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Date:  8-17-2016
Number of Hours:  3.30
Manual Reference:  46-xx
Brief Description:  Reassemble Top of Engine

Page 46-07
Removed tape and temporarily installed hose/expansion tank assembly. Marked cooling shroud where hoses touch shroud. Removed shroud and blobbed on high temperature red RTV, then re-installed hose/expansion tank assembly. Installed allen screws and torqued to 90 inch-pounds per IPC. (steps 3 and 4).
PAGE 46-07 IS COMPLETE

Page 46-08
Masked off and applied high temperature red RTV to seal fire sleeve of VA-216 fuel return assembly. (step 1) Set aside to cure.
Repositioned forward ignition bracket and installed allen screw with Loctite 243. KAI says Loctite 221 but it is hard to find and all of Rotax documentation now uses 243 so I'm going with Rotax documentation. Torqued to 18 foot-pounds per the IPC. (step 2)
Folded manifolds, ignition modules, and attached components back into proper position, installed allen screws in manifolds, and torqued to 90 inch-pounds per IPC. (step 3)
Loosely installed small ignition harness clamp. Also connected spark plug leads. (step4)
Trimmed drip tray and dip tray stiffeners. Clecoed and match drilled holes. Machine countersunk single hole on left side of each tray and set rivet (flush on both sides). Riveted stiffeners to dip trays. Scuffed dip trays and doublers with Scotch Brite pads, then applied fuel tank sealant to doublers and positioned on dip tray and secured with wood blocks and clamps. Used 5/16 drill bit shanks to allign holes before clamping. Sealed four corners of each tray with fuel tank sealant. (steps 5 through 11). Set dip tray assemblies aside for sealant to cure.
PAGE 46-08 IS COMPLETE

Page 46-09
Removed both banjo bolts and copper washers from clamp block. Removed hose nipple and stored. Loosened allen screw and rotated clamp block so main port is on forward side of block. Reinstalled lower hoses, copper washers, and banjo bolt in bottom port of clamp block. Torqued banjo bolt to 90 inch-pounds. Torqued clamp block allen screw to 55 inch-pounds per IPC. Removed jet from upper banjo bolt and loosely reinstalled upper
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Manifolds, Ignition, Etc., Reinstalled

Manifolds, Ignition, Etc., Reinstalled

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Drip Tray Assemblies

Drip Tray Assemblies

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Clamp Block Reconfigured

Clamp Block Reconfigured

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