Rotax 915 i A SERIES Original operating manual

18 November 2020 Current valid documentation see: 78-20-00
Revision 1 www.flyrotax.com Page 1 of 23
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
d06863.fm
SI-915 i-007R1
This SI revises SI-915 i-007 Initial Issue dated 7 July 2020
SERVICE INSTRUCTION
Introduction of a new turbocharger assy. with new ECU soft-
ware and exhaust requirements for ROTAX®Engine Type
915 i A (Series)
ATA System: 78-20-00 Turbocharger
1) Planning information
To obtain satisfactory results, procedures specified in this publication must be accomplished with
accepted methods in accordance with prevailing legal regulations.
BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in
accomplishing the requirements of this publication.
1.1) Applicability
All versions of ROTAX® engine types:
NOTE: On engines with equal or higher S/N than those listed above, new style turbocharger,
exhaust bracket, muffler and latest version of ECU software have already been fitted
in serial production.
1.2) Concurrent ASB/SB/SI and SL
In addition to this Service Instruction the following Service Instructions must be observed and
complied with:
- SB-915 i A-004/SI-912 i -018 - “List of approved Engine Control Unit (ECU) software and hard-
ware configurations for ROTAX® Engine Type 912 i and 915 i (Series)”, current issue
- SI-915 i-002, “B.U.D.S. Aircraft Installation Instruction”, current issue
1.3) Reason
In the course of further development and standardization, a new turbocharger assy. has been
introduced.
1.4) Subject
Introduction of a new turbocharger assy. with new ECU software and exhaust requirements for
ROTAX® Engine Type 915 i A (Series).
1.5) Compliance
NONE - For Information Only.
1.6) Approval
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.048.
Engine type Serial number
915 iS A from S/N 9132575
915 iSc A from S/N 9127353

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SI-915 i-007R1
SERVICE INSTRUCTION
1.7) Labor time
Estimated labor hours:
Engine installed in the aircraft - - - labor time will depend on airframe installation and therefore no
estimate is available from the engine manufacturer.
1.8) Mass data
Change of weight - - - insignificant.
Moment of inertia - - - unaffected.
1.9) Electrical load data
No change.
1.10) Software modifications
Yes. See section 1.2 and 2.6.
1.11) References
In addition to this technical information refer to current issue of
- Illustrated Parts Catalog (IPC)
- Installation Manual (IM)
- Maintenance Manual Line (MML)
- Maintenance Manual Heavy (MMH)
NOTE: The status of the Manuals can be determined by checking the table of amendments.
The 1st column of this table shows the revision status. Compare this number to the one
listed on the ROTAX website:
www.flyrotax.com. Updates and current revisions can be downloaded for free.
1.12) Other Publications affected
None.
1.13) Interchangeability of parts
Old and new parts are NOT interchangeable as they have different fixation positions for the turbo-
charger assy.

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2) Material Information
2.1) Material
Price and availability will be provided on request by ROTAX®Authorized Distributors or their inde-
pendent Service Centers.
2.2) Company support information
None.
2.3) Material requirement per engine
2.4) Material requirement per spare part
None.
2.5) Rework of parts
None.
New part
number
Qty/
engine Description Old part number
893108 1 Turbocharger 893105/893106
851299 1 Turbocharger bracket Metric 851296/851297
851283 1 Turbocharger bracket UNF 851296/851297
979495 1
Muffler assy. brushed
(new: 979478 being brushed + packaging
old: 979475 being brushed + packaging)
979479
626333 2 Washer -

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SI-915 i-007R1
SERVICE INSTRUCTION
2.6) Special tooling/lubricants- /adhesives- /sealing compounds
Price and availability will be supplied on request by ROTAX®Authorized Distributors or their inde-
pendent Service Centers:
Description Qty/
engine
Part
number
B.U.D.S. set Level 3 - Maintenance
(for OEM/Distributor) 1 864023
B.U.D.S. Aircraft Software (3.0.0. or higher) 1 864361
Service wiring harness assy.
(Only required for the loading process, if the ECU has
been removed from aircraft / disconnected from har-
ness)
1 864280
Y-cable
(Only required if the aircraft has two separate D-Sub
DB 9 Maintenance ports. Specification according to
the latest Maintenance Manual Heavy of the respec-
tive engine type)
1-
Software configuration ECU 915 i A Series
(Program files to be loaded onto the relevant ECU) 1 864089
mWARNUNG
NOTICE
If using these special tools observe the manufacturers specifications.

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3) Accomplishment/Instructions
-ROTAX
®reserves the right to make any amendments to existing documents, which might
become necessary due to this standardization, at the time of next revision or issue.
NOTE: Before accomplishment, review the entire documentation to make sure you have a
complete understanding of the procedure and requirements.
Accomplish-
ment
All measures must be implemented and confirmed by at least one of the following persons or
organizations:
-ROTAX
®- Authorized Distributors or their independent Service Centers
- Persons with approved qualifications for the corresponding engine types. Only authorized per-
sons (iRMT, Level Heavy Maintenance) are entitled to carry out this work
NOTE: All work has to be performed in accordance with the relevant Maintenance Manual.
NOTE: Indicates supplementary information which may be needed to fully complete or under-
stand an instruction.
General All general inspection, maintenance and repair has to be carried out e.g. in accordance with rele-
vant Advisory Circular AC 43.13 from FAA.
Advisory
Circular
This Manual "Advisory Circular" AC describes maintenance methods, techniques and practice.
These are recognized and authorized for inspection and repairs in non-pressurized areas for
which there are no separate maintenance and repair instructions.
3.1) Spare Parts - related information
3.2) Installation - related information
mWARNUNG
mWARNING
Danger of severe burns and scalds!
Allow the engine and exhaust system to cool to ambient temperature
before starting work
All work has to be performed in accordance with the relevant Maintenance Manuals of
the respective engine type.
See current Illustrated Parts Catalog (IPC) for the respective engine type.
See current Installation Manual (IM) for the respective engine type.
mWARNUNG
NOTICE
Connection turbocharger bracket with engine suspension frame requires
a Metric or UNF fixed connection.

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Fig. 1
3.3) Operation - related information
3.4) Maintenance (Line) - related information
1 Connection turbocharger
bracket with engine
suspension frame
See current Operators Manual (OM) for the respective engine type.
See current Maintenance Manual Line (MML) for the respective engine type and its pe-
riodical maintenance information
Points of inspection
Interval
Operating hours Chapter
reference
100 h
Check the wastegate lever for free running
and correct position. x 12-20-00
Lubricate the wastegate lever. x 12-20-00
Inspection of the GENUINE ROTAX®ex-
haust system included in the standard de-
livery.
x 05-20-00

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3.5) Maintenance (Heavy) - related information
3.5.1) Turbocharger assy. - removal
Preparation:
-Drainoil
- Remove the air filter
- Remove turbocharger / intercooler connection
Fig. 2
Step Procedure
1 Disconnect the turbo pressure oil line and the suction oil line.
2Remove the cable clamp (Allen screw M5x20 and lock nut) for supporting the
suction line on the turbocharger bracket.
3 Remove hose from wastegate regulator.
Step Procedure
4 Remove M8 hex. nuts and washers from turbocharger flange.
5 Remove M8x30 screws to disconnect turbocharger from exhaust manifold assy.
1 Turbo pressure oil line
2 Suction oil line
3 Wastegate regulator
4 Hose (wastegate regulator)
5 Cable clamp

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SI-915 i-007R1
SERVICE INSTRUCTION
Fig. 3
Fig. 4
Step Procedure
6 Slacken tension clamp but do not detach or remove it from the muffler bracket.
Step Procedure
7Remove the Allen screw M10x50 (attachment of the turbocharger bracket) together
with the lock washer and washer
8Loosen the engine suspension frame / muffler bracket bolt (not supplied with the en-
gine).
1 Turbocharger flange
2 Exhaust manifold assy.
3 Hex. nut M8
4 Washer
5 Screw M8x30
1 Muffler
2 Tension clamp
3 Muffler bracket

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Fig. 5
Fig. 6
Step Procedure
9Support the complete unit of muffler - turbocharger - bracket, remove the tension
clamp and take off the complete unit.
1 Turbocharger bracket
2 Allen screw M10x50
3 Lock washer
4 Washer
5 Distance sleeve
6 Connection turbocharger
bracket with engine
suspension frame
1 Turbocharger
2 Muffler
3 Turbocharger bracket

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SI-915 i-007R1
SERVICE INSTRUCTION
3.5.2) Turbocharger bracket - removal
Preparation:
- Remove turbocharger assy.
Fig. 7
3.5.3) Muffler - removal
Preparation:
- Remove turbocharger assy.
Fig. 8
Step Procedure
1Remove 2 hex. screws M8x16 with washers B 8.4 (bigger outer diameter) from turbo-
charger.
2 Remove hex. screw M8x16 with washer 8.4 and remove bracket.
1 Hex. screws M8x16
2 Washers B 8.4
3 Washer 8.4
Step Procedure
1 Remove hex. nuts with washers from the turbocharger studs.
1 Hex. nuts M8
2 Washers 8.4

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3.5.4) Muffler - inspection
Fig. 9
3.5.5) Turbocharger - inspection
Preparation:
- Clean all parts carefully
- Record the readings in the Appendix
NOTE: The turbocharger is handled as a complete unit, i.e. no spare parts are available from
BRP-Rotax. In the event of damage, the complete unit must be replaced.
Step Procedure
1 Check the muffler assy. and exhaust flange for cracks, damage and wear.
1 Muffler assy.
2 Exhaust flange
General visual inspection.
See Maintenance Manual Line (MML) for the engine type 915 i A Series Chapter
12-20-00
Step Procedure
1
Use a straight edge to test for distortion (see also section 4, Appendix). A distortion
of max. 0.1 mm (0.004 inch) is permissible. If the maximal allowed distortion is ex-
ceeded, then it is possible to rework the surface up to 0.5 mm (0.02 inch). The amount
of the rework must be recorded in the Appendix.

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SI-915 i-007R1
SERVICE INSTRUCTION
Fig. 10
Fig. 11
Step Procedure
2 Check the threaded holes for damage and wear.
3
Apply slightly a radial pressure onto the turbine shaft to minimize the gap between the
turbine casing and the turbine wheel. The gap must never be less than
0.1 mm (0.004 in.) (see also section 4, Appendix). Check the complete circumference
of 360°.
mWARNUNG
NOTICE
It is not allowed to repair any of the threads inside of the turbine housing
with thread inserts.
1 Threaded hole
2 Gap

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Fig. 12
Fig. 13
Step Procedure
4Apply slightly a radial pressure onto the compressor shaft whereby it must not contact
the compressor housing. Check the complete circumference of 360°.
Step Procedure
5Check the wastegate lever for free movement. If it does not move freely, lubricate
the axle of the wastegate with LOCTITE ANTI SEIZE 8151.

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SI-915 i-007R1
SERVICE INSTRUCTION
3.5.6) Pressure drop measuring method
Testing device consisting of:
- 2x pressure gauge
- 1x orifice jet (inner diameter = 1 mm (0.039 in.) / length = 3 mm (0.12 in.)
- 1x connecting nipple M12x1.5 for the thread in the middle section of the turbocharger
- 1x cover plate for the oil outlet connecting hoses (as required)
Fig. 14
Step Procedure
6
Apply slight in and out axial pressure onto the turbocharger shaft and check
axial clearance TC01 (see also section 4, Appendix). The gap must exceed 0.084 mm
(0.0033 in.)
7Check the turbocharger shaft for radial clearance TC02 (see also section 4, Appen-
dix). The gap must exceed 0.127 mm (0.0050 in.).
Step Procedure
1 Screw in the connecting nipple and close the oil outlet with the cover plate.
2 Connect the pressure gauge together with the regulating valves.
3
Apply a constant pressure of 2 bar (29 psi) to the connection cable. The pressure drop
must not exceed 50%. (From 2 bar (29 psi) to max. 1 bar (14.5 psi)).
NOTE: For optimum results, the position of the shaft should always be changed
slightly during the check, i.e. the shaft should be moved backwards and
forwards in axial and radial directions.

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3.5.7) Muffler - installation
Fig. 15
3.5.8) Turbocharger bracket - installation
Turbocharger bracket integrates a captive nut used for engine ring mount and aircraft suspension
frame attachment. It is available in Metric (M10) part no. 851298 or UNF (3/8-24) (AN6) part no.
851282.
Step Procedure
1
Apply LOCTITE ANTI SEIZE to the studs of the turbocharger. Tighten muffler with
washers and nuts M8 to the turbocharger housing.
Tightening torque 25 Nm (18 ft. lb.).
1 Hex. nuts M8
2 Washers 8.4
Step Procedure
1
Apply LOCTITE ANTI SEIZE to the hex. screws M8x16.
Tighten the bracket to the turbocharger using 3 hex. screws M8x16 with 1x washer
8.4 and 2x washers B 8.4 (bigger outer diameter). Tightening torque 25 Nm (18 ft. lb.).

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SI-915 i-007R1
SERVICE INSTRUCTION
Fig. 16
3.5.9) Turbocharger assy. - installation
Fig. 17
1 Hex. screws M8x16
2 Washers B 8.4
3 Washer 8.4
Step Procedure
1 Place distance spacer 10.5/17/15 into the engine suspension frame.
2
Screw turbocharger assembly to the engine housing, complete with muffler and tur-
bocharger bracket with washer, lock washer and Allen screw M10x50. Tightening
torque 60 Nm (44 ft. lb).
1 Turbocharger bracket
2 Allen screw M10x50
3 Lock washer
4 Washer
5 Distance sleeve
6 Connection turbocharger
bracket with engine
suspension frame

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Fig. 18
Fig. 19
Step Procedure
3The muffler is attached to the muffler bracket with a tension clamp. Tightening torque
20 Nm (15 ft. lb).
Step Procedure
4
Install turbo on exhaust manifold using Allen screws M8x30 with hex. nuts M8 and
washers. Apply LOCTITE ANTI SEIZE to the screws.
Tightening torque 25 Nm (18 ft. lb).
1 Muffler
2 Tension clamp
3 Muffler bracket
1 Allen screw M8x30
2 Washer 8.4
3 Hex. nut M8

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SI-915 i-007R1
SERVICE INSTRUCTION
Fig. 20
Step Procedure
5
Re-establish attachment (turbocharger bracket engine suspension frame (not sup-
plied with engine). Tightening torque as specified by the aircraft manufacturer.
NOTE: Ensure correct attachment bolt is used for the turbocharger bracket.
mWARNUNG
NOTICE
Total blockage of oil supply may occur!
Do not install ball and spring for check valve in wrong order. Ball must be
on the upper side, over the spring!
Step Procedure
6
Install spring and ball of turbo pressure oil line, see applicable Maintenance Manual
Heavy (MMH), Chapter 79-00-00 Oil line (steel line) installation.
NOTE: Ball must be on the upper side, over the spring!
NOTE: Valve housing part no. 956482 must be used in conjunction with turbocharg-
er part no. 893107.
7
Connect the turbo pressure oil line with new sealing rings, see applicable Mainte-
nance Manual Heavy (MMH), Chapter 79-00-00 Oil line (steel line) installation.. Tight-
ening torque 17 Nm (150 in. lb).
8Install turbo suction oil line with clamp, M5x20 screw and new M5 lock nut on turbo-
charger bracket, see Chapter 79-00-00 Oil line (steel line) installation.
9 Install hose on wastegate regulator assy.
1 Turbo pressure oil line
2 Suction oil line
3 Wastegate regulator
4 Hose (wastegate regulator)
5 Cable clamp

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If the location of the oil line connection does not correspond with oil pump housing, correction can
be achieved by slightly turning the turbocharger center section. After completion of installation as
described, all the screw connections on the turbocharger bracket, exhaust manifold, exhaust
bends and the tension clamp must be tightened to the specified torques:
3.6) ECU software check/update
Engines equipped with following ECU part numbers are already programmed with the latest ver-
sion of ECU software.
3.6.1) Identify current ECU configuration
Connect ECU to computer by using the Service Wiring Harness or, in case the ECU is installed in
an aircraft, by connecting the ECU directly via the aircraft wiring harness. Refer to the instructions
of the latest Maintenance Manual Heavy Chapter 76-10-00.
Description Application Tightening torque
Allen screw Turbo flange 25 Nm / 18 ft. lb
Allen screw Turbocharger bracket 60 Nm / 44 ft. lb
Allen screw Exhaust bracket 60 Nm / 44 ft. lb
Hex. screw Tension clamp 20 Nm / 15 ft. lb
mWARNUNG
NOTICE
In the high temperature zone of the turbocharger and exhaust system, use
exclusively high grade, stainless steel screws
Engine type ECU part no.
915 iSc A 864357
Step Procedure
1
Launch B.U.D.S. Aircraft by double clicking the desktop icon. Alternatively, B.U.D.S.
Aircraft can also be started through the start menu entry (e.g. Start – All Programs -
B.U.D.S. - run B.U.D.S.).

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SI-915 i-007R1
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Fig. 21
Step Procedure
2 Wait until the program has been started completely.
3Check if both Lane Health Indicators (top left corner) turn green. If they are gray
check connections and power supply and/or restart B.U.D.S. Aircraft.
4 Change to “ECU configuration” tab.