ZENAIR CH2000 SERVICE MANUAL
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REMOVAL OF ENGINE - Fig. 12
1. Remove the propeller.
2. Remove top and bottom cowl.
3. Disconnect the heat hose from the muffler and front baffle.
4. Disconnect the mechanical fuel pump inlet line.
5. Disconnect the fuel inlet line at the carburetor.
6. Disconnect the starter lead.
7. Disconnect the alternator leads.
8. Disconnect the grounding wire.
9. Disconnect the control cables from the engine components.(throttle mixture, carb.
heat)
10.Disconnect the tachometer cable from the rear of the engine.
11.Disconnect the hoses from the vacuum pump. (option)
12.Disconnect the magneto "P" leads. Insert a protective cover over the connection.
13.Disconnect the oil pressure wire. Disconnect manifold pressure line from the left rear
cylinder of the engine. (option)
14.Attach a 1,500 Lbs. (minimum) hoist to the hoisting hook and relieve the tension on
the engine mount.
15.Place a tail stand under the tail of the aircraft before removing the engine.
16.Check the engine for any attachments remaining to obstruct its removal.
17.Remove the cotter pins, nuts, washers, rear rubber mount and bolt from each engine
mounting. Swing the engine free, being careful not to damage any attached parts.
REINSTALLATION OF ENGINE
Attach a one-half ton hoist to the hoisting hook and lift the engine. Position the mounting
lugs of the engine so that they align with the engine mount attaching points.
Insert the front rubber mounts and the spacers between engine and engine mount. Position
the rear rubber mounts and insert the bolts.
Install a washer and castellated nut on each mounting bolt. Tighten the nuts until the inner
spacer is tight, then align castle nut with cotter pin hole in the bolt (approx. 40-inch
pounds) and install cotter pins..
Reconnect all engine connections in the reverse order they were removed. See reverse of
removal, items 13 to 1 above.
Note: Adjust all controls to provide full travel in particular when the throttle control is
full forward, it must contact the stop on the carburetor before it bottoms.
3 Apr 96
6.3
