General Aviation Modifications, Inc.

Cardinal Cruiser™ System

Maintenance and Troubleshooting Manual
for
Turbonormalized Cessna 177RG Aircraft
Modified per STC’s SA4081NM and SE4082NM
Instructions for Continued Airworthiness

This report applies to General Aviation Modifications Inc Cardinal Cruiser™

turbonormalizing systems per STC’s SA4081NM and SE4082NM.

77-6460004 Continued Airworthiness

Rev. C Page |1
26 Apr 2013
 General Aviation Modifications, Inc.

LOG OF REVISIONS

Pages Revision Date Remarks

1-41 A 14 Oct 09 Initial Release

5, 6, 8, 18 B 12 Oct 11 Changes due to TAT SB11-07

4, 11, 19,
22, 25, 27, C 26 Apr 13 Add IO-390
28, 32, 33

Revisions
Lettered revisions of this document will be issued periodically. Each revision will cover the entire
document. Changes to data in the previous revisions will be identified by revision bars in the
outer margins of the pages. Change bars will be shown only against the immediate prior revisions.
Extensive changes will not be accompanied by change bars but will be identified on Log of
Revisions page under the Remarks section.

Revision Distribution
The latest revision of this document in its entirety will be posted at www.taturbo.com/drawings/

77-6460004 Continued Airworthiness

Rev. C Page |2
26 Apr 2013
General Aviation Modifications, Inc.

Intentionally Left Blank

77-6460004 Continued Airworthiness

Rev. C Page |3
26 Apr 2013
 General Aviation Modifications, Inc.
TABLE OF CONTENTS
Subject Page
Referenced Instructions for Continued Airworthiness and other Publications 5
AIRWORTHINESS LIMITATIONS 6
TURBONORMALIZER SYSTEM DESCRIPTION AND OPERATION 7
TROUBLESHOOTING 8
MAINTENANCE PRACTICES
Overhaul And Replacement Schedule 16
Scheduled Maintenance Checks 16
Progressive Inspection Program 19
COMPONENT DESCRIPTIONS
Turbochargers 21
Absolute Controller 21
Magnetos 21
COMPONENT REMOVAL, INSTALLATION, ADJUSTMENTS
Absolute Pressure Controller
Removal and Installation -Absolute Pressure Controller 22
Adjustment - Absolute Pressure Controller 22
Turbocharger
Removal and Installation -Turbocharger 23
Wastegate Actuator
Removal and Installation - Wastegate Actuator 24
Adjustment - Wastegate Actuator 24
Pressure Relief Valve
Removal And Installation Of Pressure Relief Valve 24
Engine
Removal and Overhaul - Engine 25
Installation - Engine 25
Inspection - Post Engine Overhaul / Installation 25
Servicing - Post Engine Overhaul / Installation 26
Operational Inspection - First Flight Run-Up 26
Adjustments -Post Engine Overhaul / Installation 27
Functional Inspection - Return to Service Flight 28
Post Return to Service Flight 28
Fig. – Exhaust System 29
Fig. – Induction System 30
Fig. – Lubrication System 31
Fig. – Upper Deck Lines 32
Fig. – Upper Deck Lines 33
Appendix A - Torque values 34

77-6460004 Continued Airworthiness

Rev. C Page |4
26 Apr 2013
 General Aviation Modifications, Inc.
Referenced Instructions for Continued Airworthiness and other Publications

The latest revision to the following publications should be used in conjunction with this manual:

Vendor Manual Title Part Number

Hartzell Engine Kelly Aerospace Troubleshooting Reference Guide 400888-0000
Technologies
(formerly Kelly
Aerospace)
GAMI GAMIjector Installation Procedure IP-98-002
Lycoming Direct Drive Engine Overhaul Manual 60294-7
Lycoming Troubleshooting Guide SSP-475
Cessna Aircraft Service Manual 1971 - 1975 D991-3-13
Cessna Aircraft Service Manual 1976 - 1978 D2009-4-13

GAMI and TATI service instructions are available at www.taturbo.com/drawings/

TATI
Bulletin, Letter,
Subject Notes/Compliance
or Instruction
Number
TAT SB09-02 Reflow Fuel Injection Servo Mandatory
TAT SB11-07 Fine wire spark plugs Mandatory

77-6460004 Continued Airworthiness

Rev. C Page |5
26 Apr 2013
General Aviation Modifications, Inc.

77-6460004 Continued Airworthiness

Rev. C Page |6
26 Apr 2013
 General Aviation Modifications, Inc.
TURBONORMALIZER SYSTEM DESCRIPTION AND OPERATION
The Tornado Alley Turbonormalizing System utilizes one Kelly Aerospace turbocharger with a Kelly
Absolute Pressure Controller, and a Kelly pressure relief valve. The turbocharger is a new generation
turbocharger designed to provide the same boost as older design turbochargers but with lower compressor
discharge temperatures. This increase in efficiency is due to the improved design of the compressor
blades and compressor housing. However, to further reduce engine induction temperatures, a firewall
mounted intercooler is also installed in the system.

The Absolute Pressure Controller and wastegate work in conjunction with each other to provide proper
boost pressure to the engine. The wastegate is actuated using engine oil pressure to actuate a small
hydraulic cylinder which redirects the engine by-pass exhaust flow around the turbocharger. The absolute
pressure controller utilizes an aneroid bellows and spring connected to a valve that regulates the amount
of oil flowing out of the wastegate actuator hydraulic control cylinder. The aneroid bellows are located
inside a housing that is connected to the output air produced by the compressors.

As turbocharger compressor outlet pressure increases, the normally closed oil control valve opens. When
open, the valve allows metered oil to bypass the wastegate which, in turn, is spring loaded to the open
position. Oil passing through the absolute controller is returned to the engine oil sump. The wastegate
incorporates a typical butterfly exhaust bypass valve. The wastegate is spring loaded to the open position.
Increasing oil pressure from the engine causes the actuator to work against the spring to close the butterfly
valve. The wastegate is located in the exhaust system parallel with the turbocharger turbine. As the
butterfly valve opens, it allows exhaust gasses to bypass the turbocharger turbine, thereby controlling the
speed and output of the turbocharger. The wastegate helps provide even control of the turbocharger speed
and output so that the engine can maintain sea level manifold pressure into the flight levels. As
turbocharger compressor outlet pressure rises, the aneroid bellows in the absolute pressure controller
senses the increase in pressure. When at high engine speed and load and the proper absolute pressure is
reached, the force on the aneroid bellows opens the normally closed metering valve. When the oil
pressure in the wastegate actuator cylinder is lowered sufficiently, the wastegate actuator spring forces the
mechanical linkage to open the wastegate. A portion of the exhaust gases then bypasses the turbocharger
turbine, thus preventing further increase of turbocharger speed and holding the compressor outlet absolute
pressure to the desired value. Conversely, at engine idle, the turbocharger runs slowly with low
compressor pressure output; therefore, the low pressure applied to the aneroid bellows is not sufficient to
affect the unseating of the normally closed metering valve. Consequently, engine oil pressure keeps the
wastegates closed and all of the exhaust flows through the turbocharger turbine section.

The system is equipped with a spring loaded alternate air door on the back side of the induction air box.
When any restriction of the air filter is encountered, such as from ice or ice crystal formation, the alternate
air door will open automatically. The alternate air door provides a path for warm air from the lower side
of the engine compartment to go to the turbocharger when the air filter becomes blocked. After the air
filter blockage is removed, the alternate air door will close automatically.

77-6460004 Continued Airworthiness

Rev. C Page |7
26 Apr 2013
 General Aviation Modifications, Inc.
TROUBLESHOOTING
To facilitate troubleshooting, the following information provides an explanation of how the
turbonormalizer system works and points out some of the items that are affected by turbonormalizing.

The information below follows the induction air as it enters and passes through the engine until it is
expelled as exhaust gases.

• Engine induction air is taken in through an opening in the nose bowl, ducted through a filter and into
the turbocharger compressor where it is compressed.
• The pressurized induction air then passes through an intercooler (if equipped with an intercooler), then
the fuel injection servo, and finally, the induction manifold into the cylinders.
• The air and fuel are burned and exhausted to the turbocharger turbine.
• The exhaust gases drive the turbine which, in turn, drives the compressor, thus completing the cycle.

The compressor has the capability of producing manifold pressure in excess of 29.6 in. Hg. In order to
maintain 29.6 inches of manifold pressure, a wastegate is used on the exhaust so that some of the exhaust
from the cylinders will bypass the turbine and be vented into the tailpipe.

It can be seen from studying the bulleted items above that anything which affects the flow of induction air
into the compressor or the flow of exhaust gases into the turbine will increase or decrease the speed of the
turbine. A wastegate controller automatically maintains maximum allowable compressor discharge
pressure anytime the turbine and compressor are capable of producing that pressure.

At high altitude, part throttle, or low RPM, the exhaust flow is not capable of turning the turbine and
compressor fast enough to maintain maximum compressor discharge pressure, and the wastegate will
close to force all of the exhaust flow through the turbine. In normal operation at full throttle the
wastegate will seldom if ever be fully closed.

When the wastegate is fully closed, any change in turbocharger speed will mean a change in engine
operation. Thus, any increase or decrease in turbine speed will cause an increase or decrease in manifold
pressure and fuel flow. If turbine speed increases, the manifold pressure increases; if the turbine speed
decreases, the manifold pressure decreases. Since the compression ratio approaches 3 to 1 at high
altitude, any change in exhaust flow to the turbine or ram induction air pressure will be magnified
proportionally by the compressor pressure ratio and the change in flow through the exhaust system.

A. Momentary Overshoot Of Manifold Pressure

Under some circumstances (such as rapid throttle movement especially with cold oil) it is possible
that the engine can slightly overboost.

This would most likely be experienced during takeoff roll or during a change to full throttle
operation in flight.

A slight overboost to 32.0 inches of manifold pressure is not considered detrimental to the engine
as long as it’s duration is less than 2 minutes. No corrective action is required when momentary
overboost corrects itself and is followed by normal engine operation as the engine warms up.
However, if overboosting of this nature persists when oil temperature is normal or if the amount of
overboost tends to exceed 3 inches or more, the throttle should be retarded to eliminate the

77-6460004 Continued Airworthiness

Rev. C Page |8
26 Apr 2013
 General Aviation Modifications, Inc.
overboost and the controller system including the wastegate and relief valve, should be checked
for necessary adjustment or replacement of components.

This troubleshooting section primarily references items covered for the turbonormalizing system. If it is
not covered in this chart see appropriate Cessna or Lycoming troubleshooting documents.

Trouble Probable Cause Remedy

Engine will not start. No indication of fuel flow and Check fuel controls for proper
no fuel to engine. position, auxiliary fuel pump
“BOOST” and operating, fuel valve
open, mixture full rich, throttle open,
fuel filters open and visually check
fuel tank level.
Positive indication of fuel flow Perform a Flooded Engine Start.
and engine is flooded.
Positive indication of fuel flow, Check for bent or loose fuel lines.
but no fuel to engine. Check for fuel at a fuel nozzle. If no
fuel present at nozzle consult
Lycoming Direct Drive Engine
Overhaul Manual.
Engine starts but dies or will not Vaporized fuel in system. (Most Refer to Hot Start Procedure.
idle properly. likely to occur in hot weather
with a hot engine.)
Obstructed air intake. Remove obstruction; service air
filter.
Inadequate fuel to fuel manifold Set fuel control in “FULL RICH”
valve. position, turn auxiliary fuel pump
“BOOST” check to be sure feed
lines and filters are not restricted.
Clean or replace defective
components.
Upper deck air supply to fuel Check for bent lines or loose
discharge nozzle restricted or connections. Tighten loose
defective. connections. Remove restrictions
and replace defective components.
Defective ignition system. Check engine data and verify which
cylinders are affected by drop in
EGT during single magneto
operation. Check the spark plug and
ignition lead indicated by which
cylinder EGT drops on the operating
magneto.
Defective engine. Check compression and listen for
unusual engine noises. Check oil
filter for excessive metal. Repair
engine as required.

77-6460004 Continued Airworthiness

Rev. C Page |9
26 Apr 2013
 General Aviation Modifications, Inc.

Trouble Probable Cause Remedy

Engine Has Poor Acceleration. Fouled spark plugs. Check engine data and verify which
cylinders are affected by drop in
EGT during single magneto
operation. Check the spark plug and
ignition lead indicated by which
cylinder EGT drops on the operating
magneto.
Idle mixture too lean. Readjust idle setting per Lycoming
Direct Drive Engines Overhaul
Manual.
Incorrect fuel-air mixture, worn Tighten loose connections, replace
control linkage, or restricted air worn elements of linkage. Service
filter. air filter.
Engine lacks power, reduction Incorrectly adjusted throttle Check movement of linkage by
in maximum manifold pressure control, “sticky” linkage or dirty moving control from idle to full
or critical altitude. air filter. throttle. Make proper adjustments
and replace worn components.
Service air filter.
Defective ignition system. Replace the defective parts. Check
engine data and verify which
cylinders are affected by drop in
EGT during single magneto
operation. Check the spark plug and
ignition lead indicated by which
cylinder EGT drops on the operating
magneto.
Improperly adjusted wastegate. Adjust wastegate.
Wastegate capillary tube Disconnect lines from controller to
plugged. master wastegate and back flush
Wastegate and lines with oil
compatible solvent at 50 psi.
Loose or damaged exhaust Inspect entire exhaust system to
system. turbonormalizer for cracks and
leaking connections. Tighten
connections and replace damaged
parts.
Loose or damaged intake Inspect entire manifolding system
manifolding. for possible leakage at connections.
Replace damaged components,
tighten all connections and clamps.
Restricted fuel discharge Look at engine data and check fuel
nozzles. discharge nozzle that is indicated by
higher than usual EGT and CHT at
full power and full rich mixture.

77-6460004 Continued Airworthiness

Rev. C P a g e | 10
26 Apr 2013
 General Aviation Modifications, Inc.

Trouble Probable Cause Remedy

(Continued) Malfunctioning turbocharger. Check for unusual noise in
Engine lacks power, reduction turbocharger. If malfunction is
in maximum manifold pressure suspected remove tailpipe and/or air
or critical altitude. inlet connections and check rotor
assembly for possible rubbing in
housing, damaged rotor blades or
defective bearings. Replace
turbocharger if damage is noted.
Turbocharger inlet blocked. Remove obstruction.
Fuel discharge nozzle defective. Inspect fuel discharge nozzle vent
manifolding for leaking connections.
Tighten and repair as required.
Check for restricted nozzles and
lines and clean and replace as
necessary.
Absolute Pressure Controller not Check oil pump outlet pressure, oil
getting enough oil pressure to filter and external lines for
close the wastegate. obstructions.
Clean lines and replace if defective.
Replace oil filter.
Absolute Pressure Controller out Adjust Absolute Pressure Controller
of adjustment or defective. or replace controller if defective.
Defective Wastegate actuator. Replace wastegate actuator.
Engine smokes (white smoke). Defective scavenge pump. Replace scavenge pump if defective.
Wastegate actuator leaking oil. Replace wastegate actuator.
Turbo drain line (oil return to Clean line and check valve.
scavenge pump) plugged. Replace either if defective.
Turbocharger jammed. Replace turbocharger.
Turbocharger bearing seals Replace turbocharger.
leaking.
Engine smokes (black smoke). Black smoke only below 1200 Adjust idle mixture rise.
RPM idle rise too rich.
Black smoke only above 1200 Adjust fuel servo.
RPM.
Engine surges. Defective Absolute Pressure Replace Absolute Pressure
Controller. Controller if defective.

Wastegate actuator linkage Lubricate and adjust wastegate.

binding. Replace wastegate if defective.

77-6460004 Continued Airworthiness

Rev. C P a g e | 11
26 Apr 2013
 General Aviation Modifications, Inc.

Trouble Probable Cause Remedy

Engine Power Increases Slowly Pressure relief valve out of Replace Pressure relief valve if
Or Severe Manifold Pressure adjustment or defective. defective.
Fluctuations When Throttle
Advanced. Wastegate operation is sluggish. Lubricate and adjust wastegate.
Correct cause of sluggish operation.
Replace Wastegate if defective.

Engine Power Increases Rapidly Oil temperature not to operating Warm up oil temperature and try
And Manifold Pressure standards. again.
Overboosts When Throttle Wastegate operation is sluggish. Lubricate and adjust wastegate.
Advanced. Replace Wastegate if defective.
Throttle advanced too rapidly. Advance throttle smoothly.
Verify oil pressure is in proper Adjust oil pressure to proper limits
operating limits. per Lycoming Direct Drive Engine
Overhaul Manual.
Pressure relief valve out of Factory adjustments required or
adjustment or defective. replace pressure relief valve if
defective.
High Cylinder Head Defective cylinder head Verify connections. If connected
Temperature. temperature indication. properly replace CHT probe.
Engine timing incorrectly set. Reset timing to correct setting.

Restricted fuel discharge nozzle. Perform GAMI lean test to identify

problem nozzle and replace or clean
as appropriate.
Engine baffles loose, or heat Install baffles or heat shields
shields bent or missing. properly. Repair or replace if
defective.
LOP ops with insufficient Review downloaded engine data to
manifold pressure or excessive verify correct operating technique
fuel flow. per the AFMS is being used.
Debris accumulated on cylinder Clean fins thoroughly.
cooling fins.
Engine will not deliver rated See “Low manifold pressure at take-off” below.
power. Turbocharger rotating assembly Free rotating assembly per Kelly
bearing seizure. Aerospace Troubleshooting
Reference Guide.

77-6460004 Continued Airworthiness

Rev. C P a g e | 12
26 Apr 2013
 General Aviation Modifications, Inc.

Trouble Probable Cause Remedy

Engine Has Poor Acceleration, Improper fuel-air mixture. Review downloaded engine data to
Runs Rough At Speeds Above verify correct operating technique
Idle Or Lacks Power. per the AFMS is being used. Check
intake manifold connections
for leaks. Check fuel controls and
linkage for setting and adjustment.
Replace worn elements of control
linkage. Service air filter.
Loose hose connections. Tighten loose connections.

Turbocharger rotor rubbing. Replace Turbocharger.

Improperly adjusted or defective Adjust or replace Absolute Pressure

Absolute Pressure Controller. Controller as required.

Leak in turbonormalizer Correct cause of leaks. Repair or

induction system. replace damaged parts.

Engine oil viscosity too high for Replace oil with proper grade of oil.
ambient air temperature.
Exhaust system leakage. Inspect and repair excessive exhaust
leaks.
Ignition system defective. Check engine data and verify which
cylinders are affected by drop in
EGT during single magneto
operation. Check the spark plug and
ignition lead indicated by which
cylinder EGT drops on the operating
magneto. Replace damaged or
misfiring plugs.
Restricted fuel discharge Look at engine data and check fuel
nozzles. discharge nozzle that is indicated by
higher than usual EGT and CHT at
full power and full rich mixture.
High manifold pressure. Manifold pressure gage is not Check that the manifold pressure
functioning properly. gage reads the same as field
barometric pressure with the engine
not operating. (This is not the
altimeter setting).
Manifold pressure overshoot. Smoothly move throttle about two-
(Most likely to occur when thirds open. Let engine accelerate
engine is accelerated too and stabilize. Smoothly move
rapidly.) throttle to full open.

77-6460004 Continued Airworthiness

Rev. C P a g e | 13
26 Apr 2013
 General Aviation Modifications, Inc.

Trouble Probable Cause Remedy

Manifold pressure is high and Absolute Pressure Controller Check upper deck sense line is
stays high after engine is warm. sensing line broken or loose. connected and tight or replace if
needed.
Absolute Pressure Controller out Adjust Absolute Pressure Controller
of adjustment or defective. or replace controller if defective.
Wastegate not functioning. Lubricate and adjust wastegate.
Replace wastegate if defective.
Absolute Pressure Controller Remove blockage.
sensing line blocked.
Low fuel flow. Malfunctioning engine driven Replace engine driven fuel pump.
fuel pump.
Restricted flow to fuel metering Check mixture control for full travel.
valve. Check for restrictions in fuel filters
and lines, adjust control and clean
filters. Replace damaged parts.

Fuel control lever interference or Check operation of throttle and

out of adjustment. mixture control for possible
interference with other components.
Adjust as required to obtain correct
operation.
Incorrect fuel injection servo Check and adjust fuel flow. Fuel
adjustment and operation. injection servo may need to be sent
to Tornado Alley Turbo Inc for
proper flow bench adjustment per
STC.
Fluctuating fuel flow. Fuel flow transducer or wiring Verify this by determining if EGT’s
failing. fluctuate with fuel flow. If EGT’s
do not fluctuate replace fuel flow
transducer or repair wiring.
Interference from ignition Operate engine on single magneto
system. and identify which magneto is
causing the interference.
Manifold pressure fluctuating. Troubleshoot fluctuating manifold
pressure.
Unsatisfactory engine idle cut- Engine getting fuel with mixture Adjust fuel control not in full “IDLE
off. in “IDLE CUT-OFF”. CUT-OFF” position. Check
auxiliary fuel pump “OFF”. Check
for leaking fuel manifold valve.
Replace defective components.

77-6460004 Continued Airworthiness

Rev. C P a g e | 14
26 Apr 2013
 General Aviation Modifications, Inc.

Trouble Probable Cause Remedy

Low engine oil pressure or high Insufficient oil in oil sump or Add oil, or change oil to proper
oil temperature. using improper grade oil for viscosity.
prevailing ambient temperature.
Oil cooler restriction. Clean oil cooler.

Debris under oil pressure relief Check oil pressure adjuster seat for
valve. debris.
Leaking, damaged, or loose oil Check for restricted lines and loose
line connection. Restricted connections and cut the oil filter and
screen or filter. inspect for contaminates or for
partially plugged oil filter. Clean
parts, tighten connections and
replace defective parts.
Oil pressure adjusted too low. Readjust oil pressure if necessary.
Malfunctioning Turbocharger. Turbocharger rotor jammed or Replace turbocharger.
rubbing.
Turbocharger inlet blocked. Remove blockage.
See section “Engine lacks power, reduction in maximum manifold
pressure or critical altitude.”
Engine has low critical altitude. See section “Engine lacks power, reduction in maximum manifold
pressure or critical altitude.”
Manifold pressure surges at Absolute Pressure Controller Replace Absolute Pressure
altitude. malfunctioning. Controller.
Wastegate capillary tube Disconnect lines from controller to
plugged. wastegate and back flush wastegate
and lines with oil compatible solvent
at 50 psi.
Absolute Pressure Controller Remove sense line blockage.
sensing line blocked.
Induction system leaking. Tighten all connections in induction
system.
Leak in exhaust system. Adjust or repair exhaust system.
Oil leaking or dripping from Acceptable drip. Continue monitoring drip.
wastegate actuator drain. Actuator piston seal ruptured or Replace Actuator.
leaking.
Low manifold pressure at take- Absolute Pressure Controller out Adjust Absolute Pressure Controller
off. of adjustment or defective. or replace controller if defective.
Induction system leaking. Adjust or repair induction system.
Wastegate capillary tube Disconnect lines from controller to
plugged. master wastegate and back flush
wastegate and lines with oil
compatible solvent at 50 psi.
Leak in exhaust system. Eliminate any leaks.

77-6460004 Continued Airworthiness

Rev. C P a g e | 15
26 Apr 2013
 General Aviation Modifications, Inc.
MAINTENANCE PRACTICES

TIME LIMITS AND MAINTENANCE CHECKS

A. Overhaul And Replacement Schedule

The following items must be overhauled or replaced at the following intervals unless otherwise
noted. To ensure correct observation of these times, the date of removal, installation, or
overhaul of such components as well as the airplane’s flight hours must be entered into the
Service Time Record filed in the Airplane Maintenance Log.

Item Interval Replc. O’haul Notes

1. Flexible Turbo On condition not X
System Lines to exceed 10 years
2. Turbocharger See Note X Recommend overhaul turbocharger at
1000 hrs not to exceed 2000 hrs.
3. Wastegate See Note X Recommend overhaul Wastegate at
1000 hrs not to exceed 2000 hrs.
4. Absolute Pressure See Note X Recommend overhaul Absolute
Controller Pressure Controller at 1000 hrs not to
exceed 2000 hrs.
5. V-band clamps 450 hrs time in X After 350 hrs if clamp is removed or
service first annual after 350 hrs, whichever
occurs first.
6. Magneto 3 years or 300 X
Pressurization hours.
Filter

B. Scheduled Maintenance Checks

Chap-Sect Interval Initials

Airframe Group
Reference
100 Special
1. All external surfaces for signs of exhaust leaks: X 1st 25
Flat gray, gray-white or light gray powdering, or a Hrs and
sooty appearance indicate exhaust leakage. Signs of every
deterioration include warping, deformation, thinning, 50 Hrs
collapse, dents, cracking, tears, separation, scaling, after.
weld separation, discoloration, corrosion, metal
pitting or burn-through.
2. All external joints, clamps, and couplings for X 1st 25
misalignment, warpage, broken, loose or missing Hrs
fasteners, clamps, and abnormal wear.
3. Visually inspect tailpipe heat exchanger, and shields X 1st 25
for condition. Hrs
4. Visually inspect exhaust stack to flange interface for X 1st 25
cracks in welds or weld heat affected area, blown out Hrs

77-6460004 Continued Airworthiness

Rev. C P a g e | 16
26 Apr 2013
 General Aviation Modifications, Inc.
Chap-Sect Interval Initials
Airframe Group
Reference
100 Special
or missing gaskets.
5. Visually inspect all welds and area adjacent to the X 1st 25
weld for cracks or weld separation. Hrs
6. Visually inspect tailpipes, for erosion, thinning, X 1st 25
bulging or burn through. Hrs
7. Visually inspect bracing, supports and support attach X 1st 25
lugs on other structures for security. Hrs
8. Visually inspect surrounding structures for X 1st 25
discoloration, heat damage, or burning. Hrs
9. Cold and Hot Air Hoses 50 Hrs
Visually Inspect for leaks, security, and condition.
10. Engine Baffling and Seals 50 Hrs
Visual Inspection for cracks, tears, and rips.
11. Turbocharger Mounting Bracket 50 Hrs
Visually Inspect for security and condition.
12. Engine Heat Shields 50 Hrs
Visually Inspect for security and condition.
13. Engine Mount Isolators X
Visually Inspect for cracking, splitting, and general
condition.
14. Turbonormalizer Kelly Aerospace X
Visually Inspect turbine for oil deposits, and turbine Troubleshooting
impeller damage. Visually Inspect compressor wheel Reference Guide
for damage, interference, and free rotation. 400888-0000
(Inspection may be accomplished by flexible bore
scope or by removal of tailpipe.)
15. Turbonormalizer System Lines X
Visually Inspect for chafing, obstruction, security, and
general condition.
16. Wastegate and Absolute Pressure Controller X
Visually Inspect for security and condition.
17. Exhaust Heat Exchanger X
Pressure test inspection of exhaust heat exchanger for
signs of cracking. Repair or replace on condition.
19. Induction System Filter Clean per X
Clean filter at each inspection period or when filter is Cessna 177RG
more than 50% covered by foreign material. (Due at Service Manual.
annual or on condition, not less than each annual.)
20. Alternate Air Door X
Visually Inspect for secure closing. Check for loose
fasteners or rivets that may enter turbocharger. Clean
area around alternate air door.

77-6460004 Continued Airworthiness

Rev. C P a g e | 17
26 Apr 2013
 General Aviation Modifications, Inc.
All service interval times are to be referenced from initial installation of system or overhaul of
turbonormalizing system, or after replacement of major exhaust components.

Chap-Sect Interval Initials

Engine Group Reference
100 Special
1. Engine Oil 50 Hrs
Drain and change every 50 hours or 6 months,
whichever occurs first.
2. Fuel Injection System 50 Hrs
Visually Inspect for leaks, security, and condition
3. Vent Lines to Fuel Pump and Fuel Discharge Nozzles 50 Hrs
Visually Inspect for chafing, obstruction, security, and
general condition.
4. Fuel Discharge Nozzles GAMI X On
Visually Inspect nozzles and manifold valve for fuel Installation Condition
stains, security, and proper sealing of upper deck Procedure
reference manifolds. Remove and clean injector No. IP-98-002
nozzles every 5 years or 500 hours, whichever comes
first. Remove, clean, and replace per GAMI
Installation Procedure No. IP-98-002.
5. Spark Plugs TAT Initially
Replace RHB36S and RHB32S spark plugs, if SB11-07 per TAT
equipped, with RHB29E or equivalent heat range SB11-07
massive electrode spark plugs per TAT SB11-07. If
RHB29E spark plugs are not available RHB32E or Thereafter,
equivalent heat range massive electrode spark plugs On
are acceptable. Condition

77-6460004 Continued Airworthiness

Rev. C P a g e | 18
26 Apr 2013
 General Aviation Modifications, Inc.

C. Progressive Inspection Program

The following inspections are to be performed in addition to the Routine and detailed Inspection
for the Engine Group of a typical Progressive Inspection Program.

Engine Group Chap-Sect Reference

Routine Inspection Criteria
1. Induction System Hoses and Couplings
Visually Inspect for security, leaks, and condition.
2. Turbocharger
Visual inspection of turbine for carbonization, oil deposits, and turbine
impeller damage. Visually Inspect compressor wheel for damage,
interference, and free rotation.
3. Turbocharger Mounting Brackets
Visually Inspect for security and condition.
4. Flexible Turbo System Lines
Visually Inspect for chafing, obstruction, security, and general
condition.
5. Wastegate and Absolute Pressure Controller
Visually Inspect for security and condition.
6. Vent Lines to Fuel Pump and Discharge Nozzles
Visually Inspect for chafing, obstruction, security, and general
condition.
7. Engine Heat Shields
Visually Inspect for security and condition.
8. Exhaust Muffler/Heat Exchanger
Inspect muffler/heat exchanger for signs of cracking or leakage. Repair
or replace on condition.

77-6460004 Continued Airworthiness

Rev. C P a g e | 19
26 Apr 2013
 General Aviation Modifications, Inc.

Engine Group Chap-Sect Reference

Detailed Inspection Criteria
1. Induction System Hoses and Couplings
Visually Inspect for security, leaks, and condition. Tighten hose clamps
as required.
2. Turbocharger Kelly Aerospace
Visually Inspect turbine for carbonization, oil deposits, and turbine Troubleshooting
impeller damage. Visually Inspect compressor wheel for damage, Reference
interference, and free rotation. Guide 400888-0000
3. Turbocharger Mounting Brackets
Visually Inspect for security and condition. Replace any cracked or
damaged brackets.
4. Flexible Turbo System Lines
Visually Inspect for chafing, obstruction, security, and general
condition.
5. Wastegate and Absolute Pressure Controller
Visually Inspect for security and condition. Lubricate wastegate
butterfly with Mouse Milk®
6. Vent Lines to Fuel Discharge Nozzles
Visually Inspect for chafing, obstruction, security, and general
condition.
7. Engine Heat Shields
Visually Inspect for security and condition.
8. Exhaust Heat Exchanger
Pressure test heat exchanger for signs of cracking. Repair or replace on
condition.

77-6460004 Continued Airworthiness

Rev. C P a g e | 20
26 Apr 2013
 General Aviation Modifications, Inc.
TURBOCHARGERS

The turbocharger is an exhaust gas driven compressor, or air pump, which provides high air mass flow to
the engine intake manifold. The turbocharger is composed of a turbine wheel, compressor wheel, turbine
housing and compressor housing. The turbine, compressor wheel, and interconnecting drive shaft
comprise one complete assembly and are the only moving parts in the turbocharger. Turbocharger
bearings are lubricated with filtered oil supplied from the engine oil system. Engine exhaust gas enters
the turbine housing to drive the turbine wheel. The turbine wheel, in turn, drives the compressor wheel,
producing high density air entering the engine induction manifold. Exhaust gas is then dumped overboard
through the exhaust outlet of the turbine housing and exhaust tailpipe. Air is drawn into the compressor
through the induction air filter and is forced out of the compressor housing through a tangential outlet to
the intake manifold. The degree of compression is controlled by means of a wastegate valve, which
varies the amount of exhaust gas allowed to bypass the turbine.

ABSOLUTE PRESSURE CONTROLLER (APC)

The Absolute Pressure Controller (APC) uses engine oil pressure to actuate the wastegate. The
turbocharger is controlled by the wastegate, wastegate actuator, the absolute pressure controller and
pressure relief valve (PRV). The wastegate bypasses engine exhaust gas around the turbonormalizer
turbine inlet. The wastegate actuator, which is physically connected to the wastegate by mechanical
linkage, controls the position of the wastegate butterfly valve. The absolute pressure controller controls
the maximum turbonormalizer compressor discharge pressure. The pressure relief valve prevents an
excessive pressure increase from the turbocharger compressor.

The wastegate actuator is spring-loaded to position the wastegate to the normally open position when
there is not adequate oil pressure in the wastegate actuator power cylinder during engine shut down.
When the engine is started, oil pressure is fed into the wastegate actuator power cylinder through an
internal capillary tube. This automatically fills the wastegate actuator power cylinder and lines leading to
the controller, blocking the flow of oil by normally closed metering and/or poppet valves. As oil pressure
builds up in the wastegate actuator power cylinder, it overcomes the force of the wastegate open spring,
closing the wastegate. When the wastegate begins to close, the exhaust gases causes the turbonormalizer
to rotate faster, raising the turbonormalizer compressor outlet pressure. As the compressor outlet pressure
rises, the aneroid bellows in the absolute pressure controller senses the increase in pressure. When at high
engine speed and load and the proper absolute pressure is reached, the force on the aneroid bellows opens
the normally closed metering valve. When the oil pressure in the wastegate actuator power cylinder is
lowered sufficiently, the wastegate actuator opening spring forces the mechanical linkage to open the
wastegate. A portion of the exhaust gases then bypasses the turbonormalizer turbine, thus preventing
further increase of turbonormalizer speed and holding the compressor discharge absolute pressure to the
desired value. Conversely, at engine idle, the turbonormalizer runs slowly with low compressor pressure
output; therefore, the low pressure applied to aneroid bellows is not sufficient to affect the unseating of
the normally closed metering valve. Consequently, engine oil pressure keeps the wastegate closed. The
PRV will open to prevent any excessive pressure increase from the turbocharger compressor.

MAGNETOS

If the engine has two separate magnetos, then these magnetos may have been fitted with a magneto
pressurization system to enable them to work at higher altitudes without cross firing due to the reduced
resistivity of lower pressure atmosphere. This pressurization system consists of magneto housing gaskets,

77-6460004 Continued Airworthiness

Rev. C P a g e | 21
26 Apr 2013
 General Aviation Modifications, Inc.
a calibrated bleed orifice, an inlet air filter, and tubing to rout pressurized air to the magnetos. The
pressurization system gets the pressurized air from the induction system from just downstream of the
turbochargers. In this application the timing is set at 20° BTDC ±0.5°. The inlet air filter will need to be
changed periodically as shown in the Overhaul and Replacement Schedule listed under Maintenance
Practices.

Ignition timing:

Magneto Spark occurs,

Engine
pressurization degrees BTC
IO-360-A1B6 Yes 20º ± .5º
IO-360-A1B6D No 22º ± .5º
IO-390-A1A6 Yes 20º ± .5º

ABSOLUTE PRESSURE CONTROLLER (APC)

A. Removal and Installation -Absolute Pressure Controller

1) Disconnect and tag oil lines from controller and plug or cap open lines and fittings.
2) Disconnect compressor outlet pressure sensing lines from controller and plug or cap open
lines and fittings.
3) Remove two bolts attaching controller to mounting bracket on firewall.
4) Remove controller from aircraft, being careful not to drop controller unit.
5) Installation of the controller may be accomplished by reversing the preceding steps.

B. Adjustment – Absolute Pressure Controller

Caution: With engine oil temperature at 170°F or greater, slowly open

throttle and note maximum manifold pressure obtainable.

-5 Absolute Pressure Controller Adjustment Procedure

1) Adjust the Absolute Pressure Controller so that the engine maintains 29.6 in. Hg at full
throttle in flight with the oil temperature greater than 170°F. Normal in flight oil pressure
should be between 55 and 95 psi.

Note: Some aircraft have a different absolute pressure controller

installed on them. This can be identified by a square head on
the bottom of the controller instead of a hex head fitting. THIS
IS THE ADJUSTER. DO NOT TURN MORE THAN IS
NEEDED FOR THE ADJUSTMENT. See the procedure
below for the -10 absolute pressure controller.

2) Cut safety wire and remove plug from bottom of absolute controller. (It is normal for a
small amount of oil to be encountered upon removal of the plug.)

77-6460004 Continued Airworthiness

Rev. C P a g e | 22
26 Apr 2013
 General Aviation Modifications, Inc.
3) Using a flat blade screw driver, rotate metering valve seat clockwise to increase manifold
pressure and counterclockwise to decrease manifold pressure. Lightly tap the unit after
each adjustment to seat internal parts.

Note: When adjusting, rotate in VERY small increments as this is extremely

sensitive. Approximately 13 degrees rotation will change the manifold
pressure reading about one inch Hg.

4) Install the bottom plug in absolute pressure controller, then operate engine as in step “1”
above to ascertain that adjustment has not caused an unacceptable change in manifold
pressure.

Note: When making adjustment on the ground, the hotter the engine gets, the
lower the manifold pressure will be.

5) After each adjustment, the aircraft must be flight tested to check results.
6) Repeat this procedure until desired results are obtained.
7) Safety controller plug.

-10 Absolute Pressure Controller Adjustment Procedure

1) Adjust the Absolute Pressure Controller so that the engine maintains 29.6 in. Hg at full
throttle in flight with the oil temperature greater than 170°F. Normal in flight oil pressure
should be between 55 and 95 psi.
2) Cut safety wire.
3) Using a 1/2” wrench, rotate metering valve seat clockwise to increase manifold pressure
and counterclockwise to decrease manifold pressure. Lightly tap the unit after each
adjustment to seat internal parts.

Note: When adjusting, rotate in VERY small increments. Approximately

¼ turn will change the manifold pressure reading about one inch
Hg.

4) Operate engine as in step “1” above to ascertain that adjustment has not caused an
unacceptable change in manifold pressure.
5) After each adjustment, the aircraft must be flight tested to check results.
6) Repeat this procedure until desired results are obtained.
7) Safety wire adjuster.

Torque values are located in Appendix A.

TURBOCHARGER

A. Removal and Installation - Turbocharger

1) Loosen clamp and remove induction tubing from the front of the turbochargers.

77-6460004 Continued Airworthiness

Rev. C P a g e | 23
26 Apr 2013
 General Aviation Modifications, Inc.
2) Loosen clamp attaching tailpipe to turbine exhaust outlet and work tailpipe from exhaust
system.
3) Disconnect and tag oil lines from turbochargers and plug or cap open lines and fittings.
4) Remove bolts, washers, and nuts from exhaust flange that connects the turbocharger to the
exhaust manifold assembly.
5) Remove the turbocharger from aircraft being careful not to drop the unit.
6) Installation may be accomplished by reversing the preceding steps and alignment of
support rods.

Caution: Pre-oil turbocharger before engine operation.

WASTEGATE ACTUATOR

A. Removal and Installation - Wastegate Actuator

1) Disconnect and tag oil lines from actuator and plug or cap open lines and fittings.
2) Loosen clamp attaching tailpipe to turbine exhaust outlet and work tailpipe from exhaust
system.
3) Remove bolts holding wastegate manifold assembly to exhaust system.
4) Remove bolts, washers, and nuts attaching wastegate manifold assembly to the
turbocharger.
5) Remove the assembly from aircraft being careful not to drop the unit.
6) Installation may be accomplished by reversing the preceding steps.

Note: When installing the assembly, be sure the gaskets at inlet and
outlet of valve are installed and are in good condition. Replace
gaskets if damaged.

B. Adjustment - Wastegate Actuator

If adjustment of wastegate actuator is required, remove wastegate actuator in accordance with

“Removal and Installation of Wastegate Actuator” instructions and send to an approved
facility for repair or overhaul of wastegate actuators.

PRESSURE RELIEF VALVE

A. Removal And Installation Of Pressure Relief Valve

1) Remove bolts, washers, and nuts holding pressure relief valve to induction manifold assembly.
2) Remove pressure relief valve from induction manifold assembly.
3) Check condition of O-ring on face of pressure relief valve before installation.
4) Clean surface of induction manifold assembly, verify that the surface is smooth and free from
nicks, gouges, or burrs that may damage the O-ring or prevent proper seal of the pressure relief
valve.
5) Install the pressure relief valve by lining up the holes in the pressure relief valve with the holes
in the induction manifold assembly and installing bolts, washers, and nuts in the same
orientation as when removed.

77-6460004 Continued Airworthiness

Rev. C P a g e | 24
26 Apr 2013
 General Aviation Modifications, Inc.
ENGINE

A. Removal and Overhaul - Engine

If the engine is to be removed, the turbocharger and its accessories should be removed in
accordance with the following steps before removing engine mount bolts. All other procedures for
engine removal listed in the Cessna 177RG service manual apply.
1) Disconnect hoses to the intercooler.
2) Remove wastegate in accordance with “Removal and Installation of Wastegate Actuator”
instructions.
3) Remove turbocharger in accordance with “Turbocharger Removal and Installation”
instructions.

Note: The replacement normally aspirated IO-360 or IO-390 engine must be

modified before installation as a turbonormalized Cessna Cardinal RG
engine. Therefore turbonormalized engines must be overhauled by a
facility approved by Tornado Alley Turbo, Inc. (TATI) and in accordance
with procedures established by TATI. Installation of new or overhauled
engines in existing turbonormalized aircraft requires installation of
components at TATI or a facility approved by TATI. Overhaul
turbochargers, MPC, wastegates, PRV, and fuel injection servo at the
same time as engine overhaul. Contact TATI for a current list of approved
overhaul facilities for engine and components. Keep fuel injectors in
proper cylinders.

B. Installation – Engine
Before installing the engine, the aft accessories should be installed prior to attaching the engine to
the engine mounts per the Cessna service manual. The turbocharger and exhaust can then be
installed on the engine.
1) Install the turbocharger in accordance with “Turbocharger Removal and Installation”
instructions.
2) Install the wastegate per “Removal and Installation of Wastegate Actuator” instructions.
3) Connect all hoses and induction system.

C. Inspection - Post Engine Overhaul / Installation

After overhaul and reinstallation of the engine and turbonormalizing system a final inspection is
required.

Inspect the following for security, signs of chaffing, leaking, and general condition:
1) All hose connections, routing, and security.
2) All clamps and couplings for proper engagement and alignment.
3) Induction tubing for current and possible chafe problems.
4) Tightness of all exhaust mounting hardware and v-band clamps.
5) Clearance of exhaust through cowling.
6) Wiring chafe and heat related problems.
7) Engine probe wiring to exhaust clearance.
8) Cylinder lower fuel drain plumbing clearance to exhaust and heat shields.
9) Heat shield clearance off of exhaust components.
10) Turbo supports for security and safety wire.

77-6460004 Continued Airworthiness

Rev. C P a g e | 25
26 Apr 2013
 General Aviation Modifications, Inc.
11) Turbo air inlet SCEET to front cowling clearance.
12) Throttle, propeller, and mixture control levers full travel.

D. Servicing - Post Engine Overhaul / Installation (Before First Engine Start)

After overhaul and reinstallation of the engine and turbonormalizing system, pre-oil the
turbochargers as described below.
1) Remove one spark plug from each cylinder.
2) Ground all ignition leads to engine.
3) Fuel Selector to “OFF”.
4) Clear engine and propeller area from obstacles.
5) Ensure proper oil level.
6) Turn on battery power.
7) With security person outside, crank engine and monitor indicated oil pressure. Crank engine
for no more than 30 seconds at a time. When 12 psi or more is consistently indicated on the
oil pressure indicator the turbo will be considered to be pre-oiled.
8) Turn off battery power.
9) Reinstall spark plugs and leads and visually inspect the engine compartment for any oil leaks.
10) Conduct a fuel prime operation check by putting the Fuel Selector to either tank, and mixture
full rich.
11) Turn on battery.
12) Activate auxiliary fuel pump switch and observe fuel flow for brief positive indication of fuel
flow.
13) Turn off battery.
14) Inspect engine area for any fuel leaks, paying careful attention to the fuel discharge nozzles
and fuel lines.

E. Operational Inspection - First Flight Run-Up

Perform the following Run-Up Procedure prior to first flight after reinstallation of
turbonormalizing system during overhaul or maintenance of turbonormalizing system
components.

With upper and lower cowling removed, fireguard/observer present:

Note: Make sure turbocharger is pre-oiled under Servicing – Post Engine

Overhaul/Installation.

1) Start engine using normal starting procedures.

2) Keeping RPM below 1700 rpm, monitor oil pressure, fuel flow, manifold pressure, and engine
temperatures for normal operation.
3) Run engine for a short time, only long enough to check all indications and ensure no fuel or oil
leakage.
4) Shut engine down, inspect engine and turbo system for any sign of leakage, chafing, or heat
damage.
5) Install complete cowling.
6) Perform normal engine start and operation to achieve proper operating temperatures.
7) Perform magneto operational check.
8) Perform high power operation check.

77-6460004 Continued Airworthiness

Rev. C P a g e | 26
26 Apr 2013
 General Aviation Modifications, Inc.
9) Monitor engine operating parameters and make adjustments as described in section F.
10) After achieving the desired operating parameters, inspect the engine compartment for evidence
of leaking, chafing, and heat damage.
11) Release aircraft for return to service flight.

F. Adjustments -Post Engine Overhaul / Installation

Make the following adjustments as required prior to first flight after reinstallation of
turbonormalizing system during overhaul or maintenance of turbonormalizing system
components.

1) Engine Setup
a) RPM
All adjustments need to be made at full operating RPM (2700). Fuel Flow, Manifold Pressure,
Turbo Inlet Temperature, and Oil Pressure, to be measured at full RPM. If needed, make
adjustments at the propeller governor. Ensure normal operating oil temperature before making
RPM adjustments.

Note: Every airplane may not make full RPM during static ground run.
Make adjustments as close as possible, then fly and readjust after
flight per pilot information.

b) Fuel Flow
For the IO-360 turbonormalized engine, the target full power (RPM and MAP) fuel flow is
21.5 GPH ± 0.5 GPH. Normally, full power fuel flow for the IO-360 will be 21.5 GPH. For
the IO-390 turbonormalized engine, the target full power (RPM and MAP) fuel flow is 22.0
GPH ± 0.5 GPH. Normally, full power fuel flow for the IO-390 will be 22.0 GPH. To
achieve these indicated target amounts adjustments may need to be made to the fuel injection
servo.

Note: Fuel flow is proportional to RPM, and Manifold Pressure. Given

targets are set at engine operating oil temperature, engine operating
RPM, and indicated 29.6 inches of manifold pressure. During the
run-up, the oil temperature should be not less than 170° F; cooler oil
will make higher manifold pressure which will make higher fuel
flow.

c) Manifold Pressure
Maximum manifold pressure in cruise flight is 29.6 inches at full throttle with normal engine
operating oil temperature. Make adjustments to manifold pressure according to “Absolute
Controller Adjustments” section above.

Note: The APC pressure set point will vary slightly with engine oil
temperature and oil pressure. If the oil temperature is cooler, the
manifold pressure may indicate higher. Be sure to make
adjustments with the engine oil temperature at or above 170° F.

d) Oil Pressure

77-6460004 Continued Airworthiness

Rev. C P a g e | 27
26 Apr 2013
 General Aviation Modifications, Inc.
Normally, there should not be a need to make oil pressure adjustments, but if the oil pressure
is below 25 PSI at idle, the oil pressure must be increased enough to keep adequate oil flow
through the turbo at idle speeds. The turbo inlet oil pressure check valve is preset to 10 PSI.
If oil pressure is lower than this, the turbo will “starve” for oil.

Note: Make oil pressure adjustment according to Lycoming Direct Drive

Engine Overhaul Manual.

G. Functional Inspection - Return to Service Flight

Perform the following Return to Service Flight after reinstallation of turbonormalizing system
during overhaul or maintenance of turbonormalizing system components.

1) Perform normal start up, taxi, engine parameter checks and any ground operational checks
not related to the turbo system.
2) Utilizing normal Cessna before flight checklist perform additional full power performance
operational check prior to releasing the brakes for take off. Take note of: engine RPM, fuel
flow, TIT, manifold pressure, and oil temperature.
3) Depending on oil temperature the parameters may vary. Optimally, for the IO-360, 2700
RPM, 29.6 inches MP, 21.5 GPH ± 0.5 GPH at normal operating oil temperature. For the
IO-390, 2700 RPM, 29.6 inches MP, 22.0 GPH ± 0.5 GPH at normal operating oil
temperature.
4) Because of a direct correlation between oil temperature and manifold pressure at lower than
normal operating oil temperature, manifold pressure may indicate higher than redline.
5) Because of a direct correlation between manifold pressure and fuel flow higher manifold
pressure will give higher fuel flow.
6) At full power and full rich mixture, the TIT will normally be between 1250-1330° F.
7) Utilize normal Lycoming engine break-in procedures. Keep in mind the turbo parameters
and the added system components.

H. Post Return to Service Flight Inspections

1) After first flight, recheck torque on V-band clamps. Use caution to not over torque the V-band
clamps.
2) Inspect engine compartment for evidence of leaking, chafing, and heat damage.

77-6460004 Continued Airworthiness

Rev. C P a g e | 28
26 Apr 2013
General Aviation Modifications, Inc.

Exhaust System

77-6460004 Continued Airworthiness

Rev. C P a g e | 29
26 Apr 2013
General Aviation Modifications, Inc.

Induction System

77-6460004 Continued Airworthiness

Rev. C P a g e | 30
26 Apr 2013
General Aviation Modifications, Inc.

Lubrication System

77-6460004 Continued Airworthiness

Rev. C P a g e | 31
26 Apr 2013
General Aviation Modifications, Inc.

“*” denotes TCM P/N

Upper Deck Lines

For aircraft without upper deck reference to fuel pump

77-6460004 Continued Airworthiness

Rev. C P a g e | 32
26 Apr 2013
General Aviation Modifications, Inc.

“*” denotes TCM P/N

Upper Deck Lines

For aircraft with upper deck reference to fuel pump

77-6460004 Continued Airworthiness

Rev. C P a g e | 33
26 Apr 2013
 General Aviation Modifications, Inc.

Appendix A. Component Specific Torque Specifications

Torque Value
SIZE FASTENER IN./LB. FT./LB. MODELS AFFECTED
Miscellaneous Hardware (see Note 5)
10028H Clamp 45 - 50 3.7 - 4.1 All Turbonormalized models
10040H Clamp 45 - 50 3.7 - 4.1 All Turbonormalized models
10048H Clamp 45 - 50 3.7 - 4.1 All Turbonormalized models
10016H Clamp 45 - 50 3.7 - 4.1 All Turbonormalized models
Miscellaneous Fuel Injection (see Note 5)
#3 (.38-24) Nut- "B", Controller 70 - 105 5.8 - 8.7 All Turbonormalized models
reference line
#6 (.5625-18) Nut- "B", upper deck 150 - 195 12.5 - 16.2 All Turbonormalized models
reference tube
.50-24 Nut- Air reference sleeve Snug nut finger tight to set All Turbonormalized models
"B" nut to air reference line seal between nut and male
connector, then tighten
additional 3/4 to 1 turn.
.125-27 Nozzle- Fuel injector (with 55 - 65 4.6 - 5.4 All Turbonormalized models
anti-seize compound)
.31-32 Nut- Fuel injection line 40 - 45 3.3 - 3.7 All Turbonormalized models
Exhaust (see Note 5)
.3125-24 Nut- Exhaust manifold 180 - 220 15.0 - 18.3 All engine models
flange to cylinder
.38-24 Nut- Turbocharger to 275 - 325 22.9 - 27.1 All Turbonormalized models
exhaust flange
.250-28 Nut- All .250 bolts to attach 90 - 100 7.5 - 8.3 All Turbonormalized models
support brackets
#10-32 Bolt- Turbo heatshield 36 - 50 3.0 - 4.2 All Turbonormalized models
#8-32 Screw- Turbo heatshield 17.5 - 22.5 1.5 - 4.2 All Turbonormalized models
.3125-24 Nut- All .312 nuts for turbo 180 - 220 15.0 - 18.3 All Turbonormalized models
support
.25-28 Nut- Exhaust coupling "V" 60 - 65 5.0 - 5.4 All Turbonormalized models
band clamp
Turbo (see Note 2)
.3125-18 Bolt- Turbo oil inlet adapter 155 - 175 12.9 - 14.6 All Turbonormalized models
.376-15 Bolt- Turbo oil outlet 220 - 260 18.3 - 21.7 All Turbonormalized models
adapter
.125-27 Valve- Turbo oil inlet 100 - 105 8.3 - 8.7 All Turbonormalized models

.3125-18 Bolt- Turbo compressor 130 - 140 10.8 - 11.6 All Turbonormalized models
housing
Fitting and Hose connection (see Note 1 & 6)
.125-27 pipe Fitting- 1/8 Pipe thread 60 - 80 5.0 - 6.7 Plus alignment
.250-18 pipe Fitting- 1/4 Pipe thread 130 - 150 10.8 - 12.5 Plus alignment
.375-18 pipe Fitting- 3/8 pipe thread 185 - 215 15.4 - 18.0 Plus alignment

77-6460004 Continued Airworthiness

Rev. C P a g e | 34
26 Apr 2013
 General Aviation Modifications, Inc.
Appendix A. Component Specific Torque Specifications
Torque Value
SIZE FASTENER IN./LB. FT./LB. MODELS AFFECTED
.44-20 #4 Aluminum 90 - 105 7.5 - 8.7 Bulkhead fitting (with o-ring)
.44-20 #4 Steel 110 - 130 9.1 - 10.8 Bulkhead fitting (with o-ring)
.56-18 #6 Aluminum 125 - 145 10.4 - 12.0 Bulkhead fitting (with o-ring)
.56 -18 #6 Steel 225 - 275 18.7 - 22.9 Bulkhead fitting (with o-ring)
.75-16 #8 Aluminum 240 - 280 20.0 - 23.3 Bulkhead fitting (with o-ring)
.75-16 #8 Steel 400 - 450 33.3 - 37.5 Bulkhead fitting (with o-ring)
.44-20 #4 Aluminum 90 - 105 7.5 - 8.7 Straight thread (with o-ring)
.44-20 #4 Steel 110 - 130 9.1 - 10.8 Straight thread (with o-ring)
.56-18 #6 Aluminum 125 - 145 10.4 - 12.0 Straight thread (with o-ring)
.56 -18 #6 Steel 225 - 275 18.7 - 22.9 Straight thread (with o-ring)
.75-16 #8 Aluminum 240 - 280 20.0 - 23.3 Straight thread (with o-ring)
.75-16 #8 Steel 400 - 450 33.3 - 37.5 Straight thread (with o-ring)
#3 (.38-24) Brass / Aluminum fitting 70 - 105 5.8 - 8.75 Hose fitting "B" nut
#3 (.38-24) Steel fitting 95 - 140 7.9 - 11.6 Hose fitting "B" nut
#4 (.4375-20) Brass / Aluminum fitting 100 -140 8.3 - 11.6 Hose fitting "B" nut
#4 (.4375-20) Steel fitting 135 - 190 11.2 - 15.8 Hose fitting "B" nut
#6 (.5625-18) Brass / Aluminum fitting 150 - 195 12.5 - 16.2 Hose fitting "B" nut
#6 (.5625-18) Steel fitting 215 - 280 17.9 - 23.3 Hose fitting "B" nut
#8 (.750-16) Brass / Aluminum fitting 270 - 350 22.5 - 29.1 Hose fitting "B" nut
#8 (.750-16) Steel fitting 470 - 550 39.1 - 45.3 Hose fitting "B" nut

NOTE
1 Bulkhead fittings consist of fitting with o-ring and jam nut. To properly install the
fitting, thread jam nut past first set of threads and to the end of the second set, slide
o-ring over the long end to rest in the groove between threads. Thread the fitting
into the receiving port until o-ring makes contact witht he port seat. Turn fitting for
alignment while ensuring o-ring remains in the groove without contacting threads.
Tighten jam nut to specified torque above.
2 Turbo compressor housing and hot section housing require the application of Locktite
545 be placed on the threads prior to installation of bolts.
3 Use locking devices as required after installation and applying the specified torque
values.
4 The turbo oil inlet valve requires special torque of 105 inch lbs plus the application of
Locktite 545 prior to installation.
5 Specific requirements as stated in Lycoming Service Table of Limits will take
precedence over this document as it relates to Lycoming components.
6 Utilize accepted procedures and techniques for the installation of all hoses in
reguards to alignment and support. Back up all fittings when tightening hoses.

77-6460004 Continued Airworthiness

Rev. C P a g e | 35
26 Apr 2013