [3] from the special tool [4] and apply the hose [2] onto the
controller port.
13. Secure the hose with new clamp.

Revision no: 24
Page: 81-5
04 08
01
05
07 02
03
06
Fig. 81 - 6 Fig. 81 - 7
correct incorrect
Fig. 81 - 8 Fig. 81 - 9

Revision no: 13
Page: 81-6
Chapter 85-00-00 Reciprocating Engine
85-00-10 Injector Cover
85-00-11 Removal of the Injector Cover
In case the injector cover has a maintenance lid installed, remove the maintenance lid as
described in section 85-00-13 for the following work steps.
1. Disconnect the breather line [5] from the injector cover – refer to the applicable
2. Remove the oil-separator return line - refer to Chapter 79-00-91.
4. Carefully lift up the injector cover [4].
5. Open the hose clamp [2].
6. Pull off the hose [3] from the cylinder head.
7. Remove the cover.
85-00-12 Installation of the Injector Cover without maintenance lid
1. Route the oil separator hose [3] below the high pressure lines – refer to Fig. 85 - 2
and Fig. 85 - 3.
2. Push the oil separator hose on the socket and fix it with the hose clamp [2].
Make sure that the hose is installed and routed without tension. If necessary push the hose
below the high pressure lines in direction connector socket to assure the stress less routing.
In case the installed injector cover has no maintenance lid refer to MSB-E4-008/1 or higher
revisions.
3. Put the injector cover [4] in position above the cylinder head.
Install the oil separator hose stress less.
4. Screw down the injector cover with 9 Nm.

5. Attach the breather line to the injector cover - refer to the applicable Aircraft
Maintenance Manual.
6. Install the oil-separator return line - refer to Chapter 79-00-92.

Revision no: 23
Page: 85-1
1 1
5 1
Fig. 85 - 1 Injector Cover without maintenance lid
2 3
Fig. 85 - 2 Fig. 85 - 3
Above figures show oil separator hose E4A-53-100-501 rev. 020.

Revision no: 23
Page: 85-2
85-00-13 Removal of the Maintenance Lid
Only applicable to injector covers with maintenance lid installed.
1. Remove safety wire and the 3 screws.

2. Remove the maintenance lid by pushing it towards the direction of the screw holes.
Fig. 85 - 4
85-00-14 Installation of the Injector Cover with maintenance lid
1. Route the oil separator hose [3] below the high pressure lines – refer to Fig. 85 - 5.
2. Push the oil separator hose on the socket and fix it with the hose clamp [2].
Make sure that the hose is installed and routed without tension. If necessary push the hose
below the high pressure lines in direction connector socket to assure the stress less routing.
Before installation put both hose clamps over the tube.
3. Put the injector cover [4] in position above the cylinder head.
4. Connect the tube to the oil separator – refer to Fig. 85 – 7.
Install the oil separator hose stress less.
2 3
Fig. 85 - 5

Revision no: 23
Page: 85-3
5. Screw down the injector cover with 9 Nm.

6. Install the maintenance lid – refer to Chapter 85-00-15.
7. Attach the breather line to the injector cover - refer to the applicable Aircraft
Maintenance Manual.
8. Install the oil-separator return line - refer to Chapter 79-00-92.
85-00-15 Installation of the Maintenance Lid
1. Cover the overlapping area at the injector cover with silicone – refer to Fig. 85 -9.
2. Put the maintenance lid at the provided opening at the injector cover and move it
thus the holes at the lid are coaxial with the threads at the injector cover.
3. Fix the lid screws with a torque of 3 Nm.
4. Secure the screw with a safety wire – refer to Fig. 85 – 4.
Figures for Chapter 85-00-14 to 85-00-15
1
1
1
5
Fig. 85 - 6
Fig. 85 - 7

Revision no: 24
Page: 85-4
Fig. 85 - 8 Fig. 85 - 9

Revision no: 23
Page: 85-5
85-10-00 Reciprocating Engine Front System
85-10-10 Gearbox
85-10-11 Removal of the Gearbox
1. Apply a container with minimum 3 litres below the gearbox drain plug.
2. Open the gearbox filler plug [1].
3. Open the gearbox drain plug [2]
4. Remove the propeller – refer to the applicable Aircraft Maintenance Manual.
5. Remove the electrical connector [3] of the governor solenoid marked with “GOC/M55”
and secure the connector and the socket with a cap.
6. Remove the pressure line [13] from the governor (If the pressure line is installed) -
refer to the applicable Aircraft Maintenance Manual.
7. Remove the electrical connector of the gearbox temperature sensor [5] market with
“GBTS/B50/5” and secure the connector and socket with a cap.
8. Remove all clamps [14] of the cable fixation for the crankshaft sensor.
9. Remove the engine starter –refer to Chapter 80-00-11.
10. Install forward engine hinge [6] for slinging the engine (if not installed).
11. Sling the engine on the forward hinge and apply slow force.
12. Open and remove the right [7] and left [8] forward engine mounts - refer to the
applicable Aircraft Maintenance Manual.
13. Support the gearbox or sling the gearbox on the prop shaft.
14. Remove the gearbox screws [9] (11x).
Four different types of screws are used. Mark screws for correct position before removing.
15. Remove the gearbox [10].

16. Remove the governor [4]– refer to Chapter 79-00-141
85-10-12 Installation of the Gearbox
If the gearbox is replaced due to high debris contamination make sure that the parts
mounted to the gearbox and operated with gearbox oil (i.e. propeller, governor and
feathering accumulator if applicable) are properly purged before reinstallation.
1. Install the governor – refer to Chapter 79-00-142

2. Put the gearbox [10] in place in front of the engine.
3. Insert the 11 screws [9] on the gearbox and equally torque the screws with 22 Nm.
Four different types of screws are used. Make sure that the correct screws according to the
marking during removal are used.
4. Install the two forward engine mounts [7] and [8] to the gearbox - refer to the
applicable Aircraft Maintenance Manual.
5. Install the starter on the engine - refer to Chapter 80-00-12.
6. Connect the pressure line to the governor - refer to the applicable Aircraft
Maintenance Manual
7. Connect the electrical connector [3] “GOV/M55” to the governor solenoid.
8. Connect the electrical connector [5] of the gearbox temperature sensor marked with
“GBTS/B50)”.
9. Install all clamps [14] of the cable fixation for the crankshaft sensor.

Revision no: 23
Page: 85-6
10. Install the gearbox magnetic drain plug – refer to Chapter 85-10-22.
11. Fill the gearbox according to Chapter 85-10-51 General
12. Install the filling plug [1] with 12 Nm and apply safety wire according to the standard
practices.
13. Install the adequate propeller - refer to the applicable Aircraft Maintenance Manual.
15. After the ground run check gearbox oil system for leakage.
Figures for Chapter 85-10-11 and 12.
12
Fig. 85 - 10
7 8
Fig. 85 - 11 Fig. 85 - 12
11 9 11x
Fig. 85 - 13

Revision no: 23
Page: 85-7
Additional Figures for Chapter 85-10-11 and 12.

10 1 6 4 3
14
Fig. 85 - 14 (Installation of GBTS on gearbox Rev. 65 or lower or Rev. 100 and

higher)
13
Fig. 85 - 15

Revision no: 23
Page: 85-8
85-10-20 Gearbox Magnet-Drain Plug
85-10-21 Removal of the Gearbox Magnet-Drain Plug
1. Remove the wire protection from the filler screw.

2. Dismount the filler plug [1].
3. Put a container (min. 2,5 l) below it.
4. Remove the wire protection [11] of the magnet drain plug.
5. Remove the magnet drain plug. [2].
6. Drain the gearbox oil through the included filter which is included in the scheduled
maintenance kit of Austro Engine for bigger pieces of material and non magnetic
material.
7. Dip the magnetic drain plug in a solvent of remove oil contamination for better debris
inspection.
8. Investigate the drain plug for accumulation of debris. (see Note below).
If this is the first gearbox oil inspection to be conducted on this engine (gearbox TSN:
100 h) a quantity like the one shown in Fig. 85 – 16 is acceptable, as slightly more
debris is not uncommon for the first flight hours.
Fig. 85 - 16
Acceptable quantity for first 100 h inspection
If the gearbox operation time is more than 100 h TSN, less debris is allowable. Thus
compare the magnetic drain plug with the one shown in Fig. 85 – 17. Should the
particles present on the magnetic drain plug be over the allowable size or quantity
contact Austro Engine GmbH for further information and send a picture of the
contaminated magnetic drain plug via E-mail to [email protected].

Revision no: 23
Page: 85-9
Fig. 85 - 17
Accumulation of allowable debris
Following types of particles are allowable:
- Small quantities that are like thin pieces of hair (see Fig. 85 – 16).
- Small quantities that are like powder (see Fig. 85 – 16).
Following types of particle are not allowable:
- Large quantities that are like thin pieces of hair.

- Large quantities that are like powder.
- Particles that are like flakes.
- Particles greater than the above mentioned.
9. Clean the magnet drain plug [2].
85-10-22 Installation of the Gearbox Magnet-Drain Plug
1. Inspect the gaskets, if worn, use a new gasket.

2. Lubricate the gasket.
3. Install the magnet drain plug and torque the plug with 12 Nm.
4. Secure the magnet drain plug with safety wire.
5. Refill the gearbox oil – refer to Chapter 85-10-53.
6. Screw on the gearbox filler plug with 12 Nm [1] and secure it with safety wire.

Revision no: 23
Page: 85-10
85-10-30 Gearbox Oil Filter (Gearbox Rev. 70 or higher)
85-10-31 Removal of the Gearbox Oil Filter
If Gearbox is mounted on an E4-B or E4-C engine, the gearbox temperature sensor

(GBTS) is installed instead of the plug screw. Disconnect the GBTS prior conduction of
further work steps.
Removal of GBTS prior removal of the filter is recommended. Take care when
handling the GBTS.
Fig. 85 - 18 Plug screw [1] Fig. 85 - 19 Filter [2]
1. Remove the wire protection from the plug screw [1]

2. Open the plug screw [1]
3. Remove the filter [2] with screw (e.g. M8x50 or longer)
For 100h check: Check the filter (damage, debris) and clean it with Brake Cleaner.
Conduct a visual inspection of the used gearbox oil filter for contamination and metal
abrasion. If unusual contamination (metal shavings exceeding 1 mm; concentration of
particles; clogged filter) is found, or in case of doubt contact Austro Engine GmbH.
For 300h change: Dispose the old filter and replace it with a new filter.

Revision no: 23
Page: 85-11
85-10-32 Installation of the Gearbox Oil Filter
Fig. 85 - 20 Filter [2] installation with screw (e.g. M8x50 or longer)
Fig. 85 - 21 Check for tightness
Fig. 85 - 22 Plug screw [1] Fig. 85 - 23
1. Install the oil filter [2] with the tool
Check the filter for tightness -> Risk of damage!
2 Screw the plug screw [1] with 25 Nm and secure it with safety wire.
If gearbox Rev. 70 to Rev. 90 is installed on an E4-B or E4-C engine, install gearbox
temperature sensor according to chapter 85-10-40 instead of plug screw.

Revision no: 23
Page: 85-12
85-10-40 Gearbox Temperature Sensor
85-10-41 Removal of the Gearbox Temperature Sensor
1. Disconnect the electrical connector [1] (GBTS).

2. Remove the temperature sensor [2].
85-10-42 Installation of the Gearbox Temperature Sensor
1. Use new gasket [3].

2. Install the gearbox temperature sensor using Loctite 2701.
film of Loctite.
3. Torque the gearbox temperature sensor with 15 Nm.

4. Connect the electrical connector (GBTS).
Refer to Chapter 71-50-901 in case the wiring is damaged or too short.

3 2 1
5 5 5
Fig. 85 - 24 (Installation of GBTS on gearbox Rev. 65 or lower or Rev. 100 and

higher)
If gearbox Rev. 70 to Rev. 90 is installed on an E4-B or E4-C engine, the GBTS has to
be installed above the gearbox oil filter. For all other configurations the installation is
similar to Fig. 85 - 24
Note that a gearbox Rev. 80 to Rev. 90 cannot be mounted on an E4-A engine.

Revision no: 23
Page: 85-13
85-10-50 Gearbox Oil
85-10-51 General
Gearbox Oil Information:
Gearbox oil type: Shell Spirax GSX 75W-80
Oil volume: 2,3 l
For checking the gearbox oil level- refer to Chapter 12-20-11.
85-10-52 Exchange of the Gearbox Oil
For exchange of the gearbox oil refer to Chapter 85-10-21.
85-10-53 Refill of the Gearbox Oil
1. Install the magnet drain plug - refer to Chapter 85-10-22.

2. Fill in gearbox oil up to the inspection window (approx 1,8 l).
3. Conduct a ground run with more than 1800 rpm to fill A/C gearbox oil system.
4. Fill in gearbox oil up to the inspection window.
If Gearbox E4A-70-000-000 Rev. 60 or lower installed (refer to Engine Log)

fill in additional 0,5 l of gearbox oil.
With this additional gearbox oil above inspection window level the gearbox
E4-70-000-000 Rev. 60 or lower is filled with the required quantity.
5. Secure gearbox filler plug with safety wire.
1 2
5 1
5
Fig. 85 - 25 Fig. 85 - 26

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Page: 85-14
85-10-60 Two-Mass-Flywheel
85-10-61 Removal of the Two-Mass-Flywheel
1. Remove the starter - refer to Chapter 80-00-11.

2. Remove the gearbox – refer to Chapter 85-10-11.
3. Disconnect the ground strip of the crankshaft senor plugs
4. Disconnect the crankshaft sensor plugs.
5. Remove the crankshaft sensors - refer to Chapter 76-00-31.
6. Attach the flywheel locking tool [1] (see List of Tools).
7. Remove the 8 screws [2] and afterwards remove the hub [3].
8. Remove the 8 screws [4] from the two-mass-flywheel.
9. Remove the two-mass-flywheel.
10. Remove the locking tool.
11. Clean and inspect the hole threads.
85-10-62 Installation of the Two-Mass-Flywheel
1. Install the new two-mass-flywheel. Pay attention to the aligning pin.

2. Re-attach the hub [3] to the pins and tighten up the 8 screws [2] with 25 Nm.
3. Re-attach the flywheel locking tool.
4. Use new 8 bolts and screw them in finger-tight in a crosswise sequence.
5. Tighten up all 8 screws [4] in a crosswise sequence with the first step 45 Nm and the
second step with 90°.
Pay attention not to squeeze the Teflon ring during tightening of the 8 new screws [4]
between sealing surface and two-mass-flywheel. The Teflon ring should be centered.
6. Remove the flywheel locking tool.

7. Install the crankshaft sensors - refer to Chapter 76-00-32
8. Connect the crankshaft sensor plugs.
9. Attach the ground strips of the crankshaft sensor plugs
10. Install the gearbox - refer to Chapter 85-10-12.
11. Install the starter – refer to Chapter 80-00-12.
1 4 8x
5 5 5
3
1
5
2 8x
1 5
5
Fig. 85 - 27 Fig. 85 - 28

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Page: 85-15
85-10-63 Removal and Disassembly
The two–mass-flywheel has to be handled with dry and clean gloves.
For removal of the two-mass-flywheel refer to Chapter 85-10-61.
85-10-64 Cleaning
Before the two–mass-flywheel is cleaned the visual inspection has to be finished.

Cleaning agent or grease-dissolving materials must not be get to the inside of the
Two-Mass-Flywheel.
It is not permitted to clean the two-mass-flywheel in a part washing machine. Also
cleaning with a steam- or a high-pressure-cleaner is not allowed.
Before the two-mass-flywheel is cleaned an optical inspection of the two-mass-

flywheel have to be done.
To clean the surfaces of the two-mass-flywheel a cleaning cloth covered with WD40
can be used. With the cloth the contact surfaces to the crank shaft and to the hub
(E4A-73-000-203) can be cleaned from surface rust and dust.
The present of rust at the surface of the two-mass-flywheel is not critical for the
function of it. It is adequate to clean the surface with a dry Scotch-Brite hand pad
from light surface corrosion.
Important is the cleaning of the surfaces at the connecting flanges.

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Page: 85-16
At the engine side at first the flange has to be

cleaned with WD40 and a cleaning cloth.
To remove the rust from the surface WD40 has
to be dispersed over the whole surface of the
flange with slightly pressure.
Thereafter the rust can be removed with a
Scotch-Brite hand pad.
Fig. 85 - 29 Connecting Flange Engine Side
At the gearbox side the procedure to clean the

two-mass-flywheel is equal to the engine side.
Fig. 85 - 30 Connecting Flange Gearbox Side

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Page: 85-17
85-10-65 Inspection
Overview:
To describe the investigation points an overview of the two-mass-flywheel is given in the following
picture. The flywheel is build up out of two discs (masses) which are connected together with springs
at the inside of the bigger disc. The bigger disc with the starter and pick up ring is called primary
mass and sign with the number 1 (E4A-73-300-201-002) in the following figure. The smaller disc
signed with the number 2 (E4A-73-300-202-010) is named secondary mass.
Fig. 85 - 31 Two-Mass-Flywheel (Front side)

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Page: 85-18
Fig. 85 - 32 Two-Mass-Flywheel (Back Side)
Starter and Pick-up ring:

Starter and Pick-up ring are located at the outside contour of the primary mass. The pick-up ring has
a gap of two teeth which are required for engine speed measuring.
Fig. 85 - 33 Starter (1) and pick-up ring (2, with gap) at the outside contour of the primary mass.

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Page: 85-19
Visual Inspection:
Before the two-mass-flywheel is cleaned a visual inspection has to be done.
The two-mass-flywheel must not have any traces of thermal damage at the rear side or at the outside
coverage. Otherwise the two-mass-flywheel has to be replaced.
Friction control cam (E4A-73-212-402):

Residual of molten plastic between primary and secondary mass of the two-mass-flywheel. This is a
sign for thermal impact at the inside of the two-mass-flywheel. In this case the two-mass-flywheel has
to be replaced.
This check has to be repeated after the mechanical inspection. Due to the rotation during the
mechanical inspection the covered part of the friction control cam is positioned at the wholes of the
back side of the primary mass.
Fig. 85 - 34 Friction Control Cam /Rear side of the primary mass)

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Page: 85-20
Wear of the inner rivet head:

Due to possible interference between the inner components of the primary mass with the rivets which
connect the primary with the secondary mass an additional visual and dimensional inspection is
required.
min. 1,5mm
Wear due to interference

requires additional
measurement.
Fig. 85 - 35 Wear of the inner rivet head
Measurement of the rivet height:

The height of the rivet heads left must not
be less than 1,5mm. Therefore measure at
minimum four of the eight rivet heads. If
the heights mean value is less than 1,5mm
the Two Mass Flywheel can not be qualified
for further use.
Consider to measure only the worn

surface of the river head.
Fig. 85 - 36 Measurement of the worn rivet head

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Page: 85-21
Friction traces:
The gap between primary and secondary mass has to be checked. If there are traces of wear at the
surface of the primary mass, caused by friction of the secondary mass at the surface of the primary
mass, the two-mass-flywheel has to be replaced.
Fig. 85 - 37 Gap between primary (1) and secondary (2) mass

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Page: 85-22
Bearing Friction Ring:

The friction ring has to be in the correct position. If the friction ring has contact to the bearing
bushing as seen in the following figure the ring has to be repositioned. Therefore lift the secondary
mass slightly thus the ring can be repositioned with a small screwdriver. The correct position is
reached when the inner diameter of the ring has approximately the same gap to the outside diameter
of the notch in the primary mass as demonstrated with the green dotted line in Fig. 85 – 38.
Fig. 85 - 38 Bearing Friction Ring
If the friction ring is covered by the secondary mass thus the inner diameter can not be seen
completely the ring has to be repositioned. Therefore lift the secondary mass slightly thus the ring can
be repositioned with a small screwdriver. The correct position is reached when the inner diameter of
the ring has approximately the same gap to the outside diameter of the notch in the primary mass as
demonstrated with the green dotted line in Fig. 85 – 38.
If the friction ring is not in the correct position the ring can be damaged when the Two-Mass-Flywheel
is mounted at the test rig for mechanical investigation. This damage is seen in the following figure.
Fig. 85 - 39

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Page: 85-23
For further operation of the Two-Mass Flywheel the ring has to be reworked. Use a sharp knife to cut
off the ragged area of the ring. If the width of the ring is less than 50% or the ring gets broken, the
Two-Mass-Flywheel has to be replaced.
>0,5*t
Fig. 85 - 40
Thereafter reposition the ring. Therefore lift the secondary mass slightly thus the ring can be
repositioned with a small screwdriver.The correct position is reached when the inner diameter of the
ring has approximately the same gap to the outside diameter of the notch in the primary mass as
demonstrated with the green dotted line in Fig. 85 - 38.
Pick-up ring:
If the teeth of the pick-up ring are out of shape the engine run could be rough. Therefore if the teeth
are bent the two-mass-flywheel has to be replaced.
Fig. 85 - 41

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Page: 85-24
Take care that also small bending of a pick-up ring teeth could lead to engine running problems.
Fig. 85 - 42
Fig. 85 - 43

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Page: 85-25
Starter ring:
Traces of wearing or damage at the gear tooth of the starter ring. If traces are present the two-mass-
flywheel has to be replaced. Less than 95% of the present volume of each tooth is not acceptable.
If teeth are damaged the starter has to be checked. When damage is indicated the starter has to be
changed as well.
Fig. 85 - 44

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Balancing weights:
If the balancing weights are missing the two-mass-flywheel has to be replaced. This is noticeable if
weld points can be seen without the balancing weights.
If the weld points are broken the flywheel has to be replaced as well.
Fig. 85 - 45 Balancing Weight
Visual Inspection Performed:
FITTER INSPECTOR
(Name, Date, Signature) (Name, Date, Signature)

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Page: 85-27
Mechanical Inspection:
To control the mechanical function the two-mass-flywheel has to be tested in a special testing rig –
AEP-0061. The wheel is build up and fixed with its primary mass and loaded with defined torque
loads. The deflection between the primary and secondary mass will be measured at the defined
torque (see Table 1) and recorded.
Fig. 85 - 46 Flywheel fixing adapter
At first the two-mass-flywheel will be attached in the fixing adapter of the test rig.
Thereafter a hub is attached at the connecting flange of the secondary mass and the bearing support
of the test rig is mounted as seen.

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Page: 85-28
Fig. 85 - 47
To measure the deflection between the primary and secondary mass an angle measuring instrument
is attached at the input shaft.
Fig. 85 - 48
The torque will be attached with a torque wrench at the angle measuring instrument according to the
required torque values in Table 1: Tolerance Values.

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Page: 85-29
Before the measuring is started the spring packages at the inside of the two-mass-flywheel have to be
positioned. Therefore the flywheel has to be turned not more than three times into the desired
direction with a torque of about 350 Nm. After this the angle measuring system has to be reset to
null.
Thereafter the measuring can be done according to the following table. The measured angle values
have to be within the minimum and maximum tolerance values. The measuring direction may not be
changed during the procedure unless the spring packages will be repositioned for the change of the
direction.
Table 1: Tolerance values

Measured Value
Minimum Maximum
Torque Counter-
tolerance Clockwise tolerance
[Nm] clockwise
[°] turning [°]
turning
25 2 12
50 2 18
75 7 23
100 13 29
125 18 34
150 24 40
175 29 45
200 34 50
225 36 52
250 38 54
275 39 55
300 41 57
325 43 59
350 44 60
Tolerance values have been round mathematically due to the handling at the measuring process
Mechanical Inspection Performed:
FITTER INSPECTOR
(Name, Date, Signature) (Name, Date, Signature)

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Page: 85-30
Tolerance Limits
70 70
60 60
50 50
Turning Angle [°]
Turning Angle [°]

40 40
30 30
20 20
10 10
0 0
0 25 50 75 100 125 150 175 200 225 250 275 300 325 350
Torque [Nm]
Minimum Tolerance Maximum Tolerance
After the measuring the inspection is finished and the two-mass-flywheel can be dismounted from the
test rig.

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Page: 85-31
85-10-66 Repair and Replacement
If the two-mass-flywheel has passed the visual and mechanical inspection the flywheel is qualified for
a further use in an E4 engine.
Otherwise the two-mass-flywheel has to be replaced. A repair of a flywheel is not possible.
85-10-67 Marking of Inspected Two-Mass-Flywheel
If the two-mass-flywheel has passed the visual and mechanical inspection the flywheel needs to be
marked for future identification of the already performed inspections.
Engrave the Fywheel with a “x” next to the part number as shown in Fig 85 - 49. The Fywheel needs
to be engraved with a “x” every time this maintenance procedure has been performed.
Fig. 85 - 49
Do not hammer the marking on the part to avoid damage to the two-mass-flywheel.

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Page: 85-32
85-10-68 Reassembly
Always use new screws (E4A-73-000-801) for a reinstallation of the

Two-Mass-Flywheel.
After the Flywheel is attached at the crankshaft hub check the position of the friction
ring. The ring must be positioned that no tapped hole is covered by the ring. The ring
must not be screwed down by one of the screws.
Install the new two-mass-flywheel. Pay attention to the aligning pin.
1. Re-attach the hub [3] to the pins and tighten up the 8 screws [2] (DIN 912 M8x12-12.9) with
25 Nm.
2. Re-attach the flywheel locking tool.
3. Use new 8 bolts and screw them in finger-tight in a crosswise sequence.
4. Tighten up all 8 screws in a crosswise sequence with the first step 45 Nm and the
second step with 90°.
5. Remove the flywheel locking tool.
6. Install the crankshaft sensors - refer to Chapter 76-00-32.
7. Connect the crankshaft sensor plugs.
8. Attach the ground strips of the crankshaft sensor plugs.
9. Install the gearbox - refer to Chapter 85-10-12.
10. Install the starter – refer to Chapter 80-00-12.
12. After the ground run check gearbox oil system for leakage.
85-10-69 Special Tools
See “List of Special Tools” at the end of the document.

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Page: 85-33
85-10-70 Packing and Shipping
The overhauled two mass flywheel is packed in a bubble wrap and marked with a label indicating part
number, name, S/N number and revision status.
Fig. 85 - 50 Fig. 85 - 51
The two mass flywheel is packed and shipped with the 300h maintenance kit in a special packaging,
as seen below. Packaging can differ if the part is shipped independent from the 300h maintenance kit.
Fig. 85 - 52

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Page: 85-34
85-20-00 Reciprocating Engine Power Section
85-20-10 Crankshaft Cover
For removal and installation of the crankshaft cover the engine has to be removed from the aircraft.
85-20-11 Removal of the Crankshaft Cover
1. Drain coolant – refer to the applicable Aircraft Maintenance Manual.

2. Drain engine oil – refer to Chapter 79-00-20.
3. Remove the engine from the aircraft – refer to the applicable Aircraft Maintenance
Manual.
4. Remove the gearbox - refer to Chapter 85-10-11.
5. Remove the two-mass-flywheel – refer to Chapter 85-10-61.
6. Remove the oil sump – refer to Chapter 79-00-41.
7. Remove the screws [1] of the crankshaft cover.
8. Remove the crankshaft cover [2].
85-20-12 Installation of the Crankshaft Cover
1. Clean the sealing ring contact surface on the crankcase with a fibre-free cloth.
2. Mount the crankshaft cover [2] with the mounting sleeve [3] and tight the 6 screws
[1] with 9 Nm.
The cover has to be installed without any kind of fluid or lubricant.
3. Look out for correct horizontal alignment of the crankshaft cover with the crankcase
at position 4 in the picture below.
4. Remove the mounting sleeve [3]
5. Clean the sealing surface for oil sump.
6. Apply engine sealing material at the joint [4].
The recommended engine sealing material is available at Austro Engine GmbH.
7. Use new oil sump gasket.

8. Install the oil sump – refer to Chapter 79-00-42.
Don’t damage the crankshaft sensor.
9. Install two-mass-flywheel - refer to Chapter 85-10-62.

10. Install the gearbox – refer to Chapter 85-10-12.
11. Install the engine - refer to the applicable Aircraft Maintenance Manual.
12. Refill engine oil – refer to Chapter 79-00-30.
13. Refill coolant – refer to the applicable Aircraft Maintenance Manual.
For coolant information please refer to Chapter 05-20-17 Coolant

16. After the ground run inspect engine fluid systems for leakage.

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Page: 85-35
Figures for Chapter 85-20-11 and 85-20-12.
3 4 2 4
5 1 5 5
5
1 6x
5 5
Fig. 85 - 53 Fig. 85 - 54 Fig. 85 - 55

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Page: 85-36
85-30-00 Reciprocating Engine Cylinder Section
85-30-10 Intake Air
85-30-11 Removal of the Intake Air Manifold
1. Remove the intake hoses - refer to the applicable Aircraft Maintenance Manual.
2. Put a container below the engine coolant drain.
3. Drain the engine coolant - refer to the applicable Aircraft Maintenance Manual.
4. Remove the coolant hoses - refer to the applicable Aircraft Maintenance Manual.
5. Remove the coolant thermostat - refer to Chapter 85-70-41.
6. Remove the intake-air temperature sensor#1-IAT1 (B50/1) and intake air
temperature sensor #2 – IAT2 (B50/2) refer to Chapter 85-30-31.
7. Remove the boost pressure sensor #1 – BPS1 (B5/1) and boost pressure sensor #2 –
BPS2 (B5/2) refer to Chapter 85-30-21.
8. Remove the coolant temperature sensor #1 – CTS1 (B50/3) and coolant temperature
senor #2 – CTS1 (B50/4) refer to Chapter 85-70-11.
9. Remove the screw [10] 9x.
10. Remove the intake air manifold [13].
11. Take off the gasket [9].
12. Clean the sealing surface.
85-30-12 Installation of the Intake Air Manifold
1. Fit on the new gasket

2. Put the intake air manifold in position above the cylinder head sealing area.
3. Screw the intake air manifold down with 14 Nm
4. Install the coolant thermostat [11] – refer to Chapter 85-70-42.
Inspect for the correct position of the o-ring.
5. Install the coolant hoses -refer to the applicable Aircraft Maintenance Manual.
6. Install the intake air temperature sensor #1 & #2 – refer to Chapter 85-30-32.
7. Remove the security plug of the sensor and connector.
8. Install the electrical connectors to the intake-air temperature sensor +#1-IAT1
(B50/1) and intake air temperature sensor #2 – IAT2 (B50/2).
9. Install the boost pressure sensor #1 & #2 - refer to Chapter 85-30-22.
10. Install the electrical connectors to the boost pressure sensor #1 – BPS1 (B51) and
boost pressure sensor #2 – BPS2 (B5/2).
11. Install the coolant temperature sensor #1 & #2 - refer to Chapter 85-70-12.
12. Install the electrical connectors to the coolant temperature sensor #1 – CTS1 (B50/3)
and coolant temperature sensor #2 – CTS1 (B50/4).
13. Install the air intake hoses - refer to the applicable Aircraft Maintenance Manual.
14. Fill engine with coolant and bleed the cooling system – refer to the applicable Aircraft
Maintenance Manual.
16. After the ground run inspect coolant system for leakage.

Revision no: 23
Page: 85-37
Intake Air Version E4-A
15 16
14
13
08
04
07
05
02 06
02
01
03 12 11 10 9x 09
Fig. 85 - 56
Intake Air Inlet E4-A
Fig. 85 - 57

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Page: 85-38
Intake Air Version E4-B
14 16 13
15
08
04 05
07
02
04
01 02 03
06
12 10 09x 09
11
Fig. 85 - 58
Intake Air Inlet E4-B
Fig. 85 - 59

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Page: 85-39
85-30-20 Boost Pressure Sensor
85-30-21 Removal of the Boost Pressure Sensor
1. Disconnect the electrical connector “BPS1 + BPS2”

2. Remove the screws [3] and [7].
3. Remove the boost pressure sensor [4] and the spacer [8].
85-30-22 Installation of the Boost Pressure Sensor
1. Insert boost pressure sensor and the spacer with new o-ring.
2. Look out for the correct position of the o-ring.
3. Lubricate or ring with acid free lubrication.
4. Spacer [8] assembly steps in case of latest Boost Pressure Actuator installation:
Assemble the hose nipple [14] together with the sealing [15] onto the spacer [8]
using Loctite 542 and torque them with 5 Nm.
5. Screw boost pressure sensor screws down with 5 Nm using Loctite 243.
film of Loctite.
6. Connect the electrical connectors “BPS1 or BPS2”.

85-30-30 Intake Air Temperature Sensor
85-30-31 Removal of the Intake Air Temperature Sensor
1. Disconnect the electrical connectors “IAT1 or IAT2”.

2. Remove the intake air temperature sensor [1].
85-30-32 Installation of the Intake Air Temperature Sensor
1. Use new sealing rings [2].

2. Install the intake air temperature sensor with new sealing rings
3. Torque intake air temperature sensor with 15 Nm.
4. Connect the electrical connectors “IAT1 or IAT2”.

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Page: 85-40
85-40-00 Reciprocating Engine Rear Section
85-40-10 V-Ribbed Belt
85-40-11 Removal of the V-Ribbed Belt
1. Move the v-belt tensioner [1] clockwise by turning the screw [2] to release the belt
tension
2. Secure the v-belt tensioner with a locking pin [3].
3. Remove the v-ribbed belt [4].
85-40-12 Installation of the V-Ribbed Belt
1. Fit the v-ribbed belt [4] as illustrated in the diagram.
Make absolutely sure that the belt is routed as shown in the diagram.
No other routing is allowed.
Make sure that the ribbed side of the v-ribbed belt is facing inward.
In addition make sure that the ribs of the belt match the rills on the wheel.
The belt must lie within the boundaries of the wheel
2. Move the v-belt tensioner [1] clockwise by turning the screw [2]
3. Remove the locking pin [3].
The correct v-belt tension will be set automatically
4 2 3
1 1 1
5 5 5
2
1
5
Fig. 85 - 60 Fig. 85 - 61

Revision no: 23
Page: 85-41
85-40-20 Belt Tensioner
85-40-21 Removal of the Belt Tensioner
1. Remove the v-ribbed belt - refer to Chapter 85-40-11.

2. Remove the Alternator - refer to Chapter 24-00-11.
3. Remove the screw from the tensioner [5].
4. Remove the tensioner.
85-40-22 Installation of the Belt Tensioner
1. Put the belt tensioner in position.

2. Install the screws – do not torque the screws.
3. Install the Alternator - refer to Chapter 24-00-12.
4. Install the V-ribbed belt - refer to Chapter 85-40-12.
1
1 5 3x
5 1 15
5
2
1
5
Fig. 85 - 62

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Page: 85-42
85-40-30 Belt Tensioner – Roller
85-40-31 Removal of the Belt Tensioner – Roller

2. Remove the screw [1] from the roller.
3. Remove the roller.
85-40-32 Installation of the Belt Tensioner – Roller
1. Install the new roller

2. Torque the screw [1] with corresponding torque (see picture below) using Loctite
243.
film of Loctite.
3. Install the v-ribbed belt - refer to Chapter 85-40-12.

1 25 Nm 1 25 Nm
1 67 Nm
Fig. 85 - 63

Revision no: 23
Page: 85-43
85-40-40 Check of timing chain
85-40-41 Preparations prior check of timing chain
Engine configuration “–A”

Expose the engine according to aircraft maintenance instructions (AMM) to allow access to the chain
tensioner of the engine.
Engine configuration “–B” or “–C”

Expose the engine according to aircraft maintenance instructions (AMM). After the cowling parts have
been removed the engine is exposed as shown in figure below. To proceed, aircraft and engine parts
must be removed as follows:
01
02 03
04
Fig. 85 - 64 Engine overview after cowling was removed (e.g. DA 42 installation)
• Remove all coolant of the engine. For detailed information see applicable AMM.
• Remove the air tube (No. 01 at Figure 85-2) connected to the intake air manifold. For detailed
information see applicable AMM.
• Remove the expansion tank for coolant (No. 02 at Figure 85-2). For detailed information see
applicable AMM.
• Loosen the intake air manifold (No. 03 at Figure 85-2). Move the manifold until the chain
tensioner (No. 04 at Figure 85-2) is exposed and can be removed. For detailed information
see applicable engine MM.

Revision no: 24
Page: 85-44
85-40-42 Timing Chain Measuring tool (TCMT)

To conduct the checking procedure the required tool is shown below.
Aluminium
seal
Fig. 85 - 65 Timing Chain Measuring Tool (TCMT)
Remove the chain tensioner from the engine and screw the TCMT into the chain tensioner socket.
Make sure that the aluminium seal is installed at the Timing Chain Measuring Tool as
shown in figure above. In case of a replacement of the aluminium seal, make sure that
the old aluminium seal was removed before. Two or more aluminium seals and also no
aluminium seal result in measuring errors.
The timing chain measurement tool is equipped with an indicator scale.

For the following checking procedure the TCMT criteria shown below is used:
Red Indicator Rings Chain length not ok
Chain length ok
Fig. 85 - 66 Indicator scale TCMT

Revision no: 24
Page: 85-45
85-40-43 Checking procedure of timing chain
To conduct the checking procedure the engine has to be hand turned at the propeller to the top dead
center (TDC) position:
 Turn the engine into TDC position

To detect the engine position in reference to the TDC position, an indication scale is attached
at the belt pulley at the rear end of the engine. In addition a pointer is visible at the crank
case. In Figure 85 - 67 the TDC (“OT”) indicator and pointer at the crank case are shown.
Pointer
TDC Indicator
Fig. 85 - 67 Belt pulley with TDC (“OT”) indicator
The engine is in the TDC position when the mark next to “OT” is positioned at the pointer of
the crank case.
Due to the aircraft system build up the TDC position must be checked with mirror and
torch light when the engine is attached to the aircraft.
To move the engine into the TDC position turn the propeller by hand until the TDC position is
reached. Record the values visible at the dial gauge and turn the engine for one revolution to
reach the second TDC.
Due to the gearbox transmission the propeller must be turned for a 3/5 revolution to
turn the engine for one revolution.

Revision no: 24
Page: 85-46
Check the indicator scale of the TCMT according to figure 85 - 64 and repeat turning the
engine according to the described checking sequence:
• Checking sequence
• Turn the engine at the propeller two times and adjust it at the first TDC point.
• After 10 seconds (for balancing reasons) check the indicator scale of the TCMT.
• Turn the engine at the propeller for one engine revolution. (3/5 propeller revolution).
• After 10 seconds (for balancing) check the indicator scale of the TCMT.
85-40-44 Results of the timing chain check
If during the checking sequence described above in one of the check points the last or less of the last
red ring of the indicator scale on the TCMT has been visible, the timing chain and the chain wheel
have to be replaced. Proceed with Chapter 85-40-50 to Chapter 85-40-54.
If more than one red ring of the indicator scale has always been visible, proceed with
Chapter 85-40-45.

Revision no: 24
Page: 85-47
85-40-45 Assembly of engine after timing chain check
All engine configurations

Remove the TCMT by hand turning and follow the instructions given below:
• Place chain tensioner at the depending socket in the engine

(See part 04 in Figure 85 - 68).
Use a new Gasket for the chain tensioner. (Part No. E4-A-75-600-401)
• Screw chain tensioner until it is locked and fasten it with a torque wrench. Tightening
torque is 80 Nm (708 inch-lbs). After tightening rotate the engine at the propeller
to check the rotatability.
•
Engine configuration “–B” or “–C”

• Attach the intake air manifold (See item 03 in Figure 85-66) at the engine. For
detailed information refer to chapter 85-30-12 of this manual. A new gasket is
required.
• Attach the expansion tank (See part 02 in Figure 85-66) at the engine according to
aircraft maintenance instructions.
• Attach the tube (See part 01 in Figure 85-66) to the intake air manifold according to
aircraft maintenance instructions.
01
02 03
04
Fig. 85 - 68 Engine overview (e.g. DA 42 installation)
To finish the timing chain check the coolant must be refilled and the assembly of engine compartment
has to be conducted according to aircraft maintenance instructions.

Revision no: 24
Page: 85-48
85-40-50 Exposure of timing chain and camshaft chain wheel
For detailed information use the maintenance manuals of aircraft and engine.
Remove the following components from the top of the engine to expose the chain drive:
• Intake air hoses (refer to Aircraft Maintenance Manual).

• Fuel lines (refer to Aircraft Maintenance Manual).
• Wiring harness – refer to Chapter 71-50-170
• Plugs connected to engine components, which have to be removed. Therefore certain
cables have to be loosened by removing cable retainers with a nipper.
• Injector cover – refer to Chapter 85-00-11
• Injectors – refer to Chapter 73-00-11
Mark the cylinder number onto the injector and the fuel line accordingly in order to place it back
in the same order during re-assembly. To protect the injectors from dust and contamination put
the injectors in plastic bags.
• Cylinder head cover. Therefore all screws (indicated with “S” for short screws and “L”
for the long screws in the figure below) have to be removed.
S 06 L 02 L 04 L 08 L S
07 L
01 05 03 L
S 05 L
S
05 L 01 L 03 L
07 L
S 06 L 02 L 04 L 08 L S
Fig. 85 - 69 Cylinder head cover
• Lubrication line – refer to Chapter 79-00-101.

• Oil returning line – refer to Chapter 79-00-111.
• Housing for sensor E4-A-22-000-000. Therefore remove three screws. The screws
cannot be re-used.

Revision no: 24
Page: 85-49
• Front side cover E4-A-14-000-000: Loosen all five screws of the front side cover of the
cylinder head.
Do not cant the cover whilst removing. The drain plug must not be damaged
(See drain plug at Figure 85 – 70).
Fig. 85 - 70 Drain plug at side cover
• Camshaft bearing shell from the intake camshaft on the timing chain side. Replace it by a
chain guiding bar as shown in Figure 85 – 71 (AEP-00139).
Fig. 85 - 71 Chain guiding bar (AEP-00139) mounted at the cylinder head

Revision no: 24
Page: 85-50
• To maintain the chain at the camshaft, fasten the chain to the chain wheel with a able
retainer. The position of the cable retainer must be at the 11 o’clock position of the chain
wheel seen from the rear side of the engine. The position of the cable retainer is shown
in Figure 85 - 69.
To prevent small parts from falling into the chain slot cover the slot with a rag. The chain
must not be slip from the tooth of the chain wheel!
• Remove the TCMT by hand turning.
85-40-51 Exchange of timing chain
The following parts are required for changing of the timing chain and chain wheel:
No. Part Number Quantity Description

01 E4A-75-100-000-020 1 Timing chain, open version
02 - 1 Chain link, part of Timing chain
03 - 1 Chain clip, part of Timing chain
04 E4A-07-000-402-000 3 Screws for chain wheel
05 E4A-07-000-101-000 1 Chain wheel
06 E4A-22-000-803 *) 2 Screws for assy sensor housing
*) fully interchangeable with E4A-01-000-801, E4A-10-000-803 and E4A-55-100-802
The following tools are required for changing of the timing chain and chain wheel:
No. Tool Number Quantity Description

01 AEP-00150 1 Timing chain measuring tool
02 AEP-00158 1 Chain opening tool
- Bracket
- Fixing screw
- Screw with opening bolt
03 AEP-00159 1 Chain closing tool
- Bracket
- Chain link positioner
- Positioner screw
- Screw with closing bolt
- Adapter block
04 AEP-00160 1 Chain coupling
05 AEP-00139 1 Chain guiding bar
07 AE300T009 1 Camshaft adjusting tool
Only use special tools when in good condition and free of any signs of deterioration or
damage.
To replace the chain it has to be opened as follows:

 Place the chain opening tool at the position shown in Figure 85 - 72. Choose a pin
between the chain guiding bar and cable retainer. The pin must be in the counter
clockwise hole of an inner link. To prevent that the pin falls into the chain slot cover the
end of the tool with a duct tape as shown in the figure.
 Fasten the tool with the positioning screw (Figure 85 - 72, No. 1) with the chain pin
placed between the adjusting tool and screw of the opening tool.
 Screw the spindle (Figure 85 - 72, No. 2) until the chain pin is completely removed from
the link.
 Unfasten the spindle and thereafter the positioning screw.
 Remove the opening tool. Take care that the loosened pin cannot fall into the chain slot.
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Page: 85-51
Duct
tape
Cable
retainer 1
Fig. 85 - 72 Position of the chain opening tool at the chain wheel
 Connect the new timing chain with the replacing timing chain by use of a chain coupling
(AEP-00160). Position the chain in a way that the holes in the pin sleeves of the link are
on the outside of the chain as shown in Figure 85 - 73.
AEP-00160
Fig. 85 - 73 Connection of both chains via link

Revision no: 24
Page: 85-52
 Remove the cable retainer. Pull out the existing timing chain whilst ensuring permanent
contact between chain and chain wheel. Turn the engine clockwise in flight direction (as
shown in Figure 85 - 74) and feed in the new chain. The chain shall be pulled beyond the
guiding tool.
Before turning the engine, remove the cover from the chain slot.
Do not turn engine in reverse direction while pulling in the new chain.
 Turn engine until the new chain is almost completely fed in. Stop turning when
approximately two or three links are left outside the down holder. Fasten the replacing
chain on the chain wheel with a cable retainer, about two links from the connection link.
Fig. 85 - 74 Thread in the new timing chain
 Remove the chain coupling (AEP-00160). The chain coupling from the tool set must not
remain in the engine. The part is not capable for engine operation
Make sure that the chain slot is closed or covered with a rag or similar
to prevent debris inside the engine.
 The remaining free ends of the new chain have to be connected with the open chain link
(as part of E4A-75-100-000-000). Push the link with its pins in each free end of the chain.
If there is too much tension on the chain, you can ease that tension with small
movements on the prop in both directions. Push the link in coming from the camshaft
side (see Figure 85 - 75).

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Page: 85-53
Open chain link
Fig. 85 - 75 Both ends of the new chain connected with the open chain link
 Close the chain by mounting the chain clip at the open link. Therefore place the clip at
the chain closing tool. A built-in magnet in the pressure pad ensures securing of the
chain clip (see Figure 85 - 76).
Pressure pad
Chain clip
Fig. 85 - 76 Chain clip positioned in chain closing tool

Revision no: 24
Page: 85-54
• Position the chain closing tool with the clip over the free ends of the link’s pins. The
riveted ends of the connection link must sit in the groove of the tool as shown in
Figure 85 - 77.
• Turn the spindle slowly to make sure that the pins slip exactly in the holes of the plate.
Turn the spindle up to the correct torque.
• Torque to press plate onto connection link pins: 32 Nm (283 inch-Ibs.)
Open Chain Link Open Chain Clip
Fig. 85 - 77 Riveting of the chain link
• Turn back the spindle and take the pressure pad out of the tool, turn it thus the riveting
slot of the pressure pad can be used to rivet the chain. Figure 85 - 78 shows the chain
closing tool with the pressure pad is positioned to use the riveting slot.

Revision no: 24
Page: 85-55
Fig. 85 - 78 Riveting slot at the chain closing tool
• To rivet the pins place the chain closing tool back on the chain. Place the pressure pad
centered over the head of one of those pins, which have to be riveted, as the pins have
to be riveted one by one.
• Turn the screw slowly until the pad gets in contact with the pin’s head. Check again the
alignment of pressure pad and pin, turn down the screw with the correct tightening
torque.
• Tightening torque chain pins: 32 Nm (283 inch-Ibs.)
• Repeat the riveting accordingly on the second pin.
• Remove the chain closing tool and check the riveting of the pin’s head.
Figure 85 - 79 shows the riveted pins of the chain link.
Riveted pin heads
Fig. 85 - 79 Riveted pin heads of the new timing chain

Revision no: 24
Page: 85-56
• Remove the chain guiding bar. Clean the surfaces of shell and camshaft and use fresh oil
for the reassembly on the bearing surfaces of camshaft and bearing shell. Remount the
bearing shell. Turn in the screws equally and fasten them with correct tightening torque.
• Tightening torque screws: 12 Nm (106 inch-Ibs.)
• Turn the engine two or three times and check the setting of the cam timing.
• (Description in the following Chapters)
Rotate the engine clockwise (when facing flight direction).

Turn the engine very carefully. If there is a stop or resistance TURN BACK and check the
timing setup once again!
85-40-52 Replacing of timing chain wheel
• Turn the engine to top dead center (TDC) position. See Figure 85 - 80.
Misalignment can result in less power available. Duplicate inspection recommended.
Fig. 85 - 80 Engine set on TDC when control mark of the belt wheel
is aligned with mark on housing
• The punch marks on the timing wheels of the camshafts must be aligned as shown in
Figure 85 - 81.
• Both timing wheels contain a 6 mm hole. These holes must be on the exhaust side and
the lower edge must be aligned with the cylinder head surface. Figure 85 - 82 shows tool
AE-300-T009 placed into these holes of the timing wheels.
To ensure the correct setting of the camshafts insert tool AE-300-T009. The tool bolts must
be located at the exhaust side in contact with the cylinder head housing.

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Page: 85-57
Fig. 85 - 81 Punch marks at timing wheels of both camshafts
Fig. 85 - 82 AE-300-T009 placed at the camshafts

Revision no: 24
Page: 85-58
• Loosen all three screws of the chain wheel.

• Remove the chain wheel.
Do not let the chain fall into the chain slot.
• Assemble the new chain wheel. Therefore place the teeth of the timing wheel in the
chain at first. Thereafter turn the wheel in the chain to fit the wheel at the centering pin
at the camshaft.
Centering pin
Fig. 85 - 83 New chain wheel with timing chain placed at the camshaft
• Mount new chain wheel with three new screws. Do not tighten the screws.
• Install the chain tensioner with a new gasket. Tighten it with correct tightening torque.
• Tightening torque chain tensioner: 80 Nm (708 inch-Ibs.)
85-40-53 Check of engine timing
• The engine must be positioned at TDC. See Figure 85-80.

• Turn the engine until the two punch marks of the timing wheels are aligned as in Figure
85-81.
• The pins of tool AE-300-T009 must be in contact with the cylinder head housing and
must be located at the exhaust side. See Figure 85-82.

Revision no: 24
Page: 85-59
All three points must be obeyed at the same time.
• If the timing setup is ok, remove tool AE-300-T009 from the timing wheels.
• Turn the engine two turns in clockwise direction
Turn the engine very carefully. If there is a stop or resistance TURN BACK and check the
timing setup once again!
Remove the materials, which were used to cover the chain slot before you turn the
engine!
• Turn the engine to TDC and check the timing setup again.
• Tighten the 3 screws of the timing wheel with correct tightening torque.
85-40-54 Reassembly of engine
• Clean the sealing surfaces of the side cover and the cylinder head.
• Apply a line of sealant to the sealing surface of the cylinder head. Place the side cover
onto the engine and fix it with 5 screws.
Camshaft Slot
Fig. 85 - 84 Side cover at cylinder head

Revision no: 24
Page: 85-60
• Apply oil at the slot of the cam shaft (See Figure 85 - 84) and attach the sensor cover. Apply
Loctite 243 to the screws and tighten them with correct torque.
• Attach cylinder head cover. Fasten screws in the order as displayed in Figure 85 - 67
(numbers close to the “L”) with correct torque.
• Tightening torque screws: 12 Nm (106 inch-Ibs.).
• Attach oil returning line according to Chapter 79-00-112.
• Attach lubrication line according to Chapter 79-00-102.
• Mount injectors according to Chapter 73-00-12.
Place the injectors according to the numbers which were recorded during their
removal.
• Attach injector cover according to Chapter 85-00-11.

• Attach wiring harness according to Chapter 71-50-170.
• Attach fuel lines according to the instructions in the aircraft maintenance manual.
• Attach the intake air hoses according to the instructions in the Aircraft Maintenance Manual.
o The accomplishment of the above given instructions must be confirmed in the respective
engine log.
o Perform an engine ground run according to Chapter 71-00-03.

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Page: 85-61
85-70-00 Reciprocating Engine Liquid Cooling
85-70-10 Coolant Temperature Sensor
85-70-11 Removal of the Coolant Temperature Sensor
1. Drain the coolant - refer to applicable Aircraft Maintenance Manual.

2. Disconnect the electrical connector “CTS, CTS _ GPC”.
3. Remove the coolant water temperature sensor [5] from the intake air manifold.
85-70-12 Installation of the Coolant Temperature Sensor
1. Use sealing rings [6].

2. Screw down the coolant temperature sensor with 15 Nm.
3. Connect the electrical connector “CTS, CTS_CGPCP”.
4. Fill and bleed the coolant system – refer to the applicable Aircraft Maintenance
Manual.
For explosion drawing see Chapter 85-30-12 – Intake Air.

Revision no: 24
Page: 85-62
85-70-20 Water Pump
85-70-21 Removal of the Water Pump
1. Drain the coolant - refer to the applicable Aircraft Maintenance Manual.

2. Remove the coolant pipe - refer to the applicable Aircraft Maintenance Manual.
4. Disconnect the screws [1] [2].
5. Remove the water pump [3].
85-70-22 Installation of the Water Pump
1. Install the new o-ring [4]

2. Install sealing ring [5]
3. Lubricate both rings with acid free lubrication.
4. Put on water pump [3] in position.
Inspect o-ring and sealing ring for correct installation.
5. Screw down the water pump and torque the screws with 20 Nm.
6. Install the coolant pipe - refer to the applicable Aircraft Maintenance Manual.
7. Install the v-ribbed belt - refer to Chapter 85-40-12.
8. Fill and bleed the cooling system - refer to the applicable Aircraft Maintenance
Manual.
2
4
5
1
Fig. 85 - 85 Fig. 85 - 86

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Page: 85-63
85-70-30 Heat Exchanger
85-70-31 Removal of the Heat Exchanger
1. Remove the oil filter housing drain line - refer to Chapter 79-00-11.
2. Remove the oil filter housing - refer to Chapter 79-00-61.
3. Remove the screws [1] from the heat exchanger [2].
4. Remove the heat exchanger.
85-70-32 Installation of the Heat Exchanger
1. Install new gasket.

2. Put heat exchanger in place
3. Screw heat exchanger down and torque screws [1] with 9 Nm.
4. Install the oil filter housing - refer to Chapter 79-00-62.
5. Install the oil filter housing drain line - refer to Chapter 79-00-12.
7. Check the oil level – refer to Chapter 12-20-01.
9. After the ground run inspect oil and coolant system for leakage.
1
1
Fig. 85 - 87

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Page: 85-64
85-70-40 Coolant Thermostat
85-70-41 Removal of the Coolant Thermostat
1. Drain the coolant - refer to the applicable Aircraft Maintenance Manual.

2. Remove the coolant hoses attached to the coolant thermostat - refer to the applicable
4. Remove the thermostat [2].
85-70-42 Installation of the Coolant Thermostat
1. Install new o-ring.

2. Take care for the proper fit of the o-ring.
3. Attach the coolant hoses to the coolant thermostat - refer to the applicable Aircraft
Maintenance Manual.
4. Clean the connecting surface of the manifold if necessary.
5. Lubricate o-ring with acid free lubrication.
6. Install the thermostat (inspect correct position of the o-ring).
7. Ensure that the thermostat is fitted properly (see Fig. 85 - 88) and without any
preload to the manifold.
8. Install the screws [1] with the clamp of the wiring harness and torque with 12 Nm.
If engine harness E4A-95-000-000, or E4B-95-000-000 is used the clamp of the wiring
harness is not needed!
9. Fill in coolant and bleed system – refer to the applicable Aircraft Maintenance Manual.
10. Clear the working area.
Fig. 85 - 88 Fig. 85 - 89

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Page: 85-65
Chapter 92-00-00 Additional Information
Engine Wiring Diagrams for E4A-90-000-000
Fig. 92 - 1

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Page: 92-1
Fig. 92 - 2

Revision no: 10
Page: 92-2
Engine Wiring Diagrams for E4A-95-000-000 und E4B-95-000-000
Fig. 92 - 3

Revision no: 10
Page: 92-3
Fig. 92 - 4

Revision no: 10
Page: 92-4
Aircraft Interface Wiring
A/C Interface
CPC connector 1
Pin
Pin
EECU Sensor Supply
Sensor Signal
1
5
1
4
Power Lever
Sensor GND 6 2 Sensor
Sensor Supply
ECU A
2 6
Sensor Signal 4 3
Sensor GND 3 5
Pin Display and Connect to display unit and provide separate

CAN L 7 2 Diagnostic Interface SUB D (RS232) connector (female)
CAN BUS Interface 1
CAN H 8 7
CAN L 9 Currently not used

CAN BUS Interface 2
CAN H 10
Engine Master 11 Engine Master

Engine Master 12 ECU A
Selftest Signal 13 Engine Selftest

Pushbutton
Selftest GND 14 (normally open)
Caution Lamp Supply 15

Caution Lamp
ECU A
Caution Lamp Signal 16
ECU A Power Supply 17

28V Power Supply
ECU A
A/C on ground Ensures that selftest is only performed when
Signal A/C on ground indication 20 A/C is on ground
indication
ECU A GND Supply 21
ECU A GND Supply 22
GND Power Supply
ECU A GND Supply 23
ECU A
ECU A GND Supply 24
GPC GPC Power Supply

GPC Power Supply
25
26
28V Power Supply
GPC
GPC Power Supply 27
GPC Power Supply 28
GPC Announcement Lamp 29 Announcement Lamp

GPC
A/C on ground Ensures that GPC is only active when A/C is

Signal A/C on ground indication 30 on ground
indication
Glow Enable 31 Glow Enable
GPC Caution Lamp 32 Caution Lamp

GPC
Engine Aircraft
Fig. 92 - 5

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Page: 92-5
Alternator Regulator
E4A – 91-200-000
FIELD / EXCITATION
SUPPLY VOLTAGE
GROUND
OUTPUT
VSENSE
ENABLE
LAMP
Supply Voltage
Bus Voltage
Lamp Alternator
Enable Alternator
CPC connector 2
Pin
Alternator 4
Feather Feather Valve

1 Used in twin engine installations
Valve Switch
Fuel Pump Relay Output A 2 Fuel Pump Relay A
Fuel Pump Relay Output B 3 Fuel Pump Relay B
Pin
Sensor Supply 7 1
Sensor Signal 11 4 Power Lever
Sensor Supply 6
ECU B
8
Sensor Signal 10 3
Sensor GND 9 5
Voter 13 Voter Example voter switch wiring:

ECU A 15 ECU A Voter Switch Default is voter proposal, next position is
ECU B 16 ECU B „ECU A“ then „ECU B“
Signal Input 14

Engine Master 18 ECU B
Engine Synchronisation Signal 19 Synchronisation

Used in twin engine installations
Switch
Engine Synchronisation GND Currently no function
20 (normally open)
Caution Lamp Supply 21 Caution Lamp

Caution Lamp Signal ECU B
22
ECU B Power Supply 23
ECU B Power Supply 28V Power Supply
24 ECU B
26 Spare
ECU B GND Supply 27

ECU B GND Supply 28 GND Power Supply
ECU B GND Supply 29 ECU B
ECU B GND Supply 30
EECU
Engine Aircraft
Fig. 92 - 6

Revision no: 10
Page: 92-6
Regulator
Plane Power R1224
GROUND
ENABLE
FIELD
LAMP
OUT
AUX
IN
Lamp Alternator
Enable Alternator
CPC connector 2
Pin
Alternator 4
Feather Feather Valve

1 Used in twin engine installations
Valve Switch
Fuel Pump Relay Output A 2 Fuel Pump Relay A
Fuel Pump Relay Output B 3 Fuel Pump Relay B
Pin
Sensor Supply 7 1
Sensor Signal 11 4 Power Lever
Sensor Supply 6
ECU B
8
Sensor Signal 10 3
Sensor GND 9 5
Voter 13 Voter Example voter switch wiring:

ECU A 15 ECU A Voter Switch Default is voter proposal, next position is
ECU B 16 ECU B „ECU A“ then „ECU B“
Signal Input 14

Engine Master 18 ECU B
Engine Synchronisation Signal 19 Synchronisation

Used in twin engine installations
Switch
Engine Synchronisation GND Currently no function
20 (normally open)
Caution Lamp Supply 21 Caution Lamp

Caution Lamp Signal ECU B
22
ECU B Power Supply 28V Power Supply
24 ECU B
26 Spare
ECU B GND Supply 27

ECU B GND Supply 28 GND Power Supply
ECU B GND Supply 29 ECU B
ECU B GND Supply 30
EECU
Engine Aircraft
Fig. 92 - 7

Revision no: 10
Page: 92-7
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
ü A/C on the ground
ü Prop speed = idle (<1000rpm)
ü Power lever = idle (<5%) Routine to „cycle the prop“
ü No errors pending
N ü
Release Selftest button active ü Run actuator motor in
Increase propeller State „2"
criteria met ? „high rpm“ direction
speed to 1900 rpm
ü Increase engine speed
Y
State „0" Keep required
torque „frozen“
Cycle the prop using currently activ ECU
(eg. ECU-B) Increase prop
pitch until prop State „3" ü Run actuator motor in
speed drops by „low rpm“ direction
Switch-over to „passiv“ ECU (e.g. ECU-A) about 70 rpm
by simulating the „activ“ ECU (eg. ECU-B)
Abort
to be „hung“ (not responding anymore) Abort self test, Check for v Timeout reached
caution alert on errors v Release criteria not fullfilled
Continue
Abort self test, Y Decrease prop
Time out ?
caution alert on pitch until prop State „4" ü Run actuator motor in
speed increases „high rpm“ direction
N State „0" to about 1870 rpm
Cycle the prop using the previously
passiv ECU (e.g. ECU-A) Abort
Abort self test, Check for v Timeout reached
caution alert on errors v Release criteria not fullfilled
Continue State „6"
Switch-over to the previously „activ“ ECU
(e.g. ECU-B) by simulating the current Cycle count State „5" Decrease engine speed to idle,
ECU (e.g. ECU-A) to be „hung“ (not No reached return control to self test
responding anymore) coordinator
Yes
END State „7"
In case of an abort due to a failure, the current state (“0–7”) of the test is stored as one of the
environmental conditions within the Fault Code Memory (FCM) entry to help diagnosing the abort.
Diagnosing Self Test Failures using the Fault Code Memory:
If the Propeller Self Test does not complete successfully, an entry will be written into the Fault Code
Memory (FCM).
The FCM entries can be displayed by the “AE 300 Wizard” (see “List of Tools”).
For setup and usage of the AE 300 Wizard please refer to the latest revision of the “AE 300 Wizard
User Guide”, document number E4.08.09. The chapter “Using the Fault Code Memory (FCM)” in the
“Trouble Shooting”-Section explains, how to work with the FCM.
The AE 300 Wizard will display an FCM entry caused by a failure during the propeller self test which
contains information sampled at the time of the occurrence similar to the following example:

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Page: 92-8
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 picture “Self Test Overview”)
Timeout error flags = 00000001
Self test release status = 01111111

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Page: 92-9
Trouble Shooting 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.
3. Depending on the information provided by step 2, check:
4a. The “Propeller speed” to see if a speed goal had not been reached.
4b. The “Timeout error flags” to see the reason for a timeout
4c. The “Self test release status” to see if a release condition is not fulfilled anymore.
Layout of Timeout Error Flags:
Bit position 7 6 5 4 3 2 1 0
Timeout error flags shown in FCM: 0 0 0 0 0 x x x
Bits 0, 1 or 2 will be set to “1” to indicate the reason for the self test timeout:
Bit Description of reason

0 “1” = Timeout during pitch-up test “state 3” (expect rpm drop > 70rpm within 8s)
1 “1” = Timeout during pitch-down test “state 4” (expect rpm > 1870 rpm within 3s)
2 “1” = Overall propeller self test timeout (expect overall test completion within 25s)
3-7 Not used
Layout of Self Test Release Status:
Bit position 7 6 5 4 3 2 1 0
Release status as shown in FCM: x x x x x x x x
The Propeller Self Test will start if bit 0 (release self test) has been set to “1”. Bits 2-7 will indicate the
individual release criteria as described in the “Self Test Overview”.
Bit Description of release condition

0 “1” = Overall release to start self test is given
1 “1” = No active error pending
2 “1” = Bits 5 and 6 are set to “1”
3 “1” = The self test switch in the cockpit is actually pressed
4 “1” = Self test switch rising edge detected; “0” = self test switch falling edge detected
5 “1” = Power lever is in low idle position ( < 5%)
6 “1” = If propeller speed was idle ( < 1000rpm) AND squat switch (WoW) is depressed
7 “1” = Current propeller speed is idle ( <1000rpm)
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% !
There is a hysteresis in the detection of propeller idle speed. If the propeller speed increases
beyond 1000rpm, it has to be decreased below 800rpm again before the release criteria of
bits 6 and 7 can be fulfilled again.

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Page: 92-10
Diagnosing Self Test Failures using the Data Logger:
If the FCM entry of a self test failure is not available or if trouble shooting multiple events from past
flight cycles, using the Data Logger function of the EECU is recommended.
The Data Logger information can be downloaded and displayed by the “AE 300 Wizard” (see “List of
Tools”).
For setup and usage of the AE 300 Wizard please refer to the latest revision of the “AE 300 Wizard
User Guide”, document number E4.08.09. The chapter “Offline Analysis using the Data Logger” in the
“Trouble Shooting”-Section explains, how to work with the Data Logger.
The AE 300 Wizard will display the Data Logger record of a successfully performed propeller self test
similar to the following example (e.g. after replacement of a faulty governor shown below).
Engine oil temperature above 50°C
Power lever to idle, propeller speed to idle
Self test starts
State 2: Propeller speed increases beyond 1900rpm

State 3: Propeller speed decreases by at least 70rpm
State 4: Propeller speed increases again beyond 1870rpm.
Switching from ECU-A to ECU-B, perform test on ECU-B

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Page: 92-11
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):
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%”. Also the “Combined Engine Status”
shows an ECU-switchover event between the two “humps”.
Problem 1:
The pitch-up test phases (state 3) and pitch-down (state 4)

are not clearly defined on ECU-A
Problem 2:
During the pitch-down test phase (state 4) the goal of 1870 rpm had not been fulfilled on ECU-B
(actual speed reached was just over 1850 rpm) which eventually had caused a caution lamp
indication.

Revision no: 10
Page: 92-12
Harness Routing
Ensure that wires and cables are routed in such a manner that chafing will not occur against the
engine or other components.
Ensure that wires and cables are routed in such a manner that in no circumstances a contact to
extreme hot engine areas (exhaust pipes) is possible to prevent insulation break down.
Where practical, route electrical wires and cables above fluid lines and provide at least a 50 mm
separation from any flammable liquid fuel line or other low voltage wiring that enters a fuel tank and
requires electrical isolation to prevent an ignition hazard.
Ensure that a trap or drip loop is provided to prevent fluids or condensed moisture from running into
wires and cables dressed downward to a connector, terminal or junction box.
The minimum radius of bends in wire groups or bundles must not be less than 10 times the outside
diameter of the largest wire or cable.
For harness branches of diameters less than 2 cm which connect to a one actuator or one sensor a
different rule applies.
The minimum radius of the wire connecting one sensor or one actuator is 3 times the diameter of the
wire or cable.
Also where the wire is suitable supported, the radius may be 3 times the diameter of the wire or
cable. Where it is not practical to install wiring or cables within the radius requirements, the bend
should be enclosed in insulating tubing.
Ensure that wires and cables that are attached to assemblies where relative movement occurs
(rotating pieces) are installed or protected in such a manner as to prevent deterioration of the wires
and cables caused by the relative movements of the assembled parts.
Ensure that wires and cables are provided with enough slack to meet following requirements:
 Permit ease of maintenance

 Prevent mechanical strain on the wires, cables, junctions and supports
 Permit free movement of shock and vibrations mounted equipment
 Allow shifting of equipment, as necessary, to perform alignment, servicing tuning, removal of
covers and changing of internal components while installed on engine
Ensure that unused wires are individually dead-ended, tied into bundle and secured to a permanent
structure.
Each wire should have conductor strands cut even with the insulation. (no blank conductor strand
accessible).
The end of the wire shall be covered (electrically isolating) with an connector or a 25 mm piece of
insulating tubing placed over the wire with its end folded back and tied.
Wires and cables are properly supported and bound so that there is no interference with other wires,
cables and equipment.
Wires and cables are adequately supported to prevent excessive movement in areas of high vibration.
Insulating tubing and abrasion protection is secured by tying tie straps or with clamps.

Revision no: 14
Page: 92-13
List of Tools
Title: Tool: Remark:
AE 300 Wizard EECU Software Read Out Program For installation and
The user guide E4.08.09 of the AE 300 Wizard will be usage of the
delivered with the program Software refer to
the user guide
E4.08.09
Flywheel Locking Tool For use see
Chapter 85-10-61
Removal of the
Two–Mass-Flywheel
Dismount Tool for After removal of the

Injector clamping shoe
(see Chapter 73-00-
11 Removal of the
Injector point 6)
X the tool has to be
weight Y positioned with the
end “X” of the tool
below the injector
nut.
Then the injector
can be loosened
with a hint of the
“weight” to the
upper end “Y” of the
tool in upward
direction.
Two-Mass-Flywheel AEP-00061
Tester

Revision no: 15
Page: 92-14
Copyright
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.
This text must be included in any full or partial reproduction of this documentation.
Copyright © Austro Engine GmbH

Revision no: 4
Page: Last page

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Maintenance Manual E4.08.

Issue date: 07-05-2009

Date: Wiener Neustadt, 24-10-2014

Author: Austro Engine GmbH

Document number: E4.08.04

Issue date: 24-10-2014

All revisions of this manual must be recorded in chapter “List of Revision“.

Issue date: 24-10-2014

Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur

Issue date: 05-12-2012

Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur

Issue date: 05-12-2012

Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur

Issue date: 28-05-2013

Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur

Issue date: 24-10-2014

List of incorporated Temporary Revisions

Temporary Revision Number Title of Temporary Revision

Injector cover with maintenance lid &

MM-TR-MDC-E4-317 LETRIKA Alternator

Issue date: 24-10-2014

Issue date: 24-10-2014

Issue date: 24-10-2014

Issue date: 24-10-2014

Issue date: 24-10-2014

Issue date: 24-10-2014

MOK Oil Combinant Sensor Temperature

Issue date: 24-10-2014

Conversion Table of Given Torque Values

Newton Meter (Nm) Pound-force inch (lbf in)

Issue date: 24-10-2014

Conversion Table of Given Pressure Values

Pressure Pressure Pressure

Issue date: 24-10-2014

Consumables Material definition Parts applicability

Issue date: 24-10-2014

Issue date: 24-10-2014

05-20-15 Waste Gate Controller ............................................................................................ 7

Issue date: 24-10-2014

24-00-38 Maintenance / Inspection of Carbon Brushes ..........................................................22

Issue date: 24-10-2014

71-50-805 Exchange of Connector for Alternator E4A-91-000-000 ...........................................55

Issue date: 24-10-2014

79-00-01 General ................................................................................................................. 1

Issue date: 24-10-2014

81-00-11 Removal of the Turbo Charger ............................................................................... 1

Issue date: 24-10-2014

85-30-21 Removal of the Boost Pressure Sensor ...................................................................40

Issue date: 24-10-2014

Chapter 01-00-00 General

Issue date: 01-03-2013

01-10-00 General Engine Description

Brand Name: AE 300

The EECU consists of two similar ECUs (Engine control Units).

 This engine is not capable for aerobatics use.

Issue date: 19-01-2012

For detailed specifications see corresponding chapters.

Issue date: 11-08-2011

Engine Front View: