SI-PAC-026R2

SERVICE INSTRUCTION - PAC

PAC
Fuel pump and fuel pump part kits for ROTAX® Aircraft
Engines Type 915 i and 916 i (Series)
ATA System: 73-00-00 Fuel system

1) Planning information
“PAC” Service Instruction Documents provide detailed information on non-certified ROTAX®
Aircraft Engine Parts and Accessories. Referenced parts and accessories are provided without
EASA certification or ASTM compliance. Certification / Compliance of referenced Parts and
Accessories must be completed by the aircraft OEM.
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

The fuel pumps are not a part of the Engine Type Design. The pumps
NOTICE
have been tested and released by BRP-Rotax but are not certified.
The correct function in conjunction with the entire fuel system and the
certification of the fuel pump(s) is the responsibility of the aircraft
manufacturer and must be carried out jointly with the aircraft.

1.2) Concurrent ASB/SB/SI and SL

In addition to this Service Instruction - PAC the following documents must be observed and
complied with:

- In general, all relevant Alert Service Bulletins (ASB), Service Bulletins (SB), Service
Instructions (SI), Service Letters (SL), Service Instruction - Parts and Accessories (SI-PAC).
1.3) Reason
Introduction of new GENUINE ROTAX® fuel pump and fuel pump parts kit including installation
and maintenance information.

1.4) Subject
Fuel pump and fuel pump parts kits for ROTAX® Aircraft Engine Type 915 i and 916 i A
(Series).

1.5) Compliance
None – for information only.

1.6) Approval
None.
d07131

11 July 2024 Current valid documentation see: 73-00-00

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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 - - - Single pump (part no. 889731) 0.7 kg (1.54 lbs.)
Moment of inertia - - - unaffected.
1.9) Electrical load data
See section 3.2.

1.10) Software modifications

No change.

1.11) References
In addition to this technical information refer to current issue of

- In general, Illustrated Parts Catalog (IPC) and in particular:

Chapters 73-10-00 and 76-10-00
- In general, Installation Manual (IM) and in particular:
Chapters 73-10-00 and 76-00-00
- In general, Maintenance Manual Line (MML) and in particular:
Chapter 05-20-00
- In general, Maintenance Manual Heavy (MMH) and in particular:
Chapters 73-00-00 and 76-00-00
- In general, Operators Manual (OM) and in particular:
Chapters 2.3 and 3
- In general, Aircraft’s Pilot Operating Handbook (POH)

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: [Link].
Updates and current revisions can be downloaded for free.

1.12) Other Publications affected

None.
1.13) Interchangeability of parts
All parts are interchangeable.

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2) Material Information
2.1) Material
Price and availability will be provided on request by ROTAX® Authorized Distributors or
their independent Service Centers.

2.2) Company support information

Any possible support by BRP-Rotax will be provided on request by ROTAX® Authorized
Distributors or their independent Service Centers.

2.3) Material requirement per engine

Parts requirements:

Qty /
Fig. no. Part no. Description Application
engine
1 889732 (2) Fuel pump - packaged 915 i / 916 i
Consists of:
889731 1 Fuel pump 915 i / 916 i
2 481481 (2) Fuel pump parts kit UNF 915 i / 916 i UNF
Consists of:
875018 1 Check valve AN6 UNF
875017 1 Adapter AN6 / M14x1,5 UNF Inlet
250735 1 Gasket ring A14x20
875016 1 Connection AN6/M10x1 UNF Outlet
250425 1 Gasket ring 10.2/15/1.5
881305 1 Connector set fuel pump Wiring harness connection
951590 2 Clamp MS21919WDG32-2 Fuel pump
481471 1 Connector set fuel pump Fuel pump electrical
terminals

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Fig. Qty /
Part no. Description Application
no. engine
2 481483 (2) Fuel pump parts kit UNF C24 915 i / 916 i UNF C24
Consists of:
875018 1 Check valve AN6 UNF
875017 1 Adapter AN6 / M14x1,5 UNF Inlet
250735 1 Gasket ring A14x20
875016 1 Connection AN6/M10x1 UNF Outlet
250425 1 Gasket ring 10.2/15/1.5
881307 1 Connector set fuel pump Connection C24
951590 2 Clamp MS21919WDG32-2 Fuel pump
481471 1 Connector set fuel pump Fuel pump electrical
terminals

1) Fuel pump part no. 889731

2) Part number location
3) Serial number location

Fig. 1
Fuel pump part no. 889731

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Fig. 2
1) Check valve AN6 2) Gasket ring A14x20 3) Adapter Metric AN6 / M14x1.5
part no. 875018 part no. 250735 part no. 875017

4) Gasket ring 10.2/15/1.5 5) Adapter AN6/M10x1 6) Connector set

part no 250425 part no 875016 part no. 481471

7) Connector set 8) Connector set C24 9) Cable clamp

part no. 881305 part no. 881307 part no. 951590

Fig.
Qty /
no.- Part no. Description Application
engine
part
2-6 481471 (2) Connector set Fuel pump terminals
Consists of:
XXXXXX 2 Protective cap
XXXXXX 1 Lock nut M4
XXXXXX 1 Lock nut M5
XXXXXX 1 Washer 4.3
XXXXXX 1 Washer 5.3
XXXXXX 1 Ring terminal M4
XXXXXX 1 Ring terminal M5

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Fig.
Qty /
no.- Part no. Description Application
engine
part
2-7 881305 (2) Connector set fuel pump Wiring harness connection
Consists of:
XXXXXX 1 Connector housing
XXXXXX 3 Flat pin terminal
XXXXXX 3 Cable grommet
2-8 881307 1 Connector set MAIN fuel C24 Wiring harness
pump connection
Consists of:
XXXXXX 1 Connector housing
XXXXXX 3 Flat pin terminal
XXXXXX 1 Wedge lock

2.4) Material requirement per spare part

None.

2.5) Rework of parts

None.
2.6) Special tooling/lubricants- /adhesives- /sealing compounds

Qty / Part
Description Application
engine no.
CRC® Leak Detector (14503)* - n.a Fuel pump service.
Non-flammable water-based formula. Connection leak detection
No oils, silicones or harmful solvents
BERNER® Leak Finder (148383)* - n.a Fuel pump service.
Water based formula, non-corrosive, Connection leak detection
silicone free.
APTIV® 12155975 Crimp tool* - n.a Fuel pump power connectors (12V)
DEUTSCH® DTT-16-00 Crimp tool* - n.a Fuel pump power connectors (C24)
* or equivalent

NOTE: There are many third-party commercial leak detection products available.
Ensure that the leak detection solution used is non-corrosive and does not
contain harmful solvents.

If using these special tools observe the manufacturers

NOTICE
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 maintenance, review the entire documentation to make sure you have
a complete understanding of the procedure and requirements
Accomplish- All measures must be implemented and confirmed by at least one of the following persons
ment or organizations:

- ROTAX® - Airworthiness representatives

- ROTAX® - Authorized Distributors or their independent Service Centers
- Persons approved by the respective Aviation Authorities
- Persons with approved qualifications for the corresponding engine types. Only
authorized persons (iRMT, Level Heavy Maintenance) are entitled to carry out this work.
- Persons with type-specific training

All work must be performed in accordance with the relevant ROTAX®

Instructions for Continued Airworthiness (ICA) of the respective engine type.

General Further material on general inspection, maintenance and repair can also be found in relevant
Advisory Circular AC 43.13 from FAA.
Advisory
Circular The Advisory Circular (AC) contains maintenance methods, techniques and practices.

3.1) Illustrated Parts Catalog (IPC) – related information

See current Illustrated Parts Catalog (IPC) for the respective engine type,
Chapters 73-10-00 and 76-10-00.

3.2) Installation – related information

Refer to current Installation Manual (IM) for the respective engine type for
detailed fuel system requirements, Chapter 73-00-00 Engine – Fuel and
control.

The electrical fuel pumps must be installed in a well-ventilated area, near the fuel tank and
away from potential sources of heat to ensure a safe fuel supply and minimize the risk of
vapor lock. Ambient temperature of fuel pumps must not exceed 80 °C (176 °F).

NOTE: The GENUINE-ROTAX® fuel pumps have been tested and approved according to
CS-E-130. Thus, the fuel pump can be installed on the firewall without additional
fire protection. A fuel pump housing is not available for the fuel pumps.

Do not connect additional load (additional fuel pumps, lamps, LED,

NOTICE etc.) to the power supply of the fuel pumps. The wiring is
manufactured for GENUINE-ROTAX® fuel pumps only.

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Fuel pump technical information
Nominal Voltage (V) 13.8 V
Current consumption (A) Single pump 5.8 A
Current consumption (A) Both pumps 7.8 A
Fuel flow (up to dual operation) 255 l/h (67.4 gal/h)
Weight (single pump) 709 g (25.0 oz)
Fuel quality See current Service Instruction -Selection of
suitable operating fluids for the respective
engine type
Fuel pressure (sensor position at fuel 3.2 bar to 2.9 bar (46 psi - 42 psi relative to
pressure regulator) manifold pressure)

At idle speed the fuel pressure may increase up to 3.4 bar (49 psi).
NOTICE This presents no technical issue.

Non-compliance can result in serious injuries or death!

WARNING Independent from the ambient conditions (e.g. fuel pressure and
temperature) and independent from the fuel used the design of the
fuel system must prevent vapor lock conditions. Vapor lock may
result in engine stoppage.

Ambient temperature of fuel pumps must not exceed 80 °C

NOTICE (176 °F).

3.2.1) Installation - fuel pump power connection

Fuel pumps require the attachment of power connector sets part no. 881305 and part no.
481471 in order to interface with the engine wiring harness. The length of wire can be
extended to reach the installation position of the fuel pumps.

See current Installation Manual (IM) for the respective engine type,
Chapter 24-00-00 Interface description for wiring location and
requirements.

Tightening torque
M4 terminal 0.9 Nm (8 in. lb)
M5 terminal 1.6 Nm (14 in. lb)

NOTE: Wire gauge must be min. 2.1 mm2 (14 AWG).

NOTE: Place wire through protective cap before crimping ring terminals.

NOTE: Use only an aircraft grade crimping tool. See section 2.6) Special tooling.

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1) Connector set
part no. 881305
2-8) Connector set
part no. 481471
2) Ring terminal M4
3) Washer 4.3
4) Lock nut M4
5) Protective cap
6) Lock nut M5
7) Washer 5.3
8) Ring terminal M5

Fig. 3
Fuel pump power connector (12V)

1) Connector set C24

part no. 881307
2-8) Connector set
part no. 481471
2) Ring terminal M4
3) Washer 4.3
4) Lock nut M4
5) Protective cap
6) Lock nut M5
7) Washer 5.3
8) Ring terminal M5
9) X4 connector

Fig. 4
Fuel pump power connector (C24)

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3.2.2) Installation - fuel pump assy.
Fuel pump part kits part no. 481481 and 481483 contain an AN6 check valve and AN6 fuel
pump adaptor. This allows flexible connection of fuel pumps and check valves in series
configuration using readily available AN fittings. It is highly recommended to use the
check valve provided within the fuel pump kit to ensure functionality of the pumps.

Step Procedure
1 Connect both fuel pumps with check valves in series configuration.

See current Installation Manual (IM) for the respective engine type,
Chapter 73-00-00 Engine - Fuel and Control for fuel system diagram.

Tightening torque
Adaptor AN6 / M14x1.5 30 Nm (22 ft. lb)
Adaptor AN6 /M10x1 15 Nm (133 in. lb)

These are the maximum torques that the threads in the pump
NOTICE body can hold.

Step Procedure
2 Before attaching fuel pump assy. to the aircraft, perform a leak check.
See section 3.2.3).

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The figures 5 - 7 show sample installations using parts kit part no. 481481 or 481483 and
AN6 fittings.
NOTE: Assemble with clean parts only in a clean environment!
NOTE: See AN fitting manufacturer for suggested tightening torque values.

Fig. 5
Sample installation

Fig. 6
Sample installation

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Fig. 7
Sample installation

Step Procedure
3 Attach the fuel pumps securely to an appropriate mounting surface using
cable clamps.
4 Connect fuel pump power connectors (MAIN/AUX) into appropriate
wiring harness connector(s).
NOTE: For C24 engines, connect AUX fuel pump power connector to
AC-DC converter connector X4

See current Installation Manual (IM) for the respective engine type, Chapter
73-00-00 Engine - Fuel and Control for further fuel system requirements,
such as:
- Inlet and return fuel lines
- Bypass line
- Coarse and fine fuel filters
- Water trap / gascolator
- Fuel pressure sensor
- Fuel tank
- Fuel shut off valve

NOTE: The hydraulic diagram shown in the current Installation Manual (IM) for
the respective engine type must be complied with.

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NOTE: A Bypass line must be installed according to the current Installation
Manual (IM) for the respective engine type with a restriction jet part no.
963829 or similar.

25 l (6.6 gal) ±5 l/h (1.32 gal/hour)

Requirement
at 3 bar (43.5 psi) pressure

Qty. / Part no.

Description Application
engine
PILOT JET 35 1 963829 Bypass line
NOZZLE HOLDER 1 875019 Bypass line

1) Nozzle holder
part no. 875019

2) Pilot jet
part no. 963829

Fig. 8
Bypass line

3.2.3) Fuel pump assembly - Leakage check

After assembly of modular fuel pump assembly, it must be checked for leaks at each
connection point before installation in the aircraft.

For this leakage check disconnect electrical connectors to

NOTICE MAIN and AUX fuel pump.

Step Procedure
1 Block the OUTLET of the fuel pump assembly with suitable pressure cap
(e.g. AN929-6).
2 Connect the INLET of the fuel pump assembly to a differential pressure
gauge.
3 Apply operating fuel pressure to the fuel pump assy.
4 NO pressure loss is allowed on the differential pressure gauge.
5 With the fuel pump assy. temporarily pressurized with air, use an
appropriate leak detector solution at each fitting connection to verify
proper sealing.
6 If any air bubbles are present at connections, re-seat or replace
connector.

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Do not switch on either of the pumps during the leakage check.
NOTICE This could lead to destruction of one of the pump bodies.

Follow leak detector solution manufacturer’s instructions for its

NOTICE
use, clean up and safety information.

Make sure not to mix up IN (Fuel IN) and OUT (Fuel OUT) of fuel
NOTICE pump assembly in the following tasks.

1) Compressor

2) Manometer/Test gauge set

3) Cap on “Outlet”

Fig. 9
Leakage test

Step Procedure
7 Clean up leak detection fluid and dispose of in an environmentally
friendly way.

3.3) Operation – related information

See current Operators Manual (OM) for the respective engine type.

3.4) Maintenance (Line) – related information

Interval
Chapter
Points of inspection Operating Hours
Reference
100 h 200 h
Inspect the fuel pumps. See current Maintenance
- Visual inspection of lines and Manual Line (MML) for the
connections X respective engine type and its
- Check for leaks periodical maintenance
- Check for corrosion information.

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Avoid over-tightening the fastening elements. Use a suitable
NOTICE torque wrench for all work.

See current Maintenance Manual Line (MML) for the respective engine type,
Chapter 05-20-00 Scheduled maintenance checks.

3.4.1) Storage period

The maximum storage period for the fuel pump part no. 889731 is limited to 4 years from
the date of production in following storage environment:
- 30°C / + 60°C, humidity < 60%, protected from atmospheric influence
3.4.2) Time limit
Fuel pump part no. 889731 must be replaced every 5000 hours of operation or 15 years
from the date of production, whichever comes first.

3.5) Maintenance (Heavy) – related information

3.5.1) Fuel pump assy. – removal

It is recommended to perform any fuel pump assy. maintenance on an assy. that has been
removed from the aircraft.

Drain the fuel. See current Maintenance Manual Line (MML) for the respective
engine type, Chapter 12-20-00 section Planned maintenance.

Step Procedure
1 Remove the negative terminal of the battery.
2 Disconnect the fuel inlet and outlet hoses.
3 Disconnect the fuel pump power connectors from the wiring harness
connectors.
(MAIN / AUX):
- Lift the latches (1)
- Pull the connectors apart (2)
(AUX C24):
- Push in the tab (3)
- Pull the connectors apart (4)
4 Remove the fuel pump assy. from the aircraft according to the aircraft
manufacturer’s instructions.

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Fig. 10
Fuel pump power connectors

3.6) Finishing work

- Restore aircraft to original operating configuration.
- Connect negative terminal of aircraft battery.

3.7) Test run

In case of uninstalled engines test run is accomplished with the mandatory test run after
installation into aircraft.

See Chapter 12-20-00 of the latest Maintenance Manual Line (MML) for the
respective engine type.

3.8) Summary
A revision bar outside of the page margin indicates a change to text or graphic.

Translation into other languages might be performed in the course of language localization
but does not lie within ROTAX® scope of responsibility.

3.9) Inquiries
Inquiries regarding this Service Instruction - PAC should be sent to the ROTAX® Authorized
Distributor of your area.
A list of all ROTAX® Authorized Distributors and their independent Service Centers is provided
on [Link]

NOTE: The illustrations in this document show the typical construction. They may
not represent full detail or the exact shape of the parts which have the same
or similar function.

Exploded views are not technical drawings and are for reference only. For
specific detail, refer to the current documents of the respective engine
type.

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