cessna 172 engine baffle kit - air plains 172 engine baffle kit air plains, ... aps0555259-14-6 1...

Cessna 172 Engine Baffle Kit Air Plains, Corp. STC SA4428SW

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Document 1721401 Rev 2

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CESSNA 172 ENGINE BAFFLE KIT

Cessna 172 Models B thru P

Installation Instructions 1721401


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LOG OF REVISIONS

Revision Pages Description Date

- All Original May 22, 2014

1 4,6 Revised BOM and added part number 1729191-10 November 17, 2014

2 4,5,6 Added part number APS1755014-1A December 19, 2014

3 ALL Added fasteners and hardware to kits. Improved air box

bracket cover plate installation. Added additional installation Pictures.

August 22, 2016

4 ALL Added bracket APS0552120-2 for models 1961 thru 1976. May 17, 2017


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TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................................................ 4

REQUIRED HARDWARE .......................................................................................................................................... 4

INSTALLATION INSTRUCTIONS .............................................................................................................................. 6


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INTRODUCTION This installation manual illustrates the installation of the Engine Baffle Kit in a Cessna 172 aircraft modified with STC SA4428SW.

The following manuals are acceptable and should be consulted for use in deviations as required for the installation, fastener selection, priming, painting and sealing of parts and assemblies during manufacturing and/or installation:

1. Structural Repair Section of the applicable model Cessna Service Manual 2. AC 43.13-1B

This manual assumes the installation will be accomplished by an experienced mechanic. Trimming of baffles and baffle seals may be required in some cases to eliminate interference and maintain proper clearance from engine cowl and other engine components.

REQUIRED HARDWARE Our installation kit was created to accommodate different types of installations depending on aircraft serial number range. Please consult the BOM table below for reference on assembly components for each serial number range:

BILL OF MATERIALS

Part Number Qty Description

Serial 17247747

thru 17259223

(61-70)

17259224 thru 17267584 (71-74 and

75-76)Serial

Serial 17267585 thru

17274009 (77-80)

Serial 17274010 &

On (81-ON)

APS0555211-9 1 Baffle Assembly








APS0555259-14-6 1 Baffle Assembly


APS0552120-2 1 Air Box Support


APS1755014-1A 1 Baffle Support

1729191-10 1 Baffle Seal

1729011-1B 1 Baffle Boot LW

APS0555211-9-4 1 Cooling Tube

350-6-0280 1 Hose

350-6-0310 1 Hose

360-8D0280 1 Hose

360-8D0310 1 Hose

AE3663161H0272 1 Hose

AE3663161B0170 1 Hose

NAS43HT3-216 4 Spacer

AN3-40A 4 Bolt

AN960-10 9 Washer

AN960-10L 4 Washer

8RX1/2 THA 32 PK Screws


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APS0554003-1 1 Shroud Inlet Cover

A1778-8Z-1D 28 Tinnerman

AN525-832R7 6 Screw

AN525-1032R7 7 Screw

MS21045-3 7 Nut

91794A539 10 STD1925 Screw

AN960-416 10 Washer

MS35333-40 10 Lock Washer

0.125 DIA x 0.03 L 10 Large Flange Rivet

92510A765 1 Bracket Spacer

- ITEM IS SUPPLIED WITH THE KIT - ITEM IS NOT SUPPLIED WITH THE KIT


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INSTALLATION INSTRUCTIONS

Figure 1 - Engine Baffle Assembly

Remove the alternator from the engine and remove the alternator wires from the engine baffles.

1. Disconnect and remove the ignition harness wires as needed. 2. Disconnect the oil pressure fitting from the RH rear baffle if installed. 3. Remove the oil cooler mounting bolts and lay the oil cooler back against the firewall.

a. If the oil cooler is installed on the firewall, remove the cooler, and duct work. Note:

Moving the cooler from the firewall to the baffle will require replacement of the oil lines with a 28 inch and 31 inch lines of the appropriate diameter.

4. Remove the existing forward, side and rear baffles from the engine and discard.


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5. Retain the 1/4 -20 mounting hardware for reinstallation. (New hardware will be provided) 6. Retain the baffle springs and wires for reinstallation. (Optional, not required) 7. On models with a forward support between the induction air box and the engine retain the support.

Note:

During baffle installation leave the hardware loose until the adjacent baffles have been installed. This will make installation easier and eliminate stress on the baffles.

8. Install the LH and RH side baffles with the required hardware (PN# APS0555318-1, PN# APS0555213-5, PN#

APS0555215-4, PN# APS0555214-7). White arrow designate PK Screws and tinnermans where required. Blue arrow designates 1/4-20 screws.

Figure 2 - Side Baffle Installation

9. Install the LH rear baffle and mounting hardware (PN# APS0555211-9). 10. Install the RH rear baffle and mounting hardware (PN# APS0555309-1). 11. Install center baffle support (PN# APS1755014-1A) on the engine and match drill the center of the LH and RH

baffles. Use PK Screws and tinnermans.


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Figure 3 - Support Bracket

12. Install the LH forward baffle (PN# APS0555259-14) to the LH forward side baffle and the engine. Use PK Screws and tinnermans.

13. Install the RH forward baffle (PN# APS0555250-9) to the RH side baffle. Use PK Screws and tinnermans. a. If the aircraft model is not equipped with a center Air Box support (short air box) install cover plate (PN#

APS0555259-14-6) utilizing 4 sheet metal screws and tinnermans and #8 Machine screw as shown in black arrow.

b. All other models, will require the installation of air box support (PN# APS0552120-2) and bracket cover (PN# APS0555259-14-9). Use 4 sheet metal screws and tinnermans and one #8 Machine screw where applicable. Sheet Metal screws will require a #10 hole. Use #40 pilot holes in the cover plate as reference to match drill the baffle. It may be required to adjust the position of the air box cover plate. Only drill the PK Screw holes once the correct position of the cover plate has been stablished. Visit www.airplains.com/support for additional help with installation of air box bracket.

Figure 4 -Air Box Center Support later models

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14. Aircraft equipped with the light weight starter requires spacer PN# 92510A765 as indicated below.

Figure 5 - Air Box Bracket Installation

Figure 6 - Baffle Seal for Carb Heat Intake

15. Cut-out for the carb heat intake may require trimming after installation. Install Baffle seal 1729191-10 using 4 equally spaced rivets or High Temperature Red RTV Silicone 81160 (or equivalent)

16. Install starter baffle seal with provided rivets. Trim baffle and baffle seal if required.


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Figure 7 - Starter Baffle Seal

17. Tighten all baffle mounting hardware. 18. Reinstall the ignition harness thru and around the baffles as removed and connect. Reinstall alternator wiring

utilizing the stand-off on PN# APS0555250-9 and adel clamp. 19. Reinstall the oil cooler on the RH rear baffle PN# APS0555309-1.

Figure 8 - Oil Cooler Installation


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Figure 9 - Oil Cooler Hardware Mount

a. Large oil cooler is installed without the filler plate. b. Small oil cooler is installed with the filler plate. (PN# APS0555309-1-3) c. Mount the oil cooler on the baffle with AN3-40A bolts, NAS43HT3-216 spacers, AN960-10, AN960-10L

washers and AN363-1032 nuts. Use AN960-10 washers in magenta as required between spacer and oil cooler. Use AN960-10L on bolt head and lock-nut as depicted in blue.

20. Reconnect or install new oil cooler hoses. (PN# 350-6-0280 and PN# 350-6-0310, or Equivalent) 21. Reinstall the oil pressure fitting if required

a. A #40 pilot hole is provided in the RH Baffle for the fitting location.


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Figure 10 - Oil Cooler Plate

Figure 11 - Oil Cooler Detail

22. If battery cooling tube is required install PN# APS0555211-9-4. Drill #40 pilot hole in the designated location to

required size. Drill and rivet 4 equally spaced holes in the flange.


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Figure 12- Cooling Tube Installation Detail

23. Use relief cuts in baffle seals were required to provide the best cooling performance and minimize interference

wear. Once the lower cowl is installed determined the locations of the cowl stringers.

Figure 13 - Baffle Relief

cessna 172 engine baffle kit - air plains 172 engine baffle kit air plains, ... aps0555259-14-6 1...

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