Illustrated Parts Catalogue
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- Mervyn Hutchinson
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1 Illustrated Parts Catalogue UL35OiHPS AERO ENGINE M020: IPC 350iHPSA0 Revision No : Date:
2
3 Please fill in your engine and aircraft details for further reference: Engine Serial No. :... Aircraft type :... Model :... Serial No. :... Registration :... Introduction Remarks The illustrations in this Illustrated Parts Catalogue show the typical construction. They may not represent in full detail or the exact shape of the parts which have the same or similar function. Modifications All efforts are made to ensure the accuracy of this Illustrated Parts Catalogue at the time of publication. ULPower, however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured. ULPower reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. Engine serial number On all enquiries or spare parts orders, always indicate the engine serial number, as the manufacturer makes modifications to the engine for further development. The engine serial number is located at the front left side of the crankcase (above oil filter). Structure Each section of this Illustrated Parts Catalogue starts with an exploded view or assembly drawing on the left side. The corresponding heading and the listing of the parts is on the right side and the following pages. For each assembly drawing the right number of parts is listed in the relevant column. Because an engine can contain multiple times the illustrated assembly or a part can be used in several different applications, the total number of parts per engine is also given. Generally all fasteners are tightened with a torque wrench. The "Notes" column indicates the appropriate torque or refers to extra information at the end of the section. IPC 350iHPSA0 Revision No : Date: Page of 40
4 Blank IPC 350iHPSA0 Revision No : Date: Page 2 of 40
5 Table of Contents Inhoud Introduction... Remarks... Modifications... Engine serial number... Structure... Table of Contents... 3 Cylinder Head and Cylinder... 5 Crankcase, Oil Sump and Dipstick... 7 Oil Pump Assembly: BE Camshaft and Valve Train... Crankshaft, Conrod and Piston... 3 Inlet Manifold, Injectors and Throttle (Single ECU)... 5 Inlet Manifold, Injectors and Throttle (Double ECU)... 9 Fuel lines Engine Mount Plate, Starter and Alternator Exhaust System Breather and Oil/Air Separator Oil Thermostat : E Ignition and Engine Control Unit Airbox Forced Accessories Section of drawings Revision IPC 350iHPSA0 Revision No : Date: Page 3 of 40
6 IPC 350iHPSA0 Revision No : Date: Page 4 of 40
7 Cylinder Head and Cylinder Item Part No. Description Parts in assembly Note Cylinder Head Assembly BE0252 Cylinder Head Right 0 BE0253 Cylinder Head Left E03500 Valve Guide 2 E03450 Exhaust Valve Seat E Inlet Valve Seat 2 E Spark Plug 2 2 Nm (5) 3 E02504 Cylinder Head Washer 6 4 F Socket Cap Screw M8xx Steel 6 36 Nm () 5 S00605 O-Ring Viton 6x.5 6 E02505 Cylinder Head Plug 7 E02503 Locking plate M4 bolt 8 F Hexagon head screw M4x6-8.8 Steel - Zinc Plated.5 Nm 9 S00020 O-Ring Viton 00x2 0 E02506 Valve Cover F00506 Socket Cap Screw M5x6-8.8 Steel - Yellow Passivated 3 6 Nm 2 S30820 Copper Sealing Ring ø8x2x 2 3 BE04505 Cylinder Head Oil Line Left Assembly BE04506 Cylinder Head Oil Line Right Assembly 0 4 F Banjo Bolt M8x 8 Nm 5 E0300 Cylinder Gasket (3) 6 BE02004 Cylinder (4) 7 E0003 Flanged Nut M0x 4 36 Nm 8 S05020 O-Ring Viton 05x2 9 E025 Cylinder Head Oil Filter 20 E02530 Bracket oil line 2 F20050 Nordlock washer M5 3 () Apply high temperature resistant grease (Loctite 37605) (2) Apply Loctite 266 (Loctite 26773) (3) Replace when removed (4) Quick Gasket (Loctite 590) (Between cylinder and engine casing) (5) Wacker P2 IPC 350iHPSA0 Revision No : Date: Page 5 of 40
8 () Apply Sealing Silicone - Elring No (2) Apply Loctite 266 (Loctite 26773) (3) Apply Engine oil (4) Apply Loctite 542 (5) Quick gasket (Loctite 590) (Outer dia Seal) IPC 350iHPSA0 Revision No : Date: Page 6 of 40
9 Crankcase, Oil Sump and Dipstick Item Part No. Description Parts in assembly Note BE00502 Crankcase Left () 2 S Oil Seal Viton 60x75x0 GR (5) 3 BE00509 Thrust Bearing Mount () 4 F Socket Cap Screw - M6x Steel - Yellow Passivated 8 0 Nm 5 E00508 Engine Model Number Plate 6 F Button Head Socket Cap Screw - M3x8-0.9 Steel - Zinc Plated 2.5 Nm 7 S3275 Copper Sealing Ring ø2x7x F46225 Hexagon Socket Screw Plug - M2x Nm (2) 9 E Oil Filter Screw M20x.5 0 E04200 Oil Filter 5 Nm (3) E0850 Oil Temperature Sensor 20 Nm 2 S005 O-Ring Viton øx F2530 Banjo Eye M0/-3AN 20 4 S3045 Copper Sealing Ring ø0x4x F Banjo Bolt M0x L = Nm 6 F Stainless Braided TFE Hose -3AN 7 E0452 Oil Pressure Sensor Adaptor 8 S0020 O-Ring Viton øx2 7 (3) 9 E0002 Stud Short 4 20 E000 Stud Long 6 2 BE0050 Crankcase Right 22 F Socket Cap Screw - M6x Steel - Zinc Plated 4 0 Nm 23 E Dipstick Tube (4) 24 E Dipstick 25 S0800 O-Ring Viton ø8x 26 BE04450 Oil Pickup Tube with Filter 27 F20050 NordLock Washer M F00506 Socket Cap Screw - M5x6-8.8 Steel - Yellow Passivated 2 6 Nm 29 E04002 Oil Sump () 30 F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 5 0 Nm 3 F Stud - M6x20 Yellow Passivated 0 Nm 32 F Hex Nut M6 Zinc Plated 0 Nm 33 F Nylon Cable Tie 34 F All Metal Prevailing Torque Hex Nut - M6 - Zinc Plated 35 S3485 Copper Sealing Ring ø4x8x.5 36 E04020 Carter plug magnet 25 Nm 37 E04350 Oil breather tube 38 S36205 Copper sealing ring ø6x20x F25265 Banjo bolt M6x.5 25Nm 40 E0435 Oil return tube sump 4 E0405 Plug 5/8-8UNF 42 F25200 Banjo bolt M0 x 0 Nm 43 F00606 Socket cap screw M6x6 8.8 Steel - Yellow Passivated 0 Nm 44 F20060 Nordlock Washer M6 IPC 350iHPSA0 Revision No : Date: Page 7 of 40
10 IPC 350iHPSA0 Revision No : Date: Page 8 of 40
11 Oil Pump Assembly: BE04055 Item Part No. Description Parts in assembly Note BE04050 Oil Pump Housing () 2 BE04054 Oil Pump Rotor Set 3 E Oil Pump Cover 4 F00506 Socket Cap Screw - M5x6-8.8 Steel - Yellow Passivated 4 6 Nm 5 F Socket Cap Screw M6x Steel - Yellow Passivated 4 0 Nm 6 S3275 Copper Sealing Ring ø2x7x.5 7 F46225 Hexagon Socket Screw Plug - M2x.5 25 Nm 8 BE04053 Oil Pump Shaft 9 F Parallel Key 4x4x20 0 S O-Ring Viton ø30x2 S O-Ring Viton ø24x2 2 S0020 O-Ring Viton øx2 2 3 BE04056 Plunjer oil pump B25 4 E Pressure Relief Spring 5 S36205 Copper Sealing Ring ø6x20x.5 6 F46265 Hexagon Socket Screw Plug - M6x.5 25 Nm 7 S O-ring Viton 70x2 8 S03020 O-ring Viton 3x2 () Apply sealing silicone Elring No IPC 350iHPSA0 Revision No : Date: Page 9 of 40
12 IPC 350iHPSA0 Revision No : Date: Page 0 of 40
13 Camshaft and Valve Train Item Part No. Description Parts in assembly Note E camshaft 0 3.5HPS 2 E0300 Camshaft Gear 3 F Socket Cap Screw - M6x0-2.9 Steel 4 8 Nm () 4 E0350 Cam Follower 2 5 BE0450 Oil Return Tube 2 6 S07020 O-Ring Viton ø7x2 4 (3) 7 BE Push Rod 2 8 E Tappet Adjusting Screw 2 9 F2306 Shim Ring 0.5mm - ø0x6 4 0 E Rocker Tappet Right E0003 Flanged Nut M0x 2 20 Nm 2 F Socket Cap Screw - M6x6-2.9 Steel 3 2 Nm 3 E Rocker Shaft 4 E Rocker Tappet Left 5 E Collet Valve Spring Lock 4 6 E Valve Spring Retainer Top 2 7 E03350 Valve Spring 2 8 E03550 Valve Stem Seal 2 9 E03400 Valve Spring Retainer Bottom 2 20 E Inlet Valve 2 E03300 Exhaust Valve () Apply Loctite 266 (Loctite 26773) (3) Apply engine oil IPC 350iHPSA0 Revision No : Date: Page of 40
14 IPC 350iHPSA0 Revision No : Date: Page 2 of 40
15 Crankshaft, Conrod and Piston Item Part No. Description Parts in assembly Note BE Crankshaft 2 3 BE Crankshaft Bearing Set ( contains piece 2, 3 ) Crankshaft Bearing Half Crankshaft Bearing Half 4 E02200 Thrust Bearing 5 E02502 Thrust Bearing Disc Spring 2 6 S O-Ring Viton ø50x.78 7 E02504 Thrust Bearing Retention Ring 8 E gearbox flange) 9 E02300 Prop Flange Bolt 300Nm (5) 0 E02250 Locking propellor flange bolt BE02005 Parallel Key b=6/hps 2 E0200 Crankshaft Gear 3 BE Connecting Rod Assembly 4 E Connecting rod bearing set (2) 4 F Socket Cap Screw - M8xx Steel 8 36 Nm (2+3) 4 E Piston -7cc ( is engines) 5 E02506 Thrust Bearing Disc 6 E0255 Thrust Bearing Retention Ring Outer 7 E0250 Thrust Bearing Disc Spring Outer 2 8 E02050 Oil Stop M36x2 (4) 9 E0205 Oil Stop M24x,5L (4) 20 E02400 Piston ring set 4 (2) Loctite 266 (Loctite 26773) (3) Replace when removed (4) Apply Loctite 542 (5) Apply grease 5 IPC 350iHPSA0 Revision No : Date: Page 3 of 40
16 IPC 350iHPSA0 Revision No : Date: Page 4 of 40
17 Inlet Manifold, Injectors and Throttle (Single ECU) Item Part No. Description BE0650 Inlet Collector HPS 2 E06503 Injector Holder 3 E06250 Injector 4 (3) 4 S3275 Copper Sealing Ring ø2x7x.5 5 E08504 Air Temperature Sensor 20 Nm 6 F Hose Clamp single use ø E065 Rubber Hose 38x3x E06509 Inlet Tube Right 2 () 9 E06507 Injector + Fuel Pressure Regulator Holder 0 E0652 Injector Holder Lock Plate 2 F00506 Hex Head Screw - M5x6-8.8 Steel - Yellow Passivated 4 6 Nm 2 E06450 Fuel Pressure Regulator - 3bar (3) 3 F Retaining Ring - bore 36mm 4 E06508 Inlet Tube Left 2 () 5 F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 8 0 Nm (2) 6 E Fuel Pressure Regulator Hose (ø4.5x9.5 x 6cm) 7 S30820 Copper Sealing Ring ø8x2x 2 8 F Banjo Eye M8/Ø5 9 F Banjo Bolt M8x 6 Nm SUSE F00402 E08506 SE F SE B E0605 F E E E SE E SE0653 F SE SE Throttle assy 6cyl (contains piece 20-34) Socket cap screw M4x2 Yellow passivated Hall sensor + magnet Throttle Shaft Socket Cap Screw - M4x8-8.8 Steel - Yellow Passivated Throttle Lever Stop Flanged Bushing 8x0x5.5 Throttle Lever Spring Button Head Socket Cap Screw - M3x8-0.9 Steel - Zinc Plated Throttle lever outer plate hall sensor Throttle lever middle plate hall sensor Throttle lever inner plate hall sensor Throttle plate D45 Throttle bushing hall sensor Locking plate throttle shaft Prevailing torque type hexagon nut thin M6 Zinc plated Throttle connection Throttle housing D45 hall sensor 35 F Socket Cap Screw - M5x Steel - Yellow Passivated 4 6 Nm 36 SE Air Filter D60 straight 37 S O Ring Viton 36 x F Hose clamp single use ø 63, E0250 Baffle right 40 E02509 Baffle left 4 S03500 O Ring 35 x 4 42 BE655 Inlet extension tube 4 Parts in assembly Note 2 Nm 3Nm IPC 350iHPSA0 Revision No : Date: Page 5 of 40
18 Item Part No. Description 43 E0257 Protection hose Fp-regulator 44 F Hose clamp single use Ø SE Inlet hose D60-L SE Inlet tube D60 x 47 F20060 Nordlock washer M6 8 Parts in assembly Note () Apply Sealing Silicone - Elring No (2) Loctite 266 (Loctite 26773) (3) Apply engine oil IPC 350iHPSA0 Revision No : Date: Page 6 of 40
19 IPC 350iHPSA0 Revision No : Date: Page 7 of 40
20 IPC 350iHPSA0 Revision No : Date: Page 8 of 40
21 Inlet Manifold, Injectors and Throttle (Double ECU) Item Part No. Description BE0650 Inlet Collector HPS 2 E06503 Injector Holder 3 E06250 Injector 4 (3) 4 S3275 Copper Sealing Ring ø2x7x E08504 Air Temperature Sensor 2 20 Nm 6 F Hose Clamp single use ø E065 Rubber Hose 38x3x E06509 Inlet Tube Right 2 () 9 E06507 Injector + Fuel Pressure Regulator Holder 0 E0652 Injector Holder Lock Plate 2 F00506 Hex Head Screw - M5x6-8.8 Steel - Yellow Passivated 4 6 Nm 2 E06450 Fuel Pressure Regulator - 3bar (3) 3 F Retaining Ring - bore 36mm 4 E06508 Inlet Tube Left 2 () 5 F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 8 0 Nm (2) 6 E Fuel Pressure Regulator Hose (ø4.5x9.5 x 6cm) 7 S30820 Copper Sealing Ring ø8x2x 2 8 F Banjo Eye M8/Ø5 9 F Banjo Bolt M8x 6 Nm SUSE F00402 E08506 SE F SE B E0605 F E E E SE E SE0653 F SE SE Throttle assy 6cyl (contains piece 20-34) Socket cap screw M4x2 Yellow passivated Hall sensor + magnet Throttle Shaft Socket Cap Screw - M4x8-8.8 Steel - Yellow Passivated Throttle Lever Stop Flanged Bushing 8x0x5.5 Throttle Lever Spring Button Head Socket Cap Screw - M3x8-0.9 Steel - Zinc Plated Throttle lever outer plate hall sensor Throttle lever middle plate hall sensor Throttle lever inner plate hall sensor Throttle plate D45 Throttle bushing hall sensor Locking plate throttle shaft Prevailing torque type hexagon nut thin M6 Zinc plated Throttle connection Throttle housing D45 hall sensor 35 F Socket Cap Screw - M5x Steel - Yellow Passivated 4 6 Nm 36 SE Air Filter D60 straight 37 S O Ring Viton 36 x F Hose clamp single use ø 63, E0250 Baffle right 40 E02509 Baffle left 4 S03500 O Ring 35 x 4 42 BE655 Inlet extension tube 4 Parts in assembly Note 2 Nm 3Nm IPC 350iHPSA0 Revision No : Date: Page 9 of 40
22 Item Part No. Description 43 E0257 Protection hose Fp-regulator 44 F Hose clamp single use Ø SE Inlet hose D60-L SE Inlet tube D60 x 47 F20060 Nordlock washer M6 8 Parts in assembly Note () Apply Sealing Silicone - Elring No (2) Loctite 266 (Loctite 26773) (3) Apply engine oil IPC 350iHPSA0 Revision No : Date: Page 20 of 40
23 IPC 350iHPSA0 Revision No : Date: Page 2 of 40
24 IPC 350iHPSA0 Revision No : Date: Page 22 of 40
25 Fuel lines Item Part No. Description Parts in assembly Note E06302 Fuel line cross short 2 F25032 Banjo Eye M2 / 6JIC 3 E06305 Fuel return line F25220 Banjo bolt M2x.5 Long 5 F Banjo bolt M2x S3275 Copper sealing ring d2xd7x.5 7 IPC 350iHPSA0 Revision No : Date: Page 23 of 40
26 IPC 350iHPSA0 Revision No : Date: Page 24 of 40
27 Engine Mount Plate, Starter and Alternator Item Part No. Description Parts in assembly Note E03506 Engine Mount Plate () 2 F80300 Parallel Pin 3x0 2 3 E04002 Rubber Engine Mount (50/55 Shore) 8 4 F Parallel Pin 4x E07200 Locking plate hall sensor 6 E05050 Starter Engine 7 E Starter Cap 8 F Socket Cap Screw - M4x Steel - Zinc Plated 3 Nm 9 B20000 Bushing 2x4x0 0 F Socket Cap Screw - M5x Steel - Yellow Passivated 3 6 Nm F Socket Cap Screw - M8x Steel - Yellow Passivated 8 25 Nm 2 F Stud - M6x20 - Yellow Passivated 2 (2) 3 E08503 Hall Sensor 2 (4) 4 F Prevailing torque type hexagon nut - M6 Zinc plated 4 5 F Socket Cap Screw - M6x Steel - Yellow Passivated 2 0 Nm 6 S Oil Seal Viton 50x62x7 GR 7 S O-Ring Viton ø66x2 8 E05505 Alternator Stator Spacer () 9 F Socket cap screw thin - M6x6-8.8 Steel Zinc plated 3 0 Nm 20 E05200 Alternator Stator 2 F Hexagon head screw - M6x Steel Zinc plated 3 0 Nm SUBE F E05502 E E05260 Alternator rotor flange assembly HPS (Contains piece 22, 23, 24, 25) Hexagon Socket Set Screw (Flat Point) - M4 Alternator Magnet Spacer Ring Alternator Magnet Alternator Rotor Flange Forced air 26 E0500 Starter Ring Gear 27 E02302 alternator bolt washer/3.5hps 28 E02300 Alternator rotor flange bolt long 280 Nm (3) 29 E Alternator fan base E30500 F F80300 F80005 E3050 Fan forced cooling Socket Cap Screw - M6x Steel Zn Parallel pin 3x0 Parallel pin x5 Cover fan forced cooling 35 E03505 Engine Mount Washer 4 () Apply Sealing Silicone - Elring No (2) Apply Loctite 270 (3) Apply Loctite 266 (Loctite 26773) (4) Apply engine oil IPC 350iHPSA0 Revision No : Date: Page 25 of 40
28 IPC 350iHPSA0 Revision No : Date: Page 26 of 40
29 Exhaust System Item Part No. Description Parts in assembly Note BE09020 Stainless Steel Exhaust Tubes (set) 2 F20060 NordLock Washer M6 6 3 F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 6 0 Nm () 4 E09300 Exhaust Spring 4 5 BE in collector 3.5 Ø40 recht 6 E09200 Exhaust gasket ring d32xd38x F25800 hose clamp ø44-ø56 b=9 2 8 BE09300 Bracket 3.5iHPS 4in collector 2 () Apply high temperature resistant grease IPC 350iHPSA0 Revision No : Date: Page 27 of 40
30 IPC 350iHPSA0 Revision No : Date: Page 28 of 40
31 Breather and Oil/Air Separator Item Part No. Description Parts in assembly Note F Cloth Braided Hose ø2x7 2 F Rubber Hose Ø6x3.5 (25 C) E E E F F E Oil/Air separator assembly (Contains piece 3,4,5,6) Oil/Air Separator Elbow connection oil return (assembly) Hose clamp Ø20 Hose clamp Ø4.5 Reduction oil / air separator Ø5 4 IPC 350iHPSA0 Revision No : Date: Page 29 of 40
32 IPC 350iHPSA0 Revision No : Date: Page 30 of 40
33 Oil Thermostat : E04255 Item Part No. Description Parts in assembly Note E42520 Plug M22x,5 2 S Copper sealing 22x27x,5 () 3 F20000 Spring Ø 9,5 x,5; pitch=4; L=5 4 F Spring Ø 5 x,5; pitch=9; L=47 5 E Spring Holder 6 E04250 Bimetal 7 E Bimetal Cover 8 SE04250 Thermostat housing 9 F Socket Cap Screw - M6x Steel 0 S O-Ring Viton Ø 62x5 E Oil filter adapter screw M20 x.5 30Nm () Replace when removed IPC 350iHPSA0 Revision No : Date: Page 3 of 40
34 IPC 350iHPSA0 Revision No : Date: Page 32 of 40
35 Ignition and Engine Control Unit Item Part No. Description Parts in assembly Note E0700 Ignition Coil 2 E0750 Ignition Coil Cover 3 E07505 Copper Clamp (for Ignition Coil Cover) 4 E07503 Ignition Lead Cable 5 E07504 Spark Plug Cover 6 E E E E Engine Control Unit 3.5i Engine Control Unit 3.5iS Engine Control Unit 3.5iF Engine Control Unit 3.5iHPS 7 E07002 Ignition coil bracket 8 E08002 E SE08003 SE08005 ECU Wiring loom engine L = 000 (Single ECU) ECU Wiring loom engine (Double ECU) ECU Wiring loom cockpit (4 + 6 cylinder) L =000 (Single ECU) ECU Wiring loom cockpit (4 + 6 cylinder) L =000 (Double ECU) 0 F26455 Silent bloc M4 type B hoogte 5 4 F Socket Cap screw M4x30-8,8 Steel Yellow Passivated 4 4Nm 2 F Prevailing hexagon nut M4 4 4Nm IPC 350iHPSA0 Revision No : Date: Page 33 of 40
36 IPC 350iHPSA0 Revision No : Date: Page 34 of 40
37 Airbox Forced Item Part No. Description Parts in assembly Note BE0252 Ram airbox forced cooling right 2 BE02520 Ram airbox forced cooling left 3 BE02524 Bracket connection to airbox right 4 BE02523 Bracket connection to airbox left 5 BE02527 Cover for BE BE02526 Cover for BE S85070 Seal strip 5.x7,3 2,7meter 8 F Hex socket button head cap screw M4x8 0.9Zn 2 9 F Prevailing hex-nut all metal M4 2 0 F Socket cap screw M6x0 8.8Zn 0 E0503 Ignition cable grommet 2 2 F Socket cap screw M4x0 8,8 Zn 4 3 F Prevailing hexagon nut M4 4 4 E3005 Cowling mount spacer 4 5 E300 Cowling threated rod 4 6 F Prevailing hexagon nut all metal M8 8 7 BE02525 Flange for devide airbox 2 8 F Prevailing hex-nut all metal M6 6 9 E02522 Devide airbox forced 20 E03002 E03005 E0300 Cilinder baffle forced cooling Air guide flap plate Air guide flap plate forced 2 E03025 Steel Cable IPC 350iHPSA0 Revision No : Date: Page 35 of 40
38 IPC 350iHPSA0 Revision No : Date: Page 36 of 40
39 Accessories Item Part No. Description Parts in assembly Note E Alternator Stator Connector & Pins 2 E05300 Rectifier / Regulator 3 E Rectifier / Regulator Connector & Pins 4 E Fuel Filter (Pre-filter) 5 E Fuel Pump 6 E06400 Fuel Filter (Fine) IPC 350iHPSA0 Revision No : Date: Page 37 of 40
40 Section of drawings IPC 350iHPSA0 Revision No : Date: Page 38 of 40
41 Revision Revision ( ) Pg : nr 2: E03025 (Steel Cable) IPC 350iHPSA0 Revision No : Date: Page 39 of 40
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