COLLECTOR 1. DESCRIPTION This section describes the portion of the exhaust system which collects the exhaust gases from the cylinder and conducts them overboard. Included are the exhaust headers and collector weldments that combine to form the exhaust header assemblies. Each of the six headers are connected to the engine by nuts on the engine exhaust studs. Gaskets seal the header to each cylinder. Serials 22-0002 thru 22-019: The three headers on each side of the engine are connected to a Y-pipe collector weldment through a slip joint and a spring loaded bolt to allow for contraction and expansion as well as engine movement. This Y-pipe collector combines the header pipes on each side of the engine into 1 pipe (per side) which is then combined into a single pipe carrying all six cylinder's exhaust gases forward. A slip joint connects the Y-pipe collector to the mid-pipe which takes the exhaust gas across to the RH side of the engine and then aft to the heat exchanger. Ball joints and slip joints are employed to allow movement due to heat expansion and normal operating loads. Serials 22-020 & subs: The three headers on each side of the engine are connected to a collector weldment to form the exhaust header assembly. This collector weldment combines the header pipes on each side of the engine into 1 pipe (per side). Exhaust gases are ported aft from the collector weldment to the heat exchanger on the RH side and the muffler on the LH side. Ball joints and slip joints are employed to allow movement due to heat expansion and normal operating loads. Serials 22T-0001 & subs: Each engine cylinder is equipped with an exhaust header. The three headers (elbow riser, tee, and turbocharger transition) on each side of the engine are connected by slip joints to form the exhaust header assembly. Each exhaust header assembly is connected to a turbocharger. A crossover pipe with heat exchanger connects the LH and RH exhaust header assemblies. The wastegate transition, installed between the LH turbocharger transition and crossover, connects the exhaust header assemblies to the wastegate. A tie rod with a slotted hole and bushing is installed between the RH turbocharger transition and crossover to allow for expansion of the exhaust system. All Page 1 1 Jun 2010
2. MAINTENANCE PRACTICES A. Exhaust Header Assembly - Serials 22-0002 thru 22-019 (See Figure 1) (1) Removal - Exhaust Header Assembly (a) Remove engine cowling. (Refer to 1-10) (b) Remove tailpipe. (Refer to 8-20) (c) Remove heat exchanger. (Refer to 8-20) (d) Remove cotter pin, nut, spring, and bolt securing mid-pipe to Y-pipe collector and remove mid-pipe. (e) Remove cotter pin, nut, spring, and bolt securing LH headers to Y-pipe collector. (f) Remove EGT probe from #4 header pipe. (Refer to -20) (g) Remove nuts attaching exhaust headers to engine cylinders. Note: Individual headers can be removed from the Y-pipe collector at the slip joint. (h) Remove exhaust headers from airplane. (i) Remove old gaskets from cylinders. (2) Installation - Exhaust Header Assembly (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Exhaust Header Gasket 4942 TCM Seal. Permatex 124 - Any Source Antiseize lubricant. Emery Cloth - Any Source Polishing. (b) Install new exhaust gaskets on cylinder port studs. CAUTION: Ensure that no pre-load exists on the headers when assembled to the collector and to the cylinders. Misalignment during installation may result in a cracked forward header assembly. (c) (d) Position headers to cylinder head studs. Install nuts to finger tight. Assemble RH headers to Y-pipe collector. Note: Slight adjustment of nut for cotter pin installation is allowable. (e) Polish both sides of slip joint with emery cloth to ensure surface is smooth and free of burrs. CAUTION: Do not use any antiseize compound containing graphite. (f) (g) (h) Apply a thin coat of antiseize lubricant to polished slip joint surfaces. Assemble LH headers to Y-pipe collector and install bolt, spring, and nut. Tighten nut until snug, then turn two additional revolutions to compress spring. Install cotter pin. Torque header nuts to 100-110 in-lb (11. - 12.4 Nm). Note: Slight adjustment of nut for cotter pin installation is allowable. Page 2 (i) Position mid-pipe to Y-pipe collector and install bolt, spring, and nut. Tighten nut until snug, then turn two additional revolutions to compress spring. Install cotter pin. Serials 22-0002 thru 22-019
(j) Install heat exchanger. (Refer to 8-20) (k) Install tailpipe. (Refer to 8-20) (l) Install EGT probe to #4 header pipe. (Refer to -20) (m) Install engine cowling. (Refer to 1-10) Serials 22-0002 thru 22-019 Page
B. Exhaust Header Assembly - Serials 22-020 & subs (See Figure 1) (1) Removal - Exhaust Header Assembly Note: Individual exhaust headers can be removed from the assembly by removing the nuts attaching header to engine cylinder and twisting the header from the collector. The No. 1 header on the RH side and No. 4 header on the LH side are also secured to the collector through a slip joint and spring loaded bolt. (a) Remove engine cowling. (Refer to 1-10) (b) Remove tailpipe. (Refer to 8-20) (c) Remove heat exchanger or muffler. (Refer to 8-20) (d) Remove EGT probes from exhaust headers. (Refer to -20) (e) Remove nuts attaching exhaust headers to engine cylinders. (f) Remove exhaust header assembly from airplane. (g) Remove old gaskets from cylinders. (2) Installation - Exhaust Header Assembly Note: Assemble any individual headers to header collector if removed. If No. 1 or No. 4 header was removed, install bolt, washers, spring, and nut securing header to collector. Tighten nut until snug, then turn two additional revolutions to compress spring. Install cotter pin. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Exhaust Header Gasket 4942 TCM Seal. Permatex 124 - Any Source Antiseize lubricant. Emery Cloth - Any Source Polishing. (b) Polish both sides of ball and slip joint with emery cloth to ensure surface is smooth and free of burrs. CAUTION: Do not use any antiseize compound containing graphite. (c) (d) Apply a thin coat of antiseize lubricant to polished ball and slip joint surfaces. Install new exhaust gaskets on cylinder port studs. CAUTION: Ensure that no pre-load exists on the headers when assembled to the collector and to the cylinders. Misalignment during installation may result in a cracked forward header assembly. Page 4 (e) Position exhaust header assembly on cylinder port studs. (f) Install and torque nuts to 100-110 in-lb (11. - 12.4 Nm). (g) Install EGT probes to exhaust headers. (Refer to -20) (h) Install heat exchanger or muffler. (Refer to 8-20) (i) Install tailpipe. (Refer to 8-20) (j) Set BAT 1 switch to ON position. (k) Start engine in accordance with Pilot s Operating Handbook procedures. (l) Allow continuous engine run-time with engine at operating temperature. Serials 22-020 & subs
(m) Shutdown engine in accordance with Pilot s Operating Handbook procedures. (n) Allow engine to cool for 0 minutes. (o) Set BAT 1 switch to OFF position. (p) Re-torque nuts to 100-110 in-lb (11. - 12.4 Nm). (q) Install engine cowling. (Refer to 1-10) Serials 22-020 & subs Page
2 1 4 1 8 9 8 9 -A- -A- HEAT EXCHANGER NOTE Polish both sides of slip joint with emery cloth to ensure surface is smooth and free of burrs. Apply a thin coat of antiseize lubricant to polished slip joint surfaces. TAILPIPE Serials 22-0002 thru 22-019. LEGEND 1. Exhaust Headers 2. Gasket. Nut 4. Y-Pipe Collector. Mid-Pipe. Cotter Pin. Washer 8. Spring 9. Bolt SR22_MM8_18A Page Figure 1 Exhaust Header Assembly - Serials 22-0002 thru 22-019 (Sheet 1 of 2) Serials 22-0002 thru 22-019
ENGINE CYLINDER 2 1 8 9 10 11 HEAT EXCHANGER 8 9 TAIL PIPE MUFFLER NOTE Polish both sides of ball and slip joint with emery cloth to ensure surface is smooth and free of burrs. Apply a thin coat of antiseize lubricant to polished slip joint surfaces. Serials 22-020 & subs. LEGEND 1. Exhaust Headers 2. Gasket. Nut. Cotter Pin. Washer 8. Spring 9. Bolt 10. Collector 11. Ball Joint Flange SR22_MM8_188A Serials 22-020 & subs Figure 1 Exhaust Header Assembly - Serials 22-020 & subs (Sheet 2 of 2) Page
C. Exhaust Header Assembly - Serials 22T-0001 & subs (See Figure 2) (1) Removal - Exhaust Header Assembly (a) Remove engine cowling. (Refer to 1-10) (b) Remove EGT probes from exhaust headers. (Refer to -20) (c) Remove tailpipe. (Refer to 8-20) (d) Remove turbocharger. (Refer to 81-20) (e) Remove wastegate. (Refer to ) (f) Remove bolts, bushing, and nuts securing tie rod to crossover and RH turbocharger transition. (g) Remove crossover from wastegate transition and RH turbocharger transition. (h) Remove wastegate transition from LH turbocharger transition. (i) Remove nuts attaching exhaust headers to engine cylinders. (j) Remove exhaust header assembly from airplane. (k) Remove and discard exhaust flange gaskets from cylinders. (2) Installation - Exhaust Header Assembly (a) Install new exhaust flange gaskets on cylinder port studs. (b) Position exhaust header assembly over cylinder port studs and secure with nuts. Do not torque at this time. (c) Install wastegate transition to LH turbocharger transition. (d) Install crossover to wastegate transition and RH turbocharger transition. (e) Install wastegate. (Refer to ) (f) Install turbocharger. (Refer to 81-20) (g) Install tailpipe. (Refer to 8-20) (h) Torque exhaust header assembly nuts to 100-110 in-lb (11. - 12.4 Nm). CAUTION: The exhaust system requires freedom of movement for proper operation after installation. Ensure bushing is properly installed in tie rod to allow expansion and exhaust system parts have adequate clearance from surrounding objects after installation. (i) Position tie rod to crossover and RH turbocharger transition and secure with bolts, bushing, and nuts. Check installed exhaust assembly for freedom of movement. (j) Install EGT probes to exhaust headers. (Refer to -20) (k) Install engine cowling. (Refer to 1-10) Page 8 Serials 22T-0001 & subs
D. Wastegate - Serials 22T-0001 & subs (See Figure 2) (1) Removal - Wastegate (a) Remove engine cowling. (Refer to 1-10) (b) Remove LH tailpipe. (Refer to 8-20) (c) Disconnect hoses from wastegate. (d) Remove bolts, washers, and nuts securing wastegate to wastegate transition. Discard gasket. (2) Installation - Wastegate (a) Position wastegate and new gasket to wastegate transition and secure with bolts, washers, and nuts. (b) Connect hoses to wastegate. (c) Install LH tailpipe. (Refer to 8-20) (d) Install engine cowling. (Refer to 1-10) Serials 22T-0001 & subs Page 9
ENGINE CYLINDER 1 ENGINE CYLINDER 4 2 4 9 1 2 8 11 10 8 TURBOCHARGER TURBOCHARGER 8 8 12 8 TAILPIPE LEGEND 1. Elbow Riser 2. Tee. Turbocharger Transition 4. Riser. Gasket. Bolt. Washer 8. Nut 9. Tie Rod 10. Crossover 11. Wastegate Transition 12. Wastegate TAILPIPE SR22_MM8_20 Page 10 Figure 2 Exhaust Header Assembly - Serials 22T-0001 & subs Serials 22T-0001 & subs
E. Wastegate Controller - Serials 22T-0001 & subs (See Figure ) (1) Removal - Wastegate Controller (a) Remove engine cowling. (Refer to 1-10) (b) Disconnect hoses from wastegate controller. (c) Remove bolts, washers, and nuts securing wastegate controller to bracket. (2) Installation - Wastegate Controller (a) Position wastegate controller to bracket and secure with bolts, washers, and nuts. (b) Connect hoses to wastegate controller. (c) Install engine cowling. (Refer to 1-10) Serials 22T-0001 & subs Page 11
FIREWALL TO ENGINE 2 1 4 2 TO MANIFOLD TO THROTTLE BODY WASTEGATE LEGEND 1. Wastegate Controller 2. Bolt. Washer 4. Nut. Bracket. Hose SR22_MM8_20A Page 12 Figure Wastegate Controller Installation - Serials 22T-0001 & subs Serials 22T-0001 & subs