IOF-240-B4B ENGINE CONVERSION. All IOF-240-B4B Engines

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1 SSI--002 REASON FOR ACTION PURPOSE COMPLIANCE MODELS AFFECTED FADEC Software Upgrade. To provide instructions for conversion of all IOF-240-B specification 4B engines to the IOF-240-B specification 5B. To be performed at the next scheduled maintenance visit, not to exceed 100 hours time in service. Conversion must be scheduled with Teledyne Continental Motors Technical Customer Service at ext All IOF-240-B4B Engines Teledyne Continental Motors (TCM) has released the IOF-240-B5B engine to replace the IOF-240-B4B engine in all Liberty Aerospace model XL2 aircraft. Both engine and airframe modifications will be required. All existing aircraft equipped with IOF-240-B4B engine will be converted to the IO- 240-B5B configuration. The engine conversion will be accomplished by installation of Teledyne Continental Motors conversion Kit EQ7494 and Liberty Aerospace field installation kit 135A The engine modification instructions will be found in the Teledyne Continental Motors, Special Service Instruction: SSI-7. To obtain a copy of this bulletin contact TCM Technical Customer Service at CAUTION: Both TCM kit EQ7494 and Liberty Aerospace bulletin SSI--002 must be applied together. WARRANTY: The modifications performed by the installation of EQ7494 will be covered under the TCM warranty policy. Information contained below is for installation of additional wiring to provide power to the Fuel Solenoid Valve Assembly using Liberty field installation kit 135A , replacement of the Electronic Control Units and firewall fuel return bulkhead fitting with a new bulkhead Tee AN8-4. All other items required for replacement are covered by TCM SSI-7 and TCM Instruction Drawing

2 SSI--002 STEPS: 1. Ensure Battery\Alternator master switch is OFF and the Main (70amp) breaker is pulled and secured. Turn OFF fuel shut-off valve. 2. Remove upper and lower engine cowlings. 3. Remove belly panel. 4. Access K003 Fuel Pump Relay. Remove ten (10 qty.) screws that secure instrument panel to panel housing and carefully lean panel out for access. (Note: It is not necessary to completely remove instrument panel in order to remove K003 Relay. Steps 5-7 provide instructions for panel removal if desired.) 5. Disconnect pilot/static lines (purple and green) by removing the black locking ring on each quick disconnect and pushing down on tubing collar. Tube may then be removed. 6. Disconnect the white (two wire) P03 connector, Cannon plugs: P10 and P15, CDI(s) quick disconnect and associated ground wire, P69 (single ground wire T54E22N), and VM1000 display ribbon cable. 7. Instrument panel may now be carefully removed from aircraft. 8. Locate K003 Fuel Pump Relay with connector P66 and remove relay assembly. 9. Install 1Amp (FH) wire assembly as follows: Solder wire E17A20 to K003 Fuel Pump Relay terminal A1 ensuring heat shrink is covering joint upon completion. 10. Reinstall K003 Fuel Pump Relay with connector P66. Route and secure, with MS tiewraps as required every 4 to 6, E17B20 wire through center wire path of instrument console and down to P33 bulkhead connector. 11. Install E17B20 wire into P33 connector socket K. (Removal of a previously installed empty pin may be required first.). Install instrument panel in reverse order. (Note: if pilot/static lines are removed, a pilot/static system leak check is required.) 13. In engine compartment, install J72 connector assembly from Fuel Solenoid Valve to bulkhead connector as follows: Connect J72 to P72 of Fuel Solenoid Valve. Route and secure with MS tie-wraps as required every 4 to 6, E18A20N wire from J72 and attach RT84 ring terminal to engine mount ground lug located fwd of stbd (1,2) ECU. 14. Remove J33 bulkhead connector and install E17C20 wire into J33 connector socket K. (Removal of a previously installed empty pin may be required first.) Reinstall the J33 connector. Secure E17C20 wire with MS tie-wraps as required every 4 to In the cabin, replace fuel pump 7.5 amp circuit breaker with a 10 amp breaker part number 2TC2-10 as follows: Secure aircraft power by placing the master switch in the OFF position. ON the circuit breaker panel, place CB001 BAT 1 in the open position. Open the circuit breaker panel to gain access to the Fuel Boost circuit breaker. 16. From the circuit breaker rear panel loosen Fuel Boost circuit breaker CB029 terminal 2

3 SSI--002 connections followed by removal of the circuit breaker panel retaining nut freeing the circuit breaker from the panel. 17. Install the new 10 amp breaker part number 2TC2-10 in the reverse order of removal. 18. Close the circuit breaker panel in reverse order of opening. 19. Close CB001 BAT Disconnect High Tension Leads and ground straps from both ECU units 21. Remove four (4 qty.) AN4C-24A ECU attachment bolts, and associated NAS1149C-63R washers and NAS43DD4-FC spacers (located between ECU and firewall). 22. Remove MS cable tie, safety wire on 50 pin connectors, and connector from both ECU units and remove units. 23. Install new ECU units in reverse order. (Also reference TCM Instruction Drawing ). Torque 50 Pin ECU Securing Screws 10-15in.lbs and High Tension Lead Nuts to 110-0in.lbs (If required, install new Geltek Sealant Strips and EMI Gaskets). 24. Remove flexible fuel-return line from bulkhead fitting, being careful to catch any fuel that may drain, and install a protective cap on hose end. 25. Access fuel return line B nut on the aft side of bulkhead fitting by removing FASTBLOCK 100 fire caulking and removing B nut being careful to catch any fuel that may drain. Install a protective cap on fuel line. 26. Remove AN924-4 bulkhead fitting nut, MS washer and AN832-4 fitting. Install AN8-4 bulkhead Tee with additional port facing up. Reinstall items removed from steps 4 & 5. Torque fuel line B nuts 150 to 190 inch/pounds. 27. Install S4Y21.50 fuel hose from the upper port of Tee to the solenoid outlet port marked 1. Torque fuel line B nuts 135 to 190 inch/pounds. 28. Perform installation of additional items as covered under TCM Instruction Drawing Turn fuel shut-off valve ON and leak check system at all new connections. After leak check reapply FASTBLOCK 100 fire caulking removed in step 20. Instruction for using the FASTBLOCK 100 are noted below: Using a lint free cloth, remove dirt, grease, and moisture from surface to be sealed or insulated. Apply FASTBLOCK 100. Manipulate within 15 minutes. Dipping tool in isopropyl alcohol will aid in working material. Force-fill gaps for best results. Cure per manufacturers instructions for FASTBLOCK 100 sealant material. Tack-free time is less than 1 hour. While full cure may take up to 72 hours, depending on thickness and ambient conditions, the material will be fireproof within 15 minutes of application. 3

4 SSI Reinstall belly panel and engine cowlings. 31. Perform an engine/system check in accordance with Section 4 of Liberty XL2 AFM latest approved revision. Fuse installation (ground plane harness) J72 / J33 (engine compartment) Recirculation valve assembly, P72 connector detail 4

5 SSI--002 Remove AN832-4 and Install AN8-4 5

6 SSI--002 Remove & and Install &

7 SSI--002 The costs of all compliance actions identified in this Service Document will be covered under the XL-2 warranty to be determined at time of installation. Please complete and return this page by scanned , regular mail, or FAX, indicating that this SSI--002 has been received and all actions have been taken to comply with it. This document shall be returned to Liberty Aerospace. Regular Mail: ATTN: Technical Support Liberty Aerospace 1 Aerospace Drive Melbourne, FL Or FAX: LIBERTY AIRCRAFT SERIAL NUMBER AIRCRAFT TACH HOURS AT TIME OF MODIFICATION MODIFICATION COMPLETION DATE ECU Serial Numbers Removed ECU Serial Numbers Installed Owner/Operator s Name Owner/Operator s Address Telephone Numbers Owner/Operator s Signature 7

8 TELEDYNE CONTINENTAL AIRCRAFT ENGINE SPECIAL SERVICE INSTRUCTION Compliance Will Enhance Safety : Category 6 SSI-7 Technical Portions FAA Approved PURPOSE: To provide instructions for conversion of all IOF-240-B specification 4B engines to the IOF-240-B specification 5B. COMPLIANCE: To be performed at the next scheduled maintenance visit, not to exceed 100 hours time in service. Conversion must be scheduled with TCM Technical Customer Service at ext MODELS AFFECTED: All IOF-240-B4B Engines Teledyne Continental Motors has released the IOF-240-B5B engine to replace the IOF-240-B4B engine in all Liberty Aerospace model XL2 aircraft. Both engine and airframe modifications will be required. All existing aircraft equipped with the IOF-240-B4B engine will be converted to the IO- 240-B5B configuration. The engine conversion will be accomplished by installation of Teledyne Continental Motors conversion kit EQ7494.The instruction drawing for the engine modifications will be found in the EQ kit. This kit contains the following: PART NUMBER QTY DESCRIPTION PART NUMBER QTY DESCRIPTION Electronic Control Unit Cylinders 1& Support Assembly, Inter Cylinder Electronic Control Unit Cylinders 2&4 MS Screw Machine, Fillister Head Ftg. assy.-90deg Ell Orifice MS Washer lock Spring # Valve Assy.- Solenoid Fitting Gasket, EMI, 50 Pin Connector S4S Hose Assy Gasket, EMI, 25 Pin Connector AN8-4 1 Tee, Bulkhead Geltek Sealant Strip A5 1 Fuel Filter Assy., Bypass Geltek Sealant Strip Instruction Drawing The airframe modification instructions will be found in the Liberty Aerospace Bulletin SSI To obtain a copy of this bulletin contact Liberty Aerospace at or by at laitechsupport@libertyaircraft.com. CAUTION: Both the TCM kit EQ7494 and the Liberty Aerospace bulletin SSI must go into effect together. WARRANTY: The modifications performed by the installation of EQ7494 will be covered under the applicable TCM warranty policy. ISSUED REVISED PAGE NO REVISION MO DAY YEAR MO DAY YEAR Teledyne Continental M otors, Inc. 1 of P.O. BOX 90 MOBILE, AL TELEDYNE TECHNOLOGIES, INC. TM SSI-7