Caravan SERVICE KIT - Cessna

CaravanSERVICE KIT

SK208-178

TITLE

LOW-PROFILE TKS ICE PROTECTION SYSTEM INSTALLATION FOR MODEL 208 AIRPLANES WITHPROVISIONS

EFFECTIVITY

Model Serial Numbers

208 20800500, 20800505 thru 20800509, 20800511thru 20800513, 20800517, 20800521, 20800522

NOTE: This Service Kit may only be accomplished on airplanes equipped with the standby alternator system.

DESCRIPTION

To provide the parts and instructions to install the TKS Ice Protection System.

APPROVAL

FAA approval has been obtained on technical data in this publication that affects airplane type design.

Reference

SSP10-1

CHANGE IN WEIGHT AND BALANCE

The figures that follow show an estimated change only. For accurate weight and balance figures, you shouldweigh the airplane before and after this Service Kit has been accomplished.

MODEL . . . . . . . . . . . . . . . . . 208

WEIGHT INCREASE . . . . . . . . . +121.63 pounds

ARM . . . . . . . . . . . . . . . . . . . . +175.41 inches

RESULTANT MOMENT . . . . . . . +21335.04 inch-pounds

MOMENT/1000 . . . . . . . . . . . . +21.34 inch-pounds

October 14, 2010 Page 1 of 183

To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods andprevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work performed in accomplishing therequirements of this publication.

Cessna Aircraft Company, Customer Service, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) 517-5800, Facsimile (316) 517-7271

COPYRIGHT © 2010

SERVICE KITSK208-178

MATERIAL INFORMATION

The parts below cover installation for one airplane.

NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION

SK208-178 1 Kit, consisting of thefollowing parts:

AN525-10R10 21 Screw None None





AN737TW22 2 Clamp None None

C15Green 3 Tip None None

CCR244SS-3-02 24 Rivet None None

CM3827AD4-4A 3 Rivet None None

CR3213-4-5 4 Rivet None None



H610024 2 feet Tubing, Nylon

H610025 3 feet Tubing, Nylon

H610026 42 feet Tubing, Nylon None None

M81824/1-1 3 Splice None None

M83248/1-021 1 O-ring None None

M85528/2-12-A 1 Mounting Flange None None

M85528/2-16-B 1 Mounting Flange None None

MN101-12 4 Sleeve None None



MN4855 5 Nut None None


MN6079 1 Backnut 1/8 BSP None None


MN6211 2 Backnut None None

MN6216 1 Tee, Bulkhead Unequal None None

MN6235 1 Bulkhead ShortConnector

Same Discard

MN6782 1 5/16 Blanking CapAssembly

None None

SK208-178Page 2


MN6838 2 Elbow Assembly None None

MS20426AD3-3A 6 Rivet None None



MS20470A4-6N 4 Rivet None None



MS20470AD4-3A5 48 Rivet Various Discard


MS20470AD4-4A-5 212 Rivet None None

MS21042-3 1 Nut None None

MS21044N3 15 Nut None None



MS21047L08 24 Nutplate None None




MS21075L3N 1 Nutplate None None

MS21083C3 8 Nut None None

MS21919WDG20 2 Cushion Clamp None None

MS21919WDG3 3 Clamp None None

MS21919WDG4 1 Clamp None None

MS24524-23 1 Backup Switch None None

MS24524-27 1 Max Flow Switch None None

MS24694-C52 8 Screw Same Discard

MS24694-C53 8 Screw None None

MS24694-S5 2 Screw None None

MS24694-S6 2 Screw None None

MS25083-2BB16 1 Bond Jumper

MS27039-1-07 2 Screw None None

MS27407-1 1 Primary Switch None None

MS35206-215 4 Screw None None




SK208-178Page 3



MS35489-118 2 Grommet MN6235 Discard

MS35489-6 1 Grommet None None

M39029/5-115 26 Contact None None

MS85528/2-12-A 1 Mounting Flange None None

MS85528/2-16-B 1 Mounting Flange None None

NAS1149C0363R 8 Washer None None

NAS1149D1290K 1 Washer None None

NAS1149F0316P 14 Washer None None

NAS1149F0332P 30 Washer None None

NAS1149FN632P 4 Washer None None



NAS1515H08L 12 Washer None None

NAS428H4A14 1 Bolt NAS428H4A12 Discard

NAS43DD3-18FC 1 Spacer None None

NAS6203-4 14 Bolt None None

S1050-1 2 Grommet None None

S1050-1-1.70 1 Grommet None None




S1053K10W 1 Duct None None

S1212-37 1 Control None None

S1232-502 1 Circuit Breaker None None

S1232-505 2 Circuit Breaker None None

S1367-1-6 17 Terminal None None

S1495-6 3 Hose None None

S1741-1 2 Anchor None None

S1891-20S 2 Clamp None None

S1979-1 1 Knob None None

S2034-1 17 Mount None None

S2209-1 31 Tie None None



S2357-1 8 Clamp None None

SK208-178Page 4


S2357-2 2 Clamp None None

S2456-4-1 17 Rivet None None

S2548-10 2 feet Hose None None

S2548-4-6 2 feet Hose None None

S2562-3 1 foot Tube None None

S2606-1 1 Mount None None

S2800-942 42 Sealing Ring Same Discard

S2800-943 29 Sealing Ring Same Discard



S2906-4-4 2 Rivet

S2974-8 2 Solder Sleeve None None

S3017-6-6-6 1 Tee None None

0823337-2 4 Grommet None None

100-013-8810 50 Sealing Ring Same Discard

13102-61 1 Porous Panel, LeftOutboard Wing

None None

13102-62 1 Porous Panel, RightOutboard Wing

None None

13102-63 1 Porous Panel, LeftMid-Wing

None None

13102-64 1 Porous Panel, Right MidWing, No Radar

None None

13102-66 1 Porous Panel, Mid WingRadar

None None

13102-67 1 Porous Panel, LeftInboard Wing

None None

13102-68 1 Porous Panel, RightInboard Wing

None None

13102-69 1 Porous Panel, Left WingStrut

None None

13102-70 1 Porous Panel, RightWing Strut

None None

13102-73 1 Porous Panel, LeftHorizontal Stabilizer

None None

13102-74 1 Porous Panel, RightHorizontal Stabilizer

None None

13102-75 1 Porous Panel, VerticalStabilizer

None None

13122-08 2 8-Bolt Gasket Filler None None

13122-09 1 Filler Cap Flange None None

SK208-178Page 5


13122-10 1 Filler Cap None None

13146-04 1 Wire Harness, LowPressure Switch

None None

13146-05 1 Tank Wire Harness None None

13146-06 1 Low Profile Pallet WireHarness

None None

180C4 1 Valve Assembly None None

2105015-7 1 Placard, OperationalLimitations

None None

2601212-5 1 TKS Fairing Cover None None

2601548-1 1 Strap Assembly,Forward Left

None None

2601548-2 1 Strap Assembly,Forward Right

None None

2601548-3 1 Strap Assembly, Aft Left None None

2601548-4 1 Strap Assembly, AftRight

None None

2601552-1 1 TKS Tank VentWeldment

None None

2601552-7 1 Filler Port Weldment None None

2601552-9 1 Doubler, Filler Port None None

2601553-12 1 Aft Drain TubeAssembly

None None

2601553-14 1 TKS Accessory Pallet None None

2601553-3 1 TKS Filler Pallet None None

2601554-1 1 Tank and EquipmentAssembly

None None

2601558-1 1 Pump 1 Outlet Hose None None

2601558-2 1 Pump 2 Outlet Hose None None

2605070-10 1 Placard, IcingConditions

None None

2605076-14 1 Placard, TKS Filler Cap None None

2605076-4 1 Placard, OperationalLimit

None None

2605076-5 1 Placard, TKSOperational Limit

None None

2613466-7 1 Fairing Assembly None None

2613495-1 1 Doubler, TKS LeftExternal

None None

2613495-10 1 Doubler, TKSConnectors

None None

2613495-11 1 Stiffener None None

SK208-178Page 6


2613495-2 1 Doubler, TKS RightExternal

None None

2613495-3 1 Doubler, TKS LeftForward

None None

2613495-4 1 Doubler, TKS RightForward

None None

2613495-5 1 Doubler, TKS Left Aft None None

2613495-6 1 Doubler, TKS Right Aft None None

2613495-7 2 Strap Angle, TKSForward

None None

2613495-8 2 Strap Angle, TKS Aft None None

2613495-9 1 Doubler, TKS Cutouts None None

2613498-1 1 Forward FairingAssembly

None None

2613498-2 1 Aft Fairing Assembly None None

2616017-27 1 Gasket None None

2616033-4 1 Sump Drain TubeAssembly

None None

2616033-5 1 Welded Drain TubeAssembly

None None

2625000-31 1 Gurney Flap, Left None None

2625000-32 1 Gurney Flap, Right None None

2677123-3 1 Wire Assembly, W/SICE DETEC-LSWPNL

None None

2677124-1 1 Wire Assembly None None

2677124-2 1 Wire Assembly None None

2680003-1 1 TKS Fairing MTG, Left None None

2680003-2 1 TKS Fairing MTG, Right None None

336-00021-00 10 Contact None None

4D2007 8 Vortex Generator

7000-03 4 Placard, SolventCaution

7000-26 1 Placard, WindshieldAnti-Ice

None None

9910616-5 1 LED LAA Switch PlateAssembly

None None

SK208-178Page 7


The supplement below will be necessary:

NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION

208PHBUS-S1-00 1 Pilot's Operating HandbookSupplement, Ice ProtectionSystem

None None

The following material, or equivalent, is necessary.

NAME NUMBER MANUFACTURER USE

Tape P840154 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To use in the installation ofthe duct at the filler port.

Tape P840294 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To hold porous panels tightlyto leading edge

Epoxy Adhesive U000787S Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To install grommets

Detergent, Mild Purchase Locally To clean wing panels

Alodine U074093 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To apply to bare metal

CorrosionResistant Primer

K000912 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

For corrosion protection

Sealant U000884 Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To attach VGs to flaps


To fay seal doublers

SK208-178Page 8


NAME NUMBER MANUFACTURER USE


To shank seal rivets and filletseal around flange of fairingand fillet seal tube to fairingassembly

Sealant U544053S Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To do a fay surface sealbetween grommets andstructure and to fay and filletseal between fairing coverand structure


To bond the gurney flaps tothe wing flaps


To brush coat rivets and tofillet seal the porous panels

Scotch Brite Pad Purchase locally To abrade the leading edges

Denatured Alcohol Purchase locally To clean the leading edge

Sealant U544042S Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

Prepack seal voids betweenbackplate joggles and edgesof porous panels

Sealant Tape U000927S Cessna Aircraft CompanyCessna Parts Distribution5800 East PawneePO Box 1521Wichita, KS 67218

To attach the TKS fairing tothe structure

The equipment below, or equivalent, will also be necessary:

Name Number Manufacturer Use

TKS System Test Cart 09301-01CAV Aerospace, Inc.2734 Arnold CourtSalina, KS 67401Phone: 1-888-865 -5511Fax: 1-785-493-0950

To do the TKS porouspanel purge and testprocedures

Plastic Guttering Commercially Available To catch anti-ice fluidfrom the TKS panelpurge procedure

Clenching Tool, withMandrel (3/16 Inch)

T300-112A CAV Aerospace Inc. To fabricate TKS tubing

SK208-178Page 9


Name Number Manufacturer Use

Clenching Tool Body(3/16 Inch)

T300-112-01 CAV Aerospace Inc. To fabricate TKS tubing

Clenching Tool Mandrel(3/16 Inch)


Clenching Tool Body(5/16 Inch)


Clenching Tool Mandrel(5/16 Inch)


Clenching Tool (5/16Inch)

T300-120A CAV Aerospace Inc. To fabricate TKS tubing

Clenching Tool (1/2 Inch) T300-144 CAV Aerospace Inc. To fabricate TKS tubing

Clenching Tool (3/8 Inch) T300-145 CAV Aerospace Inc. To fabricate TKS tubing

Blank Olive with MN4856Nut (3/16- Inch Tube)

P075 CAV Aerospace Inc. To cap the TKS tubingduring tests

Nylon Ball with MN4855Nut (5/16- Inch Tube)

03-151-07 CAV Aerospace Inc. To cap the TKS tubingduring tests

Nylon Ball with MN6201Nut (1/2-Inch Tube)

03-151-10 CAV Aerospace Inc. To cap the TKS tubingduring tests

Plastic Sheeting Commercially Available To catch anti-ice fluidfrom the TKS panelpurge procedure

Aluminum Tape Commercially Available To attach guttering andtubes to catch anti-icefluid from the TKS panelpurge procedure

Plastic Tubes Commercially Available To catch anti-ice fluidfrom the TKS panelpurge procedure

Shutoff Valve Commercially Available To modulate systempressure duringfunctional test

0-200 PSI Fluid Gage Commercially Available To measure pressurein the system duringfunctional test

Ratcheting Straps Commercially Available To apply force to theinboard wing porouspanels

SK208-178Page 10


ACCOMPLISHMENT INSTRUCTIONS

NOTE: You must accomplish Service Kit SK208-180, Low Airspeed Awareness System Installation forAirplanes with TKS, (or latest revision) in conjunction with this Service Kit.

NOTE: Accomplish SK208-180 (or latest revision) at the same time or after this Service Kit (SK208-178) isinstalled because a necessary connector - PI003/JI003 - is not installed until you install wiring for TKS.

NOTE: You must accomplish CAB10-10 208 Horizontal Stabilizer Incidence Change (or latest revision)in conjunction with this Service Kit.

1. (Refer to Figure 18, Detail A.) Find the 13102 TKS Porous Panels and install P840294 Tape on thesurface of each panel. The tape will give some protection to the panels during their installation, andwill give an edge when you do an edge/fillet seal.

2. Prepare the airplane for maintenance as follows:

A. Electrically ground the airplane.

B. Make sure that all switches are in the OFF/NORM position.

C. Disconnect electrical power from the airplane.

(1) Disconnect the airplane battery.

(2) Disconnect external electrical power.

D. Attach maintenance warning tags to the battery and external power receptacle that have "DO NOTCONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS" written on them.

E. Obey the general cautions, warnings, and instructions that follow when you install or work nearthe ice protection system:

CAUTION: Be careful when you install the porous panels to make sure that you do nodamage to the wing leading edge skin.

WARNING: For health and environmental data, review the Material Safety DataSheet (MSDS) for TKS fluid. Refer to the MSDS that should be includedwith the shipment of TKS fluid. If you cannot locate the MSDS, contactyour supplier of the TKS fluid to obtain the MSDS.

WARNING: Make sure that you use applicable eye protection when you work nearthe ice protection system. The system uses high pressure in the linesto operate correctly, and the fluid pressure stays in the system linesuntil it is released. If you do not use applicable eye protection, fluidunder pressure can hit your eyes and cause damage when you dowork on the system.

WARNING: Discard all unwanted TKS fluid and/or dirty cloths correctly. TKSfluid is a hazardous waste and must be discarded in accordance withprocedures approved by the local jurisdiction.

(1) Make sure that you wear applicable eye protection when you do work on or near the iceprotection system.

WARNING: Before you disconnect components of the TKS anti-ice system, slowlyloosen the coupling that is connected to the component to be removedbecause it is possible that high pressure is still in the system.

(2) Slowly loosen the connection at the necessary fitting to release high pressure in the system.

SK208-178Page 11


WARNING: Make sure that you remove ice protection fluid from the floor surfaceswhere passengers and personnel walk. The fluid can make surfacesslick.

(3) Remove all ice protection fluid from areas where people walk. Since there is leakage of fluidfrom the panels for a while after the system is no longer in operation, make sure that youcollect fluid that drips from the airplane or continue to remove fluid from the floor until thereis no more leakage.

CAUTION: Never use unapproved ice protection fluids in the ice protection system. Neveruse a thickened anti-ice fluid or one that is made for use on the runway, inautomobiles, or on parked airplanes. If you use fluids that do not meet theDTD406B specification, you will do damage to the membranes in the porouspanels and other system components.

CAUTION: Use only clean, filtered fluid in the TKS system. Contamination will cause fluidblockage and/or damage to the porous panel.

(4) Use only ice protection fluids that meet the DTD406B specification in the ice protection system.

(5) You can mix fluids that meet the DTD406B specification in any proportions in the airplane tank.

CAUTION: Do not do damage to the ice protection system with solvents or paints. Mostsolvents and all paints can cause damage to the plastic membrane in the porouspanels. Use only the materials from the list below when you work on or nearthe porous panels. Never use MEK, acetone, or lacquer thinner. Always usemasking material when you use paint or solvents that are not on the list belowwhen you work on or near the porous panels.

(6) The materials that follow are approved to clean the porous panels. Use them with a brush or alint-free cloth:• Water with soaps or detergents• Aviation gasoline• Isopropyl alcohol• Industrial methylated spirit• Ice-protection fluids that are approved for use on the airplane• Aviation turbine fuel• Ethyl alcohol.

(7) Always use P840294 Tape or equivalent low-residue masking material to protect the porouspanels from unapproved materials.

(8) (Refer to Figure 11.) Use these instructions when you do the assembly and the installation ofthe tubing and the lines:

CAUTION: Do not do damage to the nylon tubing in the ice protection system. Theremust be no tension or strain on the nylon tubing, as these forces whenapplied to the nylon tubing can cause damage.

(a) Cut and install the nylon tubing in lengths that take into consideration the effects oftension and strain.

(b) When you cut the nylon tubing, add no less than 3% (1 inch for each 3 feet) to thenecessary length for thermal shrinkage and airframe flexure.

(c) Do not use components of dissimilar metals unless the instructions specify componentsthat have dissimilar metals.

(d) Use only the specified nylon tubing, coupling bodies, olives, rubber sealing rings, andnuts in accordance with these instructions to make compression fitting connections.

SK208-178Page 12


(e) In a warm water (temperature of the water is not to be more than 140 degrees) anddetergent solution, clean all tubing and fittings completely and then dry them with cleanair before you assemble the lines.

(f) Use only the specified clenching tools in accordance with these instructions to makecompression fitting connections.

(g) When you assemble the line, put the correctly sized nut on the tubing in the correctposition. (Refer to the Model 208 Maintenance Manual, Chapter 30, TKS Anti-Ice FluidDistribution System - Maintenance Practices, Figure 204.)

(h) Put the olive on the tubing with the bevel end of the olive toward the end of the tubing.(Refer to the Model 208 Maintenance Manual, Chapter 30, TKS Anti-Ice Fluid DistributionSystem - Maintenance Practices, Figure 204.)

CAUTION: Do not use the coupling nut to clench the olive to the fluid tubing. Use onlyspecified clenching tools to do the clenching operation. Also, do not torquethe couplings too much during the repair or replacement procedure. If thecouplings leak, install new seals as necessary.

CAUTION: Clench the olive to the tubing without a sealing ring in position. If youclench the olive with a sealing ring in position, you will prevent a correctclench and the sealing ring will be unserviceable.

(i) Put the end of the nylon tubing into the correctly-sized clenching tool as far as it will go.

(j) Make sure that the outer end of the olive is in the correct position in the bore of the nut.

(k) Turn the nut onto the clenching tool until it is finger tight plus 315° (five and one quarterflats).

1 Make sure that the nylon tubing stays bottomed out in the clenching tool until theclenching operation is completed.

2 Make sure that the mandrel is fully engaged in the tool.

NOTE: Clenching tools for 3/16-inch and 5/16-inch outside diameter tubing havemandrels to hold the inside of the tubing.

3 The tubing, olive, and mandrel can turn during the clenching operation, and thatis permitted.

(l) Unscrew the nut and remove the olive and the tubing from the clenching tool.

NOTE: It may be necessary to remove the mandrel from the clenching tool to removethe tubing.

(m) Do an inspection of the installed olive to see that it is correctly swaged.

CAUTION: Do not use the seals again after you loosen or disconnect a tube coupling.Replace the 3/16-inch and 5/16-inch sealing ring and/or 1/2-inch O-ring,as applicable, when you assemble a tube coupling. Examine the seal fordamage and make sure that it is in the correct position. This will help toprevent fluid leakage from the coupling.

(n) Put a sealing ring of the correct dimension over the end of the tubing.

(o) Put the tubing into the coupling body and move the sealing ring into the recess at theend of the coupling body.

(p) Push the tubing toward the coupling body to make the olive hold the sealing ring inposition.

(q) Engage and finger tighten the nut.

SK208-178Page 13


(r) Tighten the nut until the torque starts to increase quickly (to approximately 180° fromfinger tight).

(s) Use safety wire to safety nuts only where it is specified in the instructions. If not specifiedin the instructions, safety wire is not necessary on the TKS fittings.

CAUTION: After you remove and before you install a porous panel, apply P840294 Tape orequivalent low-residue masking material on the panel to give it protection.

(9) (Refer to Figure 11.) When tubing repair or replacement is necessary, the olive must alwaysbe clenched (swaged) to the tubing as a separate operation. Use approved clenching toolsbefore you assemble the coupling.

(10) (Refer to Figure 11.) Assemble the nylon tubing and the couplings in accordance withapproved maintenance practices.

CAUTION: As you accomplish this Service Kit, make sure that you keep a minimum edgedistance of no less than two times the diameter of the rivet.

(11) Install all rivets with a minimum edge distance of no less than two times the diameter of the rivet.

3. Get access for the installation as follows:

A. Do an initial weight and balance of the airplane before installation of the TKS Ice Protection SystemInstallation and the SK208-175C Low Airspeed Awareness System Installation. (Refer to theapplicable Pilot's Operating Handbook and the Model 208 Maintenance Manual, Chapter 8, Levelingand Weighing.)

B. Remove all of the wing inspection panels and access panels from both wings. (Refer to the 208Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description andOperation.)

NOTE: Although some panels need not be removed for access, all of the access panels but the fuelbay panels must be removed to apply sealant.

C. Remove the fuselage wing and wing strut fairings. (Refer to the 208 Maintenance Manual, Chapter57 - Wings - Removal/Installation.)

D. Remove the pilot's and the copilot's seats. (Refer to the 208 Maintenance Manual, Chapter 25,Flight Compartment - Maintenance Practices.)

E. Remove the cabin upholstery and passenger seats as necessary to get access to do the installationand the routing of the tubing and the wiring. (Refer to the 208 Maintenance Manual, Chapter 25,Cabin Upholstery - Maintenance Practices.)

F. Remove the floor inspection covers in the area between FS 166.00 and FS 214.00 and along the leftand the right sides of the floor. (Refer to the 208 Maintenance Manual, Chapter 53, Floorboardsand Access Plates - Maintenance Practices.)

G. Remove the aft cabin bulkhead cover.

H. Remove the stabilizer abrasion boots as necessary and clean all residue from the leading edge.

I. Remove Panel 320A from the lower tailcone area. (Refer to the 208 Maintenance Manual, Chapter6, Access Plates and Panels Identification - Description and Operation.)

J. Remove all of the horizontal and vertical stabilizer inspection panels. (Refer to the 208 MaintenanceManual, Chapter 6, Access Plates and Panels Identification - Description and Operation.)

K. (Airplanes equipped with radar) Remove the radome and the radar and put them in a safe location.Keep the attachment hardware. (Refer to the 208 Maintenance Manual, Chapter 34, GarminGWX-68 Weather Radar - Maintenance Practices.)

L. Remove the weather radar pod assembly. Keep the attachment hardware. (Refer to the 208Illustrated Parts Catalog, Chapter 34, GWX-68 Weather Radar Installation.)

SK208-178Page 14


M. Remove the stall warning detector and let it hang from the airplane wing. Discard the gasket on thestall warning detector. (Refer to the Model 208 Maintenance Manual, Chapter 27 - Stall WarningSystem - Maintenance Practices.)

NOTE: You will not use the gasket when you install the stall warning detector again.

N. Remove the access panel that is under the fuel reservoir tank on the lower belly between FS 168.70and FS 194.40. (Refer to the 208 Maintenance Manual, Chapter 28, Fuel Reservoir - MaintenancePractices.)

4. Make changes to the structure of the airplane for the ice protection system installation as follows:

A. (Refer to Figure 6, View A-A and View B-B.) Drill three additional drain holes in the tailcone at FS284.00 and install three grommets as follows:

(1) Drill three 0.25-inch diameter holes through the airplane skin 2.40 inches aft of FS 284.00. Putone hole at RBL 1.75, one hole at RBL 9.00 and one hole at LBL 9.00.

(2) Deburr and apply Alodine and epoxy primer to bare metal.

(3) Install three 0823337-2 Grommets in the three holes as follows:

(a) Make marks at the six positions on the tailcone where you will install the rivets that attachthe 0823337-2 Grommets.

(b) Match drill six Number 40 (0.098-inch diameter) holes in the tailcone.

(c) Deburr and apply Alodine to bare metal.

(d) With U544053S Sealant, do a fay surface seal between the 0823337-2 Grommets andthe structure. (Refer to the 208 Maintenance Manual, Chapter 20, Fuel, Weather, andHigh-Temperature Sealing - Maintenance Practices.)

(e) With six MS20470AD3-3A Rivets, attach the three additional 0823337-2 Grommets tothe structure.

B. (Refer to Figure 8.) Lay out the hole patterns and drill the holes in the leading edge of the leftwing for the TKS ports as follows:

1. The small vent hole in each porous panel should point down.

(1) Measure along the contour from the lower leading edge skin overlap at the wing stationsshown and snap a chalk line at the measured positions along the full length of the wing leadingedge. This line will show the correct position of the lower edges of the 13102-61 Left OutboardWing Porous Panel, 13102-63 Left Mid-Wing Porous Panel, and 13102-67 Left Inboard WingPorous Panel.

(2) (Refer to Figure 8, View G-G. ) Hold the 13102-63 Left Mid Wing Porous Panel in positionagainst the wing leading edge with the lower edge of the porous panel on the chalk line, and thecutout for the stall warning detector centered over the cutout in the leading edge of the wing.

(3) Make a mark on the leading edge of the wing at the inboard end of the 13102-63 Left MidWing Porous Panel.

NOTE: The inboard edge of the 13102-63 Left Mid Wing Porous panel should approximatelyalign with the visible leading edge skin lap.

(4) While you hold the 13102-63 Left Mid Wing Porous Panel in the correct position, make markson the wing leading edge where the vent tube and fluid inlet tube touch the leading edge.This will determine the inboard and outboard location of the two 1.00-inch diameter holesthat you must drill.

(5) (Refer to Figure 21.) Use a flexible scale to find the vertical location of each 1.00-inch diameterhole you must make in the wing leading edge. Transfer this measurement to the wing leadingedge.

SK208-178Page 15


CAUTION: Do not do damage to the ice protection system with solvents or paints thatare not approved for use on or near the porous panels. Most solvents andall paints can cause damage to the plastic membrane in the porous panels.Use only approved solvents on or near the porous panels. Never use MEK,acetone, or lacquer thinner. Always use masking material when you use paintor unapproved solvents near the porous panels.


(6) (Refer to Figure 8, View A-A. View B-B, View F-F, and View K-K.) Hold the 13102-61 LeftOutboard Wing Porous Panel and the 13102-67 Left Inboard Wing Porous Panel in position.Align the ends of the inboard panel 0.06 inch away from the mark you made that correspondsto the inboard edge of the mid wing porous panel. Put the 13102-61 Left Outboard WingPorous Panel approximately 0.01 inch from the wing tip and put the lower edge of each panelalong the chalk line.

(7) Make marks at the locations for the seven remaining 1.00-inch diameter holes along the wingleading edges. Use the same procedure to make these marks that you used for the 13102-63Left Mid Wing Porous Panel.

(8) (Refer to Figure 8, View C-C, View G-G, and View L-L.) Drill nine 1.00-inch diameter holes atthe marks that you made on the wing leading edge for the 13102-61 Left Outboard Wing PorousPanel, 13102-63 Left Mid-Wing Porous Panel, and 13102-67 Left Inboard Wing Porous Panel.

(9) Deburr and apply Alodine and primer to bare metal.

C. (Airplanes with Weather Radar) (Refer to Figure 9, View C-C, View G-G, and View L-L.) Lay out thehole patterns and drill the holes in the leading edge of the right wing for the TKS ports as follows:

(1) Measure along the contour from the lower leading edge skin overlap at the wing stations shownand make a chalk line at the measured positions along the full length of the wing leadingedge. This line will show the correct installation position of the lower edges of the 13102-62Right Outboard Wing Porous Panel, 13102-66 Mid-Wing Radar Porous Panel, and 13102-68Right Inboard Wing Porous Panel.

(2) Hold the 13102-62 Right Outboard Wing Porous Panel, 13102-66 Mid-Wing Radar PorousPanel, and 13102-68 Right Inboard Wing Porous Panel in position at the correct wing stationsshown.

NOTE: The inboard edge of the 13102-66 Mid-Wing Radar Porous Panel should approximatelyalign with the visible leading edge skin lap.

(3) Make marks on the right wing at each of the nine hole locations. Use the same method youused on the left wing.

(4) (Refer to Figure 8, View C-C, View G-G, and View L-L.) Drill nine 1.00-inch diameter holesat the marks that you made on the leading edge of the right wing for the 13102-62 RightOutboard Wing Porous Panel, 13102-66 Mid-Wing Radar Porous Panel, and 13102-68 RightInboard Wing Porous Panel.


D. (Airplanes not equipped with Weather Radar) (Refer to Figure 10, View C-C, View G-G, and ViewL-L.) Lay out the hole patterns and drill the holes in the leading edge of the right wing for the TKSports as follows:

(1) Measure along the contour from the lower leading edge skin overlap at the wing stationsshown and snap a chalk line at the measured positions along the full length of the wing leadingedge. This line will show the correct installation position of the 13102-62 Right OutboardWing Porous Panel, 13102-64 Right Mid-Wing Porous Panel, and 13102-68 Right InboardWing Porous Panel.

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(2) Make marks on the leading edge of the wing at the inboard and the outboard ends of the13102-64 Right Mid-Wing Porous Panel.

NOTE: The inboard edge of the 13102-64 Right Mid-Wing Porous Panel should approximatelyalign with the visible leading edge skin lap.

(3) Hold the 13102-62 Right Outboard Wing Porous Panel, 13102-64 Right Mid-Wing PorousPanel, and 13102-68 Right Inboard Wing Porous Panel in position at the correct wing stationsshown. Keep a distance of .0625 inch between the ends of adjacent panels and put the loweredge of each panel along the chalk line.

(4) Make marks on the right wing at each of the nine hole locations. Use the same method youused on the left wing.

(5) Drill nine 1.00-inch diameter holes at the marks that you made on the leading edge of the rightwing for the 13102-62 Right Outboard Wing Porous Panel, 13102-64 Right Mid-Wing PorousPanel, and 13102-68 Right Inboard Wing Porous Panel.


E. (Refer to Figure 7.) Lay out the hole patterns and drill the holes in the leading edge of the left andthe right horizontal stabilizers for the TKS ports as follows:

(1) Make chalk line marks to show the correct installation position of the lower edges of the13102-73 Left Horizontal Stabilizer Porous Panel and the 13102-74 Right Horizontal StabilizerPorous Panel.

NOTE: Measure perpendicular (90 degrees) to the leading edge of the horizontal stabilizer tofind the correct location of the chalk line.

(2) (Refer to Figure 7, View D-D.) Hold the 13102-73 Left Horizontal Stabilizer Porous Panel andthe 13102-74 Right Horizontal Stabilizer Porous Panel in position on the leading edge at thecorrect stabilizer stations shown.

(3) (Refer to Figure 7, View D-D.) Use the method you used on the wings to make marks on thehorizontal stabilizers at each of the four hole locations (two on the left horizontal stabilizerand two on the right horizontal stabilizer).

(4) Drill four 0.75-inch diameter holes at the marks that you made (two on each horizontalstabilizer).


F. (Refer to Figure 7.) Lay out the hole patterns and drill the holes in the leading edge of the verticalstabilizer for the TKS ports as follows:

(1) Make chalk line marks to show the correct installation position of the edges of the 13102-75Vertical Stabilizer Porous Panel.

(2) (Refer to Figure 7, View C-C.) Make a mark on the vertical stabilizer at each of the two holelocations.

(3) (Refer to Figure 7, View A-A.) Put the 13102-75 Vertical Stabilizer Porous Panel in position onthe leading edge and perpendicular to the leading edge of the root and the tip of the verticalstabilizer panels at the correct stabilizer stations shown.

(4) Make sure that the two inlet port and air bleed valve locations on the 13102-75 VerticalStabilizer Porous Panel align with the marks that you made for the hole locations on the verticalstabilizer. Adjust the location of the marks as necessary.

(5) (Refer to Figure 7, View C-C.) Drill two 0.75-inch diameter holes at the marks that you madeon the vertical stabilizer.


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CAUTION: When you drill holes in the struts, make sure that you do no damage to the innerstructure with the drill bit.

G. (Refer to Figure 8.) Lay out the hole patterns and drill the holes in the leading edge of the left andthe right wing struts for the TKS ports as follows:

(1) (Refer to Figure 8, View R-R.) Make chalk line marks to show the correct installation position ofthe 13102-69 Left Wing Strut Porous Panel and the 13102-70 Right Wing Strut Porous Panel.

(2) Make a mark on the left and the right wing struts at each of the four hole locations (two onthe left wing strut and two on the right wing strut) and each of the two slot locations (oneon each wing strut).

(3) (Refer to Figure 8, View P-P.) Put the 13102-69 Left Wing Strut Porous Panel and the 13102-70Right Wing Strut Porous Panel in position on the leading edge and perpendicular to the leadingedge at the inboard and the outboard ends of the wing struts at the correct position shown.

(4) Make sure that the four inlet port and air bleed valve locations on the 13102-69 Left Wing StrutPorous Panel and the 13102-70 Right Wing Strut Porous Panel align with the marks that youmade for the hole locations on the wing struts. Adjust the location of the marks as necessary.

(5) Drill two 0.75-inch diameter holes at the applicable marks that you made on each of the wingstruts.

(6) Make two slots of the dimensions shown at the applicable marks that you made on each ofthe wing struts.


H. (Refer to Figure 5, View A-A.) On the bottom of the airplane, install doublers for the support of theTKS tank as follows:

(1) From the right side of the airplane, remove the XPDR1 transponder antenna. (Refer to theModel 208 Maintenance Manual, Chapter 34.)

(2) (For airplanes with a XPDR2 transponder antenna) Remove the XPDR2 transponder antennafrom the left side of the airplane. (Refer to the Model 208 Maintenance Manual, Chapter 34.)

(3) Remove and keep the doubler for the XPDR1 antenna and the doubler for the XPDR2 antenna(if installed).

(4) (Refer to Figure 5, View A-A.) Use six MS20470AD4-3A5 Rivets as plugs and install them inthe holes (through the skin only) that you made when you removed the rivets that attached thedoubler for the XPDR1 transponder antenna. Leave the four screw holes open in the skin.

(5) Use six MS20470AD4-3A5 Rivets as plugs and install them (through the skin only) in theholes that you made when you removed the rivets that attached the doubler for the XPDR2transponder antenna (if installed). Leave the four screw holes open in the skin.

CAUTION: Be careful when you remove the ducts. You can damage the ducts if you arenot careful when you remove them.

(6) Remove the two 3.00-inch diameter orange ducts below the floorboards that connect tothe heater control valve wye and the left and right forward plenums and remove fromairplane. (Refer to the 208 Maintenance Manual, Chapter 21, Heating and Defrosting AirDistribution-Maintenance Practices.)

(7) Remove the power converter assembly under the copilot's seat floorboard. Remove themounting brackets as necessary. (Refer to the 208 Maintenance Manual, Chapter 24, 12-VoltDirect Current Power Outlet System- Maintenance Practices.)

(8) Remove the sound dampening material between F.S. 128.00 and F.S. 158.0 and between RBL8.00 and RBL 19.00. (Refer to the 208 Maintenance Manual, Chapter 25, Soundproofing- Mainetnance Practices.)

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(9) Install the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right ExternalDoubler on the bottom of the airplane as follows:

(a) (Refer to Figure 5, View A-A, Detail B, and Detail G.) From the structure, remove the 84rivets shown on the right side and the 88 rivets shown on the left side.

(b) Put the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right ExternalDoubler in position on the structure.

(c) Make marks on the skin to show the outline of the doublers.

(d) (Refer to Figure 5, View A-A.) Find the ten nutplates in the outline that you made.Remove the five nutplates installed on the left and the five nutplates installed on theright between FS 128.00 and FS 143.00.

NOTE: You will use one or more of these nutplate holes later to install the forwardfairing. Where you can, you will match drill holes in the skin and the doubler touse these existing nutplate hole locations.

(e) Match drill 93 Number 30 (0.128-inch diameter) holes in the 2613495-2 TKS RightExternal Doubler.

(f) Match drill 89 Number 30 (0.128-inch diameter) holes in the 2613495-1 TKS Left ExternalDoubler.

(g) Make marks for and drill 54 Number 30 (0.128-inch diameter) holes in the 2613495-2TKS Right External Doubler.

(h) Make marks for and drill 51 Number 30 (0.128-inch diameter) holes in the 2613495-1TKS Left External Doubler.

(i) Match drill one existing hole in the 2613495-2 TKS Right External Doubler for the XPDR1transponder antenna.

(j) Match drill one existing hole in the 2613495-1 TKS Left External Doubler for the XPDR2transponder antenna, if installed.

CAUTION: Make sure that you do no damage to the nutplates when you drill thescrew holes.

(k) Match drill two 0.812-inch diameter holes in the 2613495-1 TKS Left External Doubler.Match drill the four screw holes through the doubler to the nut plates.

(l) Match drill one 0.75-inch diameter hole in the 2613495-1 TKS Left External Doubler andairplane skin and one 0.75-inch diameter hole in the 2613495-2 TKS Right ExternalDoubler and airplane skin for drain holes

(m) Drill six 0.219 inch-diameter holes for the fairing screws through the 2613495-1 and2613495-2 Doublers to match the six nutplates.

(n) Drill 12 Number 40 (0.098-inch diameter) holes through the 2613495-1 and 2613495-2Doublers to match the existing rivet hole locations in the belly skin.

(o) Drill four 0.193-inch-diameter holes for the fairing screws through the 2613495-1 and2613495-2 Doublers to match the six nutplates.

(p) Drill eight Number 40 (0.098-inch diameter) holes through the 2613495-1 and 2613495-2Doublers to match the existing rivet hole locations in the belly skin.

(q) Deburr and apply Alodine to bare metal.

(r) Fay seal the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS RightExternal Doubler with U470642 Sealant.

(s) Put the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right ExternalDoubler in position on the structure.

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(t) Attach the 2613495-1 TKS Left External Doubler and the 2613495-2 TKS Right ExternalDoubler to the structure with the 210 MS20470AD4-4A-5 Rivets.

(u) Install the four kept screws through the holes in the left doubler around the two 0.812drain holes.

(v) Attach the six MS21059L3 Nutplates at these locations.

(w) Attach the four MS21059L3 Nutplates at these locations.

(x) (Refer to Figure 5, Detail G.) Install the eight S2906-4-2 Rivets (heads on the near side)that attach the 2613495-2 TKS Right External Doubler to the structure.

(10) (Refer to Figure 5.) Install the 2613495-11 Stiffener, 2613495-10 TKS Connectors Doubler,and 2613495-9 TKS Cutouts Doubler on the bottom of the airplane as follows:

(a) (Refer to Figure 5, View A-A and Detail E.) Put the 2613495-11 Stiffener in position on thestructure in the airplane and make marks for and match drill 13 Number 30 (0.128-inchdiameter) holes in the 2613495-11 Stiffener and the structure.

(b) Deburr and apply Alodine to bare metal.

(c) (Refer to Figure 5, View A-A and Detail F.) Put the 2613495-10 TKS Connectors Doublerin position on the structure in the airplane on the lower skin.

(d) Make marks on the 2613495-10 TKS Connectors Doubler for the 35 rivet holes to attachthe 2613495-10 TKS Connectors Doubler to the structure.

(e) Make marks on the 2613495-10 TKS Connectors Doubler for the 0.87-inch diameter hole,0.44-inch diameter hole, 0.69-inch diameter hole, and 1.11-inch diameter hole.

(f) Make marks on the 2613495-10 TKS Connectors Doubler for the eight 0.15-inch diameterholes. Use the MS3472L10-6S and the MS3472L16-26S Connectors in the 2677124Wire Assembly to find the eight holes.

(g) Match drill 35 Number 30 (0.128-inch diameter) rivet holes, 0.87-inch diameter hole,0.44-inch diameter hole, 0.68-inch diameter hole, 1.11-inch diameter hole, and eight0.15-inch diameter holes in the lower skin and in the 2613495-10 TKS ConnectorsDoubler.

(h) Deburr and apply Alodine to bare metal.

(i) (Refer to Figure 5, View A-A and Detail A.) Put the 2613495-9 TKS Cutouts Doubler inposition on the structure and make marks on the 2613495-9 TKS Cutouts Doubler forthe 3.34-inch diameter hole, 1.75-inch diameter hole, and 52 rivet holes to attach the2613495-9 TKS Cutouts Doubler to the structure.

(j) Match drill the 3.34-inch diameter hole and the 1.75-inch diameter hole in the 2613495-9TKS Cutouts Doubler and the structure.

(k) Match drill the 52 Number 30 (0.128-inch diameter) holes in the 2613495-9 TKS CutoutsDoubler and the structure.

(l) Deburr and apply Alodine to bare metal.

(m) Fay seal all around the edges of the 2613495-9 TKS Cutouts Doubler and the 2613495-10TKS Connectors Doubler with U470642 Sealant.

(n) With 35 MS20470AD4-4A Rivets, attach the 2613495-10 TKS Connectors Doubler tothe structure.

(o) With two MS20470AD4-4A-5 Rivets and 11 MS20470AD4-4A Rivets, install the2613495-11 Stiffener to the structure.

(p) With the 52 MS20470AD4-4A Rivets, attach the 2613495-9 TKS Cutouts Doubler tothe structure.

SK208-178Page 20


(q) With U000787S Epoxy Adhesive, install an S1050-1-5.25 Grommet in the rear half onlyof the 3.34-inch diameter hole.

(11) (Refer to Figure 5, View A-A, Detail C, and Detail D.) Make a 6.23-inch slot and a 4.07-inch slotat the four positions shown.

(12) Deburr and apply Alodine to bare metal.

I. (Refer to Figure 5, View A-A and View B-B.) Install doublers on the longeron for the tank strapsas follows:

(1) Install the 2613495-3 TKS Left Forward Doubler and the 2613495-5 TKS Left Aft Doubler:

(a) Remove the two rivets that you will replace to install the 2613495-3 TKS Left ForwardDoubler.

(b) Put the 2613495-3 TKS Left Forward Doubler in position and match drill 19 Number 30(0.128-inch diameter) holes in the 2613495-3 TKS Left Forward Doubler and 17 Number30 (0.128-inch diameter) holes in the structure.

(c) Put the 2613495-5 TKS Left Aft Doubler in position and match drill 17 Number 30(0.128-inch diameter) holes in the 2613495-5 TKS Left Aft Doubler and the structure.

(d) Deburr and apply Alodine to bare metal.

(e) With the 19 MS20470AD4-3A5 Rivets, install the 2613495-3 TKS Left Forward Doubler tothe structure.

(f) With the 17 MS20470AD4-3A5 Rivets, install the 2613495-5 TKS Left Aft Doubler tothe structure.

(2) (Refer to Figure 5, View A-A and View C-C.) Install the 2613495-6 TKS Right Aft Doubler andthe 2613495-4 TKS Right Forward Doubler.

(a) Remove the four rivets that you will replace to install the 2613495-6 TKS Right AftDoubler. Remove the aileron servo motor for access to the rivets. (Refer to the 208Maintenance Manual, Chapter 22, Auto Flight.)

(b) Put the 2613495-6 TKS Right Aft Doubler in position and match drill four Number 30(0.128-inch diameter) holes in the 2613495-6 TKS Right Aft Doubler and four Number 30(0.128-inch diameter) holes in the structure.

(c) Put the 2613495-4 TKS Right Forward Doubler in position and match drill 19 Number30 (0.128-inch diameter) holes in the 2613495-4 TKS Right Forward Doubler and thestructure.

(d) Deburr and apply Alodine to bare metal.

(e) With the two S2906-4-2 Rivets, five MS20470AD4-4A Rivets, and one CM3827AD4-4Rivet (you will remove the existing rivets at four positions), install the 2613495-6 TKSRight Aft Doubler to the structure.

(f) With the 19 MS20470AD4-4A Rivets, install the 2613495-4 TKS Right Forward Doublerto the structure.

(3) (Refer to Figure 26, View E-E.) Make a 1.50-inch diameter hole at FS 163.80.

(4) Apply primer to the hole and use U000787S Epoxy Adhesive to install the S1050-1-4.30Grommet.

J. (Refer to Figure 5, View D-D, Detail H, and Detail J.) Do the modification of the 2611127-23Floorboard Assembly as follows:

(1) Remove the 2611058-22 Access Cover from the 2611127-23 Floorboard Assembly. Keepthe attachment hardware.

(2) Make marks for the hole that you will make in the 2611058-22 Access Cover and the2611127-23 Floorboard Assembly.

SK208-178Page 21


(3) With a permanent marker, draw a line through the 2611127-23 part number on the 2611127-23Floorboard Assembly.

(4) With the permanent marker, write the new part number of 2611127-35 on the floorboardassembly.

(5) With the permanent marker, draw a line through the 2611058-22 part number on the2611058-22 Access Cover.

(6) With the permanent marker, write the new part number of 2611058-25 on the access cover.

(7) Install the 2611058-22 Access Cover with the kept attachment hardware.

(8) Match drill the hole in the 2611058-22 Access Cover and the 2611127-23 Floorboard Assembly.

(9) Round off the exterior corners of the 2611127 Floorboard to a 0.25 radius.


(11) With U000787S Epoxy Adhesive, install the S1050-3-2.75 Grommet and the S1050-1-1.70Grommet in the new hole.

K. (Refer to Figure 12, View J-J.) If not already installed, with U000787S Epoxy Adhesive, install oneS1050-1 Grommet of the correct length on the flanges of the tank.

L. (Refer to Figure 12.) Install the nutplates for the tank as follows:

(1) Attach the 2680003-1 and the 2680003-2 TKS Fairing MTG templates to the inside of theairplane on the belly.

(2) Put the tank in position on the belly of the airplane.

(3) (Refer to Figure 12, View C-C, View D-D, and View E-E.) Match drill 16 Number 30 (0.128-inchdiameter) holes in the airplane lower skin.

(4) (Refer to Figure 12, Detail C.) On the left and the right side of the belly at the locations shownnear FS 128.00 and LBL 8.00 and RBL 8.00, drill one 0.3125-inch diameter hole in each of thetwo tank forward brackets for clearance of the rivet heads at this location.

(5) (Refer to Figure 12, View F-F and View G-G.) Drill eight Number 40 (0.098-inch diameter)holes through the doubler and the skin only for the rivet holes to attach the nutplates.

(6) (Refer to Figure 12, View C-C, View D-D, and View E-E.) In the airplane belly, enlarge the 16holes to 0.167-inch to 0.171-inch in diameter.

(7) (Refer to Figure 12, View H-H.) Drill eight Number 40 (0.098-inch diameter) holes through thedoubler, skin, and bulkhead segment for the rivet holes to attach the nutplates.

(8) Countersink the 32 rivet holes and apply Alodine to bare metal.

(9) With the 32 MS20426AD3-4A Rivets, install the 14 MS21047L08 Nutplates and the twoMS21073L08 Nutplates to the structure.

M. (Refer to Figure 27.) Install the tank straps as follows:

(1) Use the tank to help find the correct installation position for the tank straps.

(2) (Refer to Figure 27, View E-E and View F-F.) Put the straps in position in the channels on thetank and feed the ends through the fuselage. Make marks to show the correct position ofeach strap end.

(3) Match drill the airplane structure at the 14 holes.

(4) Put the strap angles in position and match drill the angles to the straps. After you drill theholes, hold it all together with clecos. Then drill nine Number 30 (0.128-inch diameter) holesthrough the bottom of the angles and the airplane structure.

(5) (Refer to Figure 27, View B-B.) With 18 MS20470AD4-4A Rivets, attach the 2613495-7 TKSForward Strap Angle and the 2613495-8 TKS Aft Strap Angle to the floor.

SK208-178Page 22


(6) (Refer to Figure 27, View E-E and View F-F.) Align the 2601548-3 Aft Left Strap Assembly andthe 2601548-4 Aft Right Strap Assembly with the 2613495-8 TKS Aft Strap Angles and thestructure and match drill to enlarge the 14 Number 21 holes through the straps, angles, andstructure to 0.193-inch in diameter.

(7) Apply Alodine to bare metal.

(8) (Refer to Figure 27, View E-E.) Put the 2601548-1 Forward Left Strap Assembly and the2601548-2 Forward Right Strap Assembly in position and attach them to the structureand to the strap angles with the six MS21044N3 Nuts and NAS6203-4 Bolts and the 12NAS1149F0332P Washers.

(9) (Refer to Figure 27, View F-F.) Put the 2601548-3 Aft Left Strap Assembly and the 2601548-4Aft Right Strap Assembly in position and attach them to the structure and to the strap angleswith the eight MS21044N3 Nuts and NAS6203-4 Bolts and the 16 NAS1149F0332P Washers.

(10) (Refer to Figure 12, View C-C, View D-D, and View E-E.) With the 16 AN525-832R7 Screwsand NAS1149FN832P Washers, install the 2601554-1 Tank and Equipment Assembly.

N. Install the structure for the filler port and the tank vent outlet as follows:

(1) Install the 2601552-9 Filler Port Doubler and the cutout for the filler port on the left side of theairplane:

(a) Remove the cargo door staple on the fuselage.

(b) Remove sound dampening between FS 166.70 and FS 181.50 and WL 97.50.

(c) (Refer to Figure 26, View B-B.) Remove and discard the NAS680A3 Nutplate.

(d) (Refer to Fig 26, View G-G) Remove the rivets in the skin at the locations where you willinstall the doubler.

(e) (Refer to Figure 26, View G-G.) Put the 2601552-9 Filler Port Doubler in position on theexterior left side of the airplane and make marks for two 0.172-inch diameter holes tomatch the 2615112 Staple holes (hook for the cargo door) and one 0.193-inch diameterhole to match the one in the 2611000 Skin.

(f) Match drill 17 Number 30 (0.128-inch diameter) holes in the 2601552-9 Filler PortDoubler and the 2611000 Skin.

(g) Match drill five Number 21 (0.159-inch diameter) holes in the 2601552-9 Filler PortDoubler and the 2611000 Skin.

(h) Drill two 0.172-inch diameter holes in the 2601552-9 Filler Port Doubler.

(i) Drill one 0.193-inch diameter hole in the 2601552-9 Filler Port Doubler and two Number40 (0.098-inch diameter) holes to install the nutplate.

(j) Drill one 3.25-inch diameter hole in the 2611000 Skin to match the one in the 2601552-9Filler Port Doubler.

(k) Drill one 0.25-inch diameter hole in the 2611000 Skin to match the one in the 2601552-9Filler Port Doubler.

(l) Apply Alodine to bare metal.

(m) Fay seal around the 3.25-inch diameter hole in the doubler and the skin with U470642Sealant.

(n) Attach the 2601552-9 Filler Port Doubler to the structure with the five MS20470AD5-4ARivets and the 17 MS20470AD4-4A Rivets.

(o) Install the staple with the kept hardware.

(p) (Refer to Figure 26, View B-B.) Drill two Number 40 (0.098-inch diameter) holes in thestructure.

SK208-178Page 23


(q) Apply Alodine to bare metal.

(r) Install the MS21051L3 Nutplate with the two MS20426AD3-3A Rivets.

(2) (Refer to Figure 25, View E-E.) Install the tank vent weldment and the 0823337-2 Grommet onthe 2601552-9 Filler Port Doubler:

(a) Drill four Number 40 (0.098-inch diameter) holes in the 2601552-9 Filler Port Doubler toinstall the tank vent outlet.

(b) Match drill two holes in the tank vent weldment to the 0823337-2 Grommet.

(c) Apply Alodine to bare metal.

(d) With U470642 Sealant, fay seal the 0823337-2 Grommet to the outer side of the2601552-9 Filler Port Doubler and fay seal the 2601552-1 TKS Tank Vent Weldmentto the inner side of the fuselage.

(e) With four MS20470AD3-3A Rivets, attach the 0823337-2 Grommet, 2601552-9 Filler PortDoubler, and 2601552-1 TKS Tank Vent Weldment to each other.

(3) Install the mounts for the filler tube installation and for the vent tube installation as follows:

(a) (Refer to Figure 26, Detail A, View B-B, View C-C, View D-D, and View F-F.) Make fourNumber 30 (0.128-inch diameter) holes in the structure for the rivets that attach themounts for the filler tube.

(b) Apply Alodine to bare metal.

(c) With four CR3213-4-5 Rivets, install four S2034-1 Mounts on the structure for supportsfor the routing of the filler tube.

(d) (Refer to Figure 25, View A-A, View B-B, View C-C, and View D-D.) Make four Number30 (0.128-inch diameter) holes in the structure for the rivets that attach the mounts forthe vent tube.

(e) Apply Alodine to bare metal.

(f) With four MS20470A4-6N Rivets, install four S2034-1 Mounts on the structure forsupports for the routing of the vent tube.

(4) Install the filler port as follows:

(a) (Refer to Figure 26, View B-B and View G-G.) Match drill eight 0.307-inch diameter holesin the 2611000 Skin to match the 2601552-9 Filler Port Doubler.

(b) Apply Alodine to bare metal.

(c) Put the two 13122-08 8-Bolt Gasket Fillers, one 13122-09 Filler Cap Flange, 13122-10Filler Cap, and 2601552-7 Filler Port Weldment in position and install them with the eightMS24694-C53 Screws, NAS1149C0363R Washers, and MS21083C3 Nuts.

O. (Refer to Figure 22.) Install nutplates that will attach the TKS fairing to the structure as follows:

(1) On the outside of the airplane on the belly, use the Mylar pattern to make marks at the correctposition for each of the nutplates.

CAUTION: Make sure before you drill the holes that you will do no damage to the structureor the components when you drill.

(2) From inside and outside the airplane, match drill 52 holes that are 0.219 inch in diameterin the airplane belly.

(3) From the inside or outside of the airplane, drill 104 Number 40 (0.098-inch diameter) holes inthe airplane belly for the installation of the nutplates.


(5) Attach 52 MS21059L3 Nutplates to the airplane belly with 104 MS20470AD3-3A Rivets.

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5. Install the TKS tank as follows:

A. (Refer to Figure 19, View G-G and View H-H.) Install the 13146-05 LP Tank Wire Harness on theTKS tank.

B. Bond and attach the ground wires on the 13146-05 LP Tank Wire Harness to the lower inboardmount screws on Auxiliary Pump 1 and Auxiliary Pump 2.

C. (Refer to Figure 27, View E-E and View F-F.) Torque the fasteners for the four TKS tank strapassemblies to 20 inch-pounds.

6. Install and connect the filler tubing and the vent tubing as follows:

A. (Refer to Figure 26, Detail A and View A-A.) Put the S1053K10W Duct in position in the airplane belly.

B. Wrap P840154 Tape around the part of the S1053K10W Duct that is adjacent to the filler portwhere you will install the S1891-20S Clamp.

C. Attach the S1053K10W Duct to the filler port with the S1891-20S Clamp.

D. Do the routing of the S1053K10W Duct toward the TKS tank.

E. (Refer to Figure 26, View B-B, View C-C, View D-D, and View F-F.) With the four S2209-1 Ties,attach the S1053K10W Duct to the structure at the four S2034-1 Mounts.

F. Use S2209-1 Ties to attach the S1053K10W Duct to the structure as necessary to make sure thatthe duct does not touch or cause interference with the structure or the control cables.

G. (Refer to Figure 26, Detail A.) Wrap P840154 Tape around the part of the S1053K10W Duct that isadjacent to the TKS tank where you will install the S1891-20S Clamp.

H. Attach the S1053K10W Duct to the TKS tank with the S1891-20S Clamp.

I. (Refer to Figure 25, View E-E.) With U000787S Adhesive, install the 0823337-2 Grommet on the2601552-1 TKS Vent Weldment.

J. (Refer to Figure 25, Detail A.) Attach the S1495-6 Hose to the filler port vent with the S2357-1 Clamp.

K. Do the routing of the S1495-6 Hose forward.

L. (Refer to Figure 25, Detail A.) With the S3017-6-6-6 Tee and three S2357-1 Clamps, attach the endof the S1495-6 Hose to the S1495-6 Hose and the S1495-6 Hose.

M. With two S2357-1 Clamps, attach the two S1495-6 Hoses to the structure.

N. (Refer to Figure 25, View A-A, View B-B, View C-C, and View D-D.) With the four S2209-1 Ties,attach the S1495-6 Hoses to the vent tubes in the top of the tank at the four S2034-1 Mounts.

7. (Refer to Figure 23, View B-B.) Install the bulkhead connectors on the airplane belly as follows:

A. In the 0.87-inch diameter hole that you made in the airplane belly, install the MN6216 BulkheadUnequal Tee, two MN6211 Backnuts, and MN6782 5/16 Blanking Cap Assembly.

B. In the 0.44-inch diameter hole that you made in the airplane belly, install the MN6235 BulkheadShort Connector and the MN6079 Backnut 1/8 BSP.

8. (Refer to Figure 24, View A-A and View C-C.) Install the antenna doubler for the XPDR1 transponderantenna on the forward fairing as follows:

NOTE: You can use the existing plate assembly to make the antenna doubler.

A. Drill a 0.812-inch diameter hole in the airplane skin that aligns with the hole in the XPDR1transponder antenna.

B. Drill four 0.201-inch diameter holes in the 9507001-3 Plate Assembly to align with the XPDR1transponder antenna.

C. Match drill six Number 30 (0.128-inch diameter) holes in the 9507001-3 Plate Assembly and thestructure.

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D. Drill a 0.812-inch diameter hole in the 2613000 Forward Fuselage Assembly.

E. Install an MS35489-118 Grommet in the 0.812-inch diameter hole in the 2613000 Forward FuselageAssembly.

F. With U470638 Sealant, fay seal the 9507001-3 Plate Assembly.

G. With U470638 Sealant, shank seal the six CR3522-4-3 Rivets for the installation of the 9507001-3Plate Assembly.

H. With six CR3522-4-3 Rivets, attach the 9507001-3 Plate Assembly to the 2613494 TKS FairingAssembly.

I. With primer, do a touch-up as necessary on the rivet heads.

9. (Airplanes with XPDR2 transponder antenna installed) (Refer to Figure 24.) Install the antenna doubler forthe XPDR2 transponder antenna on the forward fairing as follows:

NOTE: You can use the existing plate assembly to make the antenna doubler.

A. Drill a 0.812-inch diameter hole in the airplane skin that aligns with the hole in the XPDR2transponder antenna.

B. Drill four 0.201-inch diameter holes in the 9507001-3 Plate Assembly to align with the XPDR2transponder antenna.

C. Match drill six Number 30 (0.128-inch diameter) holes in the 9507001-3 Plate Assembly and thestructure.

D. Drill a 0.812-inch diameter hole in the 2613000 Forward Fuselage Assembly.

E. Install an MS35489-118 Grommet in the 0.812-inch diameter hole in the 2613000 Forward FuselageAssembly.

F. With U470642 Sealant, fay seal the 9507001-3 Plate Assembly.

G. With U470638 Sealant, shank seal the six CR3522-4-3 Rivets for the installation of the 9507001-3Plate Assembly.

H. With six CR3522-4-3 Rivets, attach the 9507001-3 Plate Assembly to the 2613494 TKS FairingAssembly.

10. Install the equipment and filter pallets on the forward low-profile TKS fairing as follows:

A. Do the modification of the equipment pallet as follows:

CAUTION: Be careful that you do not make a hole in the tank when you drill the holes thatmodify the equipment pallet.

(1) (Refer to Figure 19, View H-H, View J-J, and View K-K.) Drill one 0.204-inch diameter holethrough the Number 2 pump mount bracket.

(2) Drill two Number 21 (0.159-inch diameter) holes in the equipment pallet.

(3) Drill one 0.204-inch diameter hole and two Number 40 (0.098-inch diameter) holes through theequipment pallet for the installation of the MS21075L3N Nutplate.


(5) Install two S1741-1 Anchors with the two MS20470AD5-4A Rivets.

(6) Install one MS21075L3N Nutplate with the two MS20426AD3-4A Rivets.

B. (Refer to Figure 23.) Install the 2601553-12 Aft Drain Tube Assembly on the equipment pallet.

C. (Refer to Figure 19, View G-G.) Install the 13146-06 Low Profile Pallet Wire Harness on theequipment pallet.

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D. (Refer to Figure 19, View K-K.) Attach the windshield pump EMI shield to the TKS equipment palletwith an MS21919WDG20 Cushion Clamp and one MS27039-1-07 Screw.

E. (Refer to Figure 19, View K-K.) On the tank, install the MS21919WDG20 Cushion Clamp with theMS27039-1-07 Screw, NAS1149F0332P Washer, and MS21042-3 Nut to the 0.204-inch diameterhole you drilled on the Number 2 pump mount bracket to attach the level sender EMI shield.

F. (Refer to Figure 19, View L-L.) Use U000787S Adhesive to install a S1050-1 Grommet (cut to length)on the aft upper edge of the access hole cover as protection for the sender wires.

G. (Refer to Figure 23.) Install one MN6838 Elbow Assembly and 100-013-8810 Seal on each of thetwo ends of the 2601553-3 Filter Pallet.

H. (Refer to Figure 23, View B-B and View C-C.) Install the 2601553-3 TKS Filter Pallet on the TKS lowprofile fairing with eight MS35207-258 Screws and NAS1149F0316P Washers.

I. (Refer to Figure 23, View A-A.) Install the 2601553-14 TKS Accessory Pallet on the TKS low profilefairing with six MS35207-258 Screws and NAS1149F0316P Washers.

J. Put the H610026 Nylon Tubing in position between the 2601553-3 TKS Filter Pallet and the2601553-14 TKS Accessory Pallet. Cut the S2562-3 Protective Conduit to the length that it will goover the hose and still attach to the S2606-1 Mount Wiring Adhesive Backed Anchor.

K. Install the two MN6201 Nuts, MN101-32 Sleeves, and 100-013-8810 Seals on the H610026 NylonTubing and connect it to the 2601553-3 TKS Filter Pallet at the two MN6838 Elbow Assemblies.

L. Use an S2209-5 Wire Tie to attach the H610026 Nylon Tubing at the equipment pallet.

M. Install the S2606-1 Mount on the TKS low profile fairing and attach the H610026 Nylon Tubingto the S2606-1 Mount with the S2209-1 Tie.

N. (Refer to Figure 19, View G-G.) Connect the large connector on the 13146-05 Low Profile Tank WireHarness to the large connector on the 13146-06 Low Profile Pallet Wire Harness.

11. (Refer to Figure 29, View A-A.) Install the low profile TKS fairing as follows:

A. Put the 2613498-1 Forward Fairing Assembly, 2613498-2 Aft Fairing Assembly, and 2613466-7Fairing Assembly in position on the belly.

B. Align the 2613466-7 Fairing Assembly with the nose gear fairing, and center the fairings on the belly.

C. To make sure that you keep correct alignment, use 0.100-inch spacers in the gap where the2613498 fairing flanges overlap.

D. Remove any installed screws that cause interference with the fairing flange. You will cover the holeswith the sealant when you fillet seal the fairings.

E. Remove the bolts and washers shown that are installed at the rear edge of the 2613498-2 AftFairing Assembly.

F. Match drill 54 0.193-inch diameter holes in the 2613498-1 Forward Fairing Assembly and the2613498-2 Aft Fairing Assembly to align with the nutplate holes on the fuselage.

G. Match drill 16 0.193-inch diameter holes in the flange of the 2613498-2 Aft Fairing Assembly to alignwith the nutplates on the flange of the 2613498-1 Forward Fairing Assembly.

H. Temporarily install the 2641018 Main Landing Gear Fairings and make marks on the 2613498-2Aft Fairing Assembly where the 2641018 Main Landing Gear Fairings overlap with the 2613498-2Aft Fairing Assembly.

I. Trim the flange of the 2613498-2 Aft Fairing Assembly in the area that overlaps the 2641018 MainLanding Gear Fairings. Make sure before you trim that you keep the correct edge distance oftwice the rivet diameter from the rivet holes.

J. Apply U000927S Sealant Tape between the flange of the 2613498-1 Forward Fairing Assemblyand the fuselage.

SK208-178Page 27


K. Install the 2613498-1 Forward Fairing Assembly and the 2613498-2 Aft Fairing Assembly withthe 54 AN525-10R8 Screws.

L. Attach the 2613498-2 Aft Fairing Assembly with the 16 AN525-10R10 Screws.

M. With U470644 Sealant, fillet seal all around the flange edge of the 2613498-1 Forward FairingAssembly where it is adjacent to the fuselage.

N. Install the 2601212-5 TKS Fairing Cover over the front fairing nose gear cutout with the fiveAN525-10R11 Screws.

O. Fay seal and fillet seal the 2601212-5 TKS Fairing Cover to the fuselage, nose gear spring, andfairing with U544053S Sealant.

P. Install the 2613466-7 Fairing Assembly to the fuselage with the kept attachment hardware and thefive AN525-10R10 Screws.

12. (Refer to Figure 23, View A-A, View B-B, and View C-C.) Connect the tank and pallets.

A. Connect the 2601558-1 Pump 1 Outlet Hose between the 9514A-1 Pump Assembly and the relatedcheck valve on the equipment pallet with the two S2800-942 Sealing Rings, MN101-20 Sleeves, andMN4855 Nuts.

B. Connect the 2601558-2 Pump 2 Outlet Hose between the 9514A-1 Pump Assembly and the relatedcheck valve on the equipment pallet with the two S2800-942 Sealing rings, MN101-20 Sleeves, andMN4855 Nuts.

C. With the MN4856 Nut, MN101-12 Sleeve, and S2800-943 Sealing Ring, connect the H610024 NylonTubing that comes from the windshield pump on the equipment pallet to the MN6235 BulkheadShort Connector on the airplane belly.

D. With the MN6201 Nut, MN101-32 Sleeve, and 100-013-8810 Seal, connect the H610026 NylonTubing from the filter pallet outlet to the airplane belly at the MN6216 Bulkhead Unequal Tee.

E. Cut the S2548-10 Hose to the correct length and, with the S2357-2 Clamps, install it between thestrainer weld assembly on the equipment pallet and the TKS tank.

13. (Refer to Figure 20.) Do the modification of the fuel reservoir tank sump system as follows:

A. Put the fuel shutoff valves in the OFF position.

B. Drain all fuel from the reservoir tank. (Refer to the Model 208 Maintenance Manual, Chapter 28,Fuel Reservoir - Maintenance Practices.)

C. Remove the 2616017-28 Lower Access Cover from the reservoir tank.

D. Remove and discard the 967B5 Drain Valve. Keep the nut and discard the o-ring.

E. Install the 180C4 Valve Assembly with the new M83248/1-021 O-ring and NAS1149D1290K Washerand the kept 856A2 Nut. Install the washer under the nut.

F. Use safety wire and the double-twist method to safety the 856A2 Nut. (Refer to the Model 208Maintenance Manual, Chapter 20, Safetying - Maintenance Practices.)

G. Apply sealant to the two sides of the 2616017-27 Gasket and install it between the 2616017-28Access Cover Assembly and the fuel reservoir tank. (Refer to the Model 208 Maintenance Manual,Chapter 28, Fuel Tank Sealing - Maintenance Practices.)

H. Do the modification of the 2611000-12 Removable Skin Panel as follows:

(1) Make the hole of the dimensions shown in the 2611000-12 Removable Skin Panel.

(2) Drill one 0.219-inch diameter hole in the 2611000-12 Removable Skin Panel.


(4) Change the part number on the Removable Skin Panel from 2611000-12 to 2616033-3.

I. Install the MS35489-6 Grommet on the left side of the forward fairing for the fuel sump drain tube.

SK208-178Page 28


J. Install the 2616033-4 Sump Drain Tube Assembly through the side of the 2613498 Forward FairingAssembly and through the MS35489-6 Grommet and connect the B-nut to the sump valve assembly.

K. Install the S1212-37 Control and the S1979-1 Knob Assembly as follows:

(1) Push knob on to the S1212-37 Control Cable. Push evenly on the knob as you push it onto the control cable.

(2) Attach the S1212-37 Control Cable to the side of the forward fairing and do the routing ofthe S1212-37 Control.

(3) With the two MS21919WDG3 Clamps and AN525-10R8 Screws and one MS21044N3 Nutand NAS1149F0332P Washer (installed under the nut), attach the S1212-37 Control to the2611000-12 Removable Skin Panel.

(4) With the MS21919WDG4 Clamp, AN525-10R14 Screw, and NAS43DD3-18FC Spacer, attachthe 2616033-4 Sump Drain Tube Assembly to the 2616033-3 Removable Skin Panel.

(5) Bend the S1212-37 Control through the arm of the 180C4 Valve Assembly as shown.

L. (Refer to Figure 20, View A-A.) Install the 2616033-5 Welded Drain Tube Assembly as follows:

(1) (Refer to Figure 20, View A-A.) Drill a 0.265-inch diameter hole in the 2613498 Forward Fairingand install the 2616033-5 Welded Drain Tube Assembly through the hole.

(2) Cut the two existing S2548-4-6.00 Hoses.

(3) Do the routing of the two S2548-4-6.00 Hoses from the shrouds down through the belly and donot remove the grommets that are installed in the holes in the belly skin.

(4) Attach the two S2548-4-6.00 Hoses to the 2616033-5 Welded Drain Tube Assembly with thetwo AN737TW22 Clamps.

(5) With U470644 Sealant, fillet seal the tube to the inner and the outer sides of the 2613498Fairing Assembly.

M. Make sure that the fuel 180C4 Valve Assembly operates correctly as follows:

(1) Open the fuel shutoff valves to let some fuel go into the reservoir tank.

(2) Do a check for leaks around the lower access cover.

(3) Pull the S1212-37 Control to open and close the drain valve.

(4) Make sure that there are no leaks and that fuel flows from the 2616033-4 Sump Drain TubeAssembly when the drain valve is open.

(5) Make sure that there are no drips when the valve is closed.

14. (Refer to Figure 24.) Install the XPDR1 transponder antenna on the forward low profile TKS fairingas follows:

A. With the four MS24694-C52 Screws, install the kept XPDR1 transponder antenna.

B. Pull the existing cable through the hole in the belly and connect it to the XPDR1 transponder antenna.

C. With U470644 Sealant, fillet seal around the base of the antenna on the exterior of the airplane andaround the connector hole on the interior fairing.

D. Clean and electrically bond the antenna, and make sure that the maximum resistance value isno more than 0.5 ohms. (Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding- Maintenance Practices.)

15. (Airplane equipped with XPDR2 transponder antenna) Install the XPDR2 transponder antenna as follows:

A. With the four MS24694-C52 Screws, Install the kept XPDR2 transponder antenna.

B. Pull the existing cable through the hole in the belly and connect it to the XPDR2 transponder antenna.

SK208-178Page 29


C. With U470644 Sealant, fillet seal around the base of the antenna on the exterior of the airplane andaround the connector hole on the interior fairing.

D. Clean and electrically bond the antenna, and make sure that the maximum resistance value isno more than 0.5 ohms. (Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding- Maintenance Practices.)

16. Do a dry fit of the TKS system porous panels as follows:

CAUTION: Do not do damage to the ice protection system with solvents or paints that are notapproved for use on or near the porous panels. Most solvents and all paints cancause damage to the plastic membrane in the porous panels. Use only approvedsolvents on or near the porous panels. Never use MEK, acetone, or lacquer thinner.Always use masking material when you use paint or unapproved solvents near theporous panels.


A. (Refer to Figure 6 and Figure 7.) Do a dry fit of the 13102-75 Vertical Stabilizer Porous Panel:

(1) (Refer to Figure 7, View A-A.) Put the 13102-75 Vertical Stabilizer Porous Panel in positionon the vertical stabilizer.

(2) (Refer to Figure 7, View B-B.) If necessary for clearance of the bleed port tubing, lightly make adimple in the skin at the location shown. Deformation must not be more than 0.08 inch. Theremust be no sharp transitions in the skin or surface damage at the dimple.

(3) At all dimples that you make in the skin, do a surface eddy current inspection for cracks.(Refer to the Model 208 Nondestructive Testing Manual, Chapter 20, Eddy Current SurfaceTechniques - General - Description and Operation.)

(a) If there are cracks, refer to the Model 208 Structural Repair Manual for repair instructions.

(b) If there are cracks and you have specific questions about the cracks that are notanswered in the Model 208 Structural Repair Manual, contact Cessna Customer Servicefor more instructions: Telephone 316-517-5800, or FAX 316-517-7271.

(c) Make sure after you do the repair that you have the necessary clearance for bleed porttubing.

(4) Put the 13102-75 Vertical Stabilizer Porous Panel in position for a good fit at the top and thebottom trailing edges of the 13102-75 Vertical Stabilizer Porous Panel.

(5) Push hard and hold the 13102-75 Vertical Stabilizer Porous Panel tightly against the leadingedge.

(6) Make sure that all of the edges of the 13102-75 Vertical Stabilizer Porous Panel continuouslytouch the chalk line marks that show where the edges of the porous panel must be when theporous panel is installed.

(7) Use P840294 Tape or equivalent as necessary to hold the porous panels tightly against theleading edge.

(8) (Refer to Figure 7, View A-A.) When you are sure that the 13102-75 Vertical Stabilizer PorousPanel is held in the correct position, make marks for the four rivet holes in the 13102-75Vertical Stabilizer Porous Panel.

CAUTION: When you make holes for the rivets, do not drill into a rib.

(9) Match drill four Number 30 (0.128-inch diameter) holes in the 13102-75 Vertical StabilizerPorous Panel and the vertical stabilizer for the rivets.

(10) Make marks for the six MS35206-246 Screws that attach the 13102-75 Vertical StabilizerPorous Panel to the vertical stabilizer tip assembly.

SK208-178Page 30


(11) Match drill six 0.168-inch diameter holes in the skin and the 13102-75 Vertical StabilizerPorous Panel.

(12) Remove the porous panel from the vertical stabilizer.

(13) Do a countersink of the four rivet holes in the 13102-75 Vertical Stabilizer Porous Panel.

(14) Remove the 2631039 Tip Assembly from the vertical stabilizer. Keep the attachment screws.

(15) Drill 12 Number 40 (0.098-inch diameter) holes in the 2631039 Tip Assembly for the nutplates.

(16) Countersink the 12 rivet holes in the 2631039 Tip Assembly.

(17) With the 12 CCR244SS-3-02 Rivets, install the six MS21047L08 Nutplates to the 2631039Tip Assembly.

B. (Refer to Figure 7.) Do a dry fit of the 13102-73 Left Horizontal Stabilizer Porous Panel and the13102-74 Right Horizontal Stabilizer Porous Panel:

CAUTION: Do not do damage to the ice protection system with solvents or paints thatare not approved for use on or near the porous panels. Most solvents andall paints can cause damage to the plastic membrane in the porous panels.Use only approved solvents on or near the porous panels. Never use MEK,acetone, or lacquer thinner. Always use masking material when you use paintor unapproved solvents near the porous panels.


(1) (Refer to Figure 7, View C-C.) Put the 13102-73 Left Horizontal Stabilizer Porous Panel andthe 13102-74 Right Horizontal Stabilizer Porous Panel in position on the horizontal stabilizers.Align the lower edge of each panel with the chalk line that you made.

(2) (Refer to Figure 7, View D-D.) If necessary for clearance of the bleed port tubing, lightly make adimple in the skin at the location shown. Deformation must not be more than 0.08 inch. Theremust be no sharp transitions in the skin or surface damage at the dimple.





(4) Push and hold the 13102-73 Left Horizontal Stabilizer Porous Panel and the 13102-74 RightHorizontal Stabilizer Porous Panel tightly in the correct position.

(5) Make sure that all of the edges of the 13102-73 Left Horizontal Stabilizer Porous Panel andthe 13102-74 Right Horizontal Stabilizer Porous Panel continuously touch the horizontalstabilizer skins.

(6) Make sure that the lower edges of the 13102-73 Left Horizontal Stabilizer Porous Panel andthe 13102-74 Right Horizontal Stabilizer Porous Panel continuously touch the chalk line marks.

(7) Use P840294 Tape or equivalent as necessary to hold the porous panels tightly against theleading edge.

SK208-178Page 31


(8) When you are sure 13102-73 Left Horizontal Stabilizer Porous Panel and the 13102-74 RightHorizontal Stabilizer Porous Panel are in the correct position, make marks for the six rivet holesin each of the two porous panels.


(9) Match drill six Number 30 (0.128-inch diameter) holes in the 13102-73 Left Horizontal StabilizerPorous Panel and six Number 30 (0.128-inch diameter) holes in the 13102-74 Right HorizontalStabilizer Porous Panel and in the two horizontal stabilizers for the rivets.

(10) Remove the 13102-73 Left Horizontal Stabilizer Porous Panel and the 13102-74 RightHorizontal Stabilizer Porous Panel from the horizontal stabilizer.

(11) Countersink the 12 rivet holes in the 13102-73 Left Horizontal Stabilizer Porous Panel and the13102-74 Right Horizontal Stabilizer Porous Panel.

C. (Refer to Figure 8.) Do a dry fit of the 13102-69 Left Wing Strut Porous Panel and the 13102-70Right Wing Strut Porous Panel as follows:

(1) (Refer to Figure 8, View P-P, View Q-Q, and View R-R.) Put the 13102-69 Left Wing StrutPorous Panel and the 13102-70 Right Wing Strut Porous Panel in position on the wing struts.Align the upper and lower edges of each panel with the chalk lines.

(2) (Refer to Figure 8, View P-P.) If necessary for clearance of the bleed port tubing, lightly make adimple in the skin at the location shown. Deformation must not be more than 0.08 inch. Theremust be no sharp transitions in the skin or surface damage at the dimple.





(4) Push and hold the 13102-69 Left Wing Strut Porous Panel and the 13102-70 Right Wing StrutPorous Panel tightly in the correct position.

(5) Make sure that all of the edges of the 13102-69 Left Wing Strut Porous Panel and the 13102-70Right Wing Strut Porous Panel continuously touch the wing strut skins.

(6) Make sure that all of the edges of the 13102-69 Left Wing Strut Porous Panel and the 13102-70Right Wing Strut Porous Panel continuously touch the chalk line marks that show where theedges of the porous panels must be when the porous panels are installed.

(7) Use P840294 Tape or equivalent as necessary to hold the panels tightly against the leadingedge.

(8) (Refer to Figure 8, View Q-Q.) When you are sure that the porous panels are in the correctpositions, make marks for the rivet holes in the 13102-69 Left Wing Strut Porous Panel and the13102-70 Right Wing Strut Porous Panel.

(9) Match drill four Number 30 (0.128-inch diameter) holes in the skin and in each of the twoporous panels for the rivets.

(10) Remove the porous panels from the wing struts.

(11) Countersink the eight rivet holes in the 13102-69 Left Wing Strut Porous Panel and the13102-70 Right Wing Strut Porous Panel.

SK208-178Page 32


D. (Refer to Figure 8, View A-A.) Do a dry fit of the 13102-61 Left Outboard Wing Porous Panel,13102-63 Left Mid-Wing Porous Panel, and 13102-67 Left Inboard Wing Porous Panel as follows:

(1) Put the 13102-61 Left Outboard Wing Porous Panel, 13102-63 Left Mid-Wing Porous Panel,and 13102-67 Left Inboard Wing Porous Panel in position on the left wing. Align the loweredges of each panel with the chalk line.

(2) (Refer to Figure 8, View C-C.) If necessary for clearance of the bleed port tubing, lightly makea dimple in the skin at the locations shown. Deformation must not be more than 0.08 inch.There must be no sharp transitions in the skin or surface damage at the dimple.





(4) Hold the 13102-61 Left Outboard Wing Porous Panel, 13102-63 Left Mid-Wing Porous Panel,and 13102-67 Left Inboard Wing Porous Panel tightly in the correct position.

(5) Make sure that all of the edges of the 13102-61 Left Outboard Wing Porous Panel, 13102-63Left Mid-Wing Porous Panel, and 13102-67 Left Inboard Wing Porous Panel continuouslytouch the wing skins.

(6) Make sure that all of the lower edges of the 13102-61 Left Outboard Wing Porous Panel,13102-63 Left Mid-Wing Porous Panel, and 13102-67 Left Inboard Wing Porous Panelcontinuously touch the chalk line marks.

CAUTION: Make sure that when you tighten the ratcheting straps you do no damage to theflap. Use foam or blankets to protect the airplane structure and do not use toomuch force when you tighten the straps.

(7) Put ratcheting straps on the 13102-67 Left Inboard Wing Porous Panel only to tightly conformthe contour of the panel to the wing leading edge prior to drilling the panel to the leadingedge skin.

(8) Use P840294 Tape or equivalent as necessary to hold the remaining panels tightly against theleading edge.

(9) (Refer to Figure 8, View B-B, View F-F, and View K-K.) When you are sure that the 13102-61Left Outboard Wing Porous Panel, 13102-63 Left Mid-Wing Porous Panel, and 13102-67 LeftInboard Wing Porous Panel are in the correct positions, make marks for the 16 rivet holes inthe porous panels.


(10) Match drill 16 Number 30 (0.128-inch diameter) holes in the skin and the 13102-61 LeftOutboard Wing Porous Panel, 13102-63 Left Mid-Wing Porous Panel, and 13102-67 LeftInboard Wing Porous Panel for the rivets.

(11) Remove the ratchet straps from the inboard wing porous panel.

(12) Remove the porous panels from the left wing.

(13) Countersink the 16 rivet holes in the 13102-61 Left Outboard Wing Porous Panel, 13102-63Left Mid-Wing Porous Panel, and 13102-67 Left Inboard Wing Porous Panel.

SK208-178Page 33


E. (Airplanes with Weather Radar) (Refer to Figure 9, View A-A.) Do a dry fit of the 13102-62 RightOutboard Wing Porous Panel, 13102-66 Mid-Wing Radar Porous Panel, and 13102-68 RightInboard Wing Porous Panel as follows:

(1) Put the 13102-62 Right Outboard Wing Porous Panel, 13102-66 Mid-Wing Radar PorousPanel, and 13102-68 Right Inboard Wing Porous Panel in position on the right wing.

(2) (Refer to Figure 9, View L-L.) If necessary for clearance of the bleed port tubing, lightly make adimple in the skin at the location shown. Deformation must not be more than 0.08 inch. Theremust be no sharp transitions in the skin or surface damage at the dimple.





(4) Hold the 13102-62 Right Outboard Wing Porous Panel, 13102-66 Mid-Wing Radar PorousPanel, and 13102-68 Right Inboard Wing Porous Panel tightly in the correct position.

(5) Make sure that all of the edges of the 13102-62 Right Outboard Wing Porous Panel, 13102-66Mid-Wing Radar Porous Panel, and 13102-68 Right Inboard Wing Porous Panel continuouslytouch the wing skins.

(6) Make sure that the lower edges of the 13102-62 Right Outboard Wing Porous Panel, 13102-66Mid-Wing Radar Porous Panel, and 13102-68 Right Inboard Wing Porous Panel continuouslytouch the chalk line marks.


(7) Put ratcheting straps on the 13102-68 Right Inboard Wing Porous Panel only to tightly conformthe contour of the panel to the wing leading edge before you drill the panel to the leadingedge skin.


(9) (Refer to Figure 9, View B-B, View F-F, and View K-K.) When you are sure that the 13102-62Right Outboard Wing Porous Panel, 13102-66 Mid-Wing Radar Porous Panel, and 13102-68Right Inboard Wing Porous Panel are in the correct positions, make marks for the 16 rivet holes.


(10) Match drill 16 Number 30 (0.128-inch diameter) holes in the skin and the 13102-62 RightOutboard Wing Porous Panel, 13102-66 Mid-Wing Radar Porous Panel, and 13102-68 RightInboard Wing Porous Panel for the rivets.


(12) Remove the porous panels from the right wing.

(13) Countersink the 16 rivet holes in the 13102-62 Right Outboard Wing Porous Panel, 13102-66Mid-Wing Radar Porous Panel, and 13102-68 Right Inboard Wing Porous Panel.

(14) Clean the leading edges of the wings and the rear sides of the 13102-62 Right Outboard WingPorous Panel, 13102-66 Mid-Wing Radar Porous Panel, and 13102-68 Right Inboard Wing

SK208-178Page 34


Porous Panel to remove all grease and FOD. (Refer to the 208 Maintenance Manual, Chapter20, General Solvents/Cleaners - Maintenance Practices.)

F. (Airplanes not equipped with Weather Radar) (Refer to Figure 10, View A-A.) Do a dry fit ofthe 13102-62 Right Outboard Wing Porous Panel, 13102-64 Right Mid-Wing Porous Panel, and13102-68 Right Inboard Wing Porous Panel as follows:

(1) (Refer to Figure 10, View D-D, View E-E, View H-H, View J-J, and View N-N.) Put the 13102-62Right Outboard Wing Porous Panel, 13102-64 Right Mid-Wing Porous Panel, and 13102-68Right Inboard Wing Porous Panel in position on the right wing.

(2) (Refer to Figure 10, View C-C.) If necessary for clearance of the bleed port tubing, lightly makea dimple in the skin at the locations shown. Deformation must not be more than 0.08 inch.There must be no sharp transitions in the skin or surface damage at the dimple.





(4) Hold the 13102-62 Right Outboard Wing Porous Panel, 13102-64 Right Mid-Wing PorousPanel, and 13102-68 Right Inboard Wing Porous Panel tightly in the correct position. Align thelower edges of each panel with the chalk line.

(5) Make sure that all of the edges of the 13102-62 Right Outboard Wing Porous Panel, 13102-64Right Mid-Wing Porous Panel, and 13102-68 Right Inboard Wing Porous Panel continuouslytouch the wing skins.

(6) Make sure that the lower edges of the 13102-62 Right Outboard Wing Porous Panel, 13102-64Right Mid-Wing Porous Panel, and 13102-68 Right Inboard Wing Porous Panel continuouslytouch the chalk line marks.


(7) Put ratcheting straps on the 13102-68 Right Inboard Wing Porous Panel only to tightly conformthe contour of the panel to the wing leading edge before you drill the panel to the leadingedge skin.


(9) (Refer to Figure 10, View B-B, View F-F, and View K-K.) When you are sure that the 13102-62Right Outboard Wing Porous Panel, 13102-64 Right Mid-Wing Porous Panel, and 13102-68Right Inboard Wing Porous Panel are in the correct positions, make marks for the 16 rivet holes.


(10) Match drill 16 Number 30 (0.128-inch diameter) holes in the skin and the 13102-62 RightOutboard Wing Porous Panel, 13102-64 Right Mid-Wing Porous Panel, and 13102-68 RightInboard Wing Porous Panel for the rivets.


(12) Remove the porous panels from the right wing.

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(13) Countersink the 16 rivet holes in the 13102-62 Right Outboard Wing Porous Panel, 13102-64Right Mid-Wing Porous Panel, and 13102-68 Right Inboard Wing Porous Panel.

CAUTION: Do not do damage to the nylon tubing in the ice protection system. There must be notension or strain on the nylon tubing, as these forces when applied to the nylon tubingcan cause damage.

CAUTION: Do not do damage to the nylon tubing in the ice protection system. Cut and install the nylontubing in lengths that take into consideration the effects of tension and strain. When youcut the nylon tubing, add no less than 3% (1 inch for each 3 feet) to the necessary lengthfor thermal shrinkage and airframe flexure, as too much shrinkage of the nylon tubingand airframe flexure can cause damage.

CAUTION: Do not do damage to the nylon tubing in the ice protection system. Assemble the nylontubing and the couplings in accordance with best shop practices.

CAUTION: Use tie straps as necessary during the routing of the nylon tubing to make sure that thereis sufficient clearance from and that they do not rub against other equipment. If there is notsufficient clearance from other equipment, damage to the nylon tubing can result.

CAUTION: Remember before you do the installation of the porous panels that the TKS porous panelsmust be installed on primed or painted surfaces.

17. (Refer to Figures 2 and 3 for reference only. Refer to Figures 4 and 20 to do the routing and theinstallation.) Do the routing and the modification of the nylon tubing and attachment parts for the tubing inthe TKS system as follows:

A. (Refer to Figure 4.) Remove and keep the tubing that follows:• tailcone bracket to tee• belly to tee• belly tee to prop tee• prop tee to prop proportioning unit• prop tee to right wing bulkhead.

B. (Refer to Figure 4, View A-A and View B-B.) Remove and keep the MN6210 Equal Tee, Bulkhead(and attachment hardware).

C. (Refer to Figure 30.) Install S2034-1 Mounts at the positions that follow:

NOTE: One or more of the mounts that follow may already be installed if the airplane is equippedwith air conditioning, and if they are you will use tie straps to attach the tubing to the airconditioning hoses.

• (Refer to Figure 30, View H-H.) at FS 166.37 for the new belly tubing• Refer to Figure 30, View A-A.) two at FS 158.00 left for the new belly tube and the new

windshield tubing)• (Refer to Figure 30, View F-F.) at LBL 8.00, for the new belly tubing• (Refer to Figure 30, View D-D.) at FS 194.40 left for the new tailcone tubing• (Refer to Figure 30, View G-G.) two at RBL 8.00• (Refer to Figure 30, View J-J.) at FS 181.50.

(1) Drill eight Number 30 (0.128-inch diameter) holes at the positions shown.


(3) With the eight MS20470AD4-3A Rivets, attach the eight S2034-1 Mounts to the structure.

D. (Refer to Figure 30, View C-C.) Make new tubing from the kept H610026 Hose and install thetubing from the short left aft wing tee.

E. With the kept H610026 hose attach the left equal tee to the unequal tee with a new MN101-32Sleeve, 100-013-8810 Seals, and a MN6201 Nut.

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F. (Refer to Figure 30, View B-B.) With two 100-013-8810 Seals and one S2800-942 Sealing Ring,attach the kept 6216 Bulkhead Unequal Tee as shown. As you do the routing of the tubing here,you can, if required, route the tubing through one lightening hole outboard of the one shown tomaintain the necessary bend radius.

G. (Refer to Figure 30, View C-C.) With kept attachment hardware, install the kept MN6210 EqualTee, Bulkhead on the short tubing from the left wing tee aft, short. Install one new 100-013-8810Sealing Ring.

H. Make new tubing from the kept H610026 Hose and install the tubing as follows with new seals:• from tee to tailcone bracket (coil the excess tubing in the tailcone)

NOTE: The tubing is 252.00 inch, +1.00 or -1.00.• from tee to belly

I. Use S2209-2 Ties to attach the tubing to the structure at the S2034-1 Mounts and to other attachpoints as necessary to make sure that there will be no chafing and that there will be sufficientclearance for the tubing.

J. (Refer to Figure 23, View A-A, View B-B, and View C-C.) Attach the H610024 Nylon Tubing to theMN6235 Short Bulkhead Connector at the 2613495 TKS Connectors Doubler with the MN4856 Nut,MN101-12 Sleeve, and S2800-943 Sealing Ring that you installed.

K. Attach the H610026 Nylon Tubing to the MN6216 Bulkhead Unequal Tee at the 2613495 TKSConnectors Doubler with the MN6201 Nut, MN101-32 Sleeve, and 100-013-8810 Seal that youinstalled.

18. (Refer to Figure 18.) Temporarily install the porous panels and apply masking tape (or equivalent) on theairplane skin around the perimeter of the porous panels. This will allow you to fillet seal the edges ofthe porous panels later.

19. Remove the porous panels.

20. (Refer to Figure 13.) Install the porous panels as follows (Refer to the 208 Maintenance Manual, Chapter30, TKS Anti-Ice Leading Edge Porous Panel - Maintenance Practices.):

CAUTION: Do not do damage to the ice protection system with solvents or paints that are notapproved for use on or near the porous panels. Most solvents and all paints can causedamage to the plastic membrane in the porous panels. Use only approved solvents on ornear the porous panels. Never use MEK, acetone, or lacquer thinner. Always use maskingmaterial when you use paint or unapproved solvents near the porous panels.

CAUTION: After you remove and before you install a porous panel, apply P840294 Tape or equivalentlow-residue masking material on the panel to give it protection.

CAUTION: Be careful when you remove and install the porous panels, as you can do damage duringremoval and installation. Use nonmetallic tools when you can to prevent tears, gouges,scratches, and other damage.

A. Clean the airplane leading edges (where you will install the porous panels) and the rear surfaces ofthe porous panels to remove all grease and FOD. (Refer to the Model 208 Maintenance Manual,Chapter 20, General Solvents/Cleaners - Maintenance Practices.)

B. Inside the areas that have masking tape around them (where you will install the porous panels),lightly abrade the airplane leading edges with a Scotch Brite pad.

C. Use a 50/50 mixture of denatured alcohol and water with a sponge or medium-hard short bristlebrush to clean the area of the leading edge where you will install the porous panel.

D. Use a clean, lint-free cloth to dry the area before the cleaning solution dries.

E. Use a clean, lint-free cloth that is wet with denatured alcohol (no water) to clean the rear surfaceof the porous panel as necessary.

SK208-178Page 37


F. Use a clean, lint-free cloth to dry the area before the cleaning solution dries.

G. (Refer to Figure 15.) With U544042S Sealant, prepack seal the voids between the backplate jogglesand edges of the porous panels. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel,Weather and High-Temperature Sealing - Maintenance Practices.)

H. (Refer to Figure 15.) Apply a 0.50-inch (inboard wing panels) or a 0.25-inch diameter bead (allother panels) of U544042S Sealant that is equivalent to a prepack seal along the centerline of thebackplate of the porous panel. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel,Weather and High-Temperature Sealing - Maintenance Practices.)

I. On the inboard wing porous panels only, apply U544042S Sealant as a prepack seal along theentire backplate.

CAUTION: When you apply sealant to the inboard wing panels, you must fill all of the spacebetween the inboard wing porous panels and the wing leading edges with sealant.Sealant squeeze out along the upper and the lower edges of the inboard wing porouspanels in this area is a sign that sufficient sealant has been applied.

J. (Refer to Figure 15.) Apply U544042S Sealant as a prepack seal around all fluid inlet ports or airbleed ports on the porous panels. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel,Weather and High-Temperature Sealing - Maintenance Practices.)

K. Put the porous panels adjacent to the applicable leading edge and connect the fluid tubes to theinlet ports.

CAUTION: Make sure that you install the fluid tubes to each porous panel correctly with ano-ring installed on each fitting, and make sure that you use approved procedures totorque the TKS fittings as described in the first steps of this Service Kit. Once theporous panels are installed, there will be no access to the fluid port fittings on someporous panels.

L. Put the porous panels on the applicable leading edges and use temporary fasteners (Clecos) in therivet holes to hold the panels in the correct position.

M. Apply aftward pressure to the forward edges of the porous panels to make sure that they are heldtightly against the leading edges.

CAUTION: Make sure that when you tighten the ratcheting straps you do no damage to the flap.Use foam or blankets to protect the airplane structure and do not use too muchforce when you tighten the straps.

N. (For installation of 13102-67 and 13102-68 Inboard Wing Porous Panels only) After the panels havebeen put into position with the temporary fasteners, use ratchet straps around the flap and betweenthe fastener positions to pull the inboard wing porous panel edges against the contour of the wingleading edge. Look for sealant that squeezes out around all edges of the porous panels as anindication that you applied sufficient sealant to the inboard wing porous panels.

O. Apply pressure to the edges of the panel as necessary to remove all gaps between the edges ofthe panel and the leading edge skin.

P. Install strips of P840294 Tape across the remaining panels to apply pressure after the panels are inthe correct position and do not remove the tape until the sealant is fully cured.

CAUTION: Always use P840294 Tape or equivalent low-residue masking material to make surethat unapproved materials do not touch the porous panels.

Q. (Refer to Figure 7, Figure 8, and Figure 9.) With U544042S Sealant, shank seal the CR3524-4-02Rivets and the MS35206-246 Screws (screws on 13102-75 Vertical Stabilizer Porous Panel only)before you install them. (Refer to the Model 208 Maintenance Manual, Chapter 20, Fuel, Weatherand High-Temperature Sealing - Maintenance Practices.)

SK208-178Page 38


R. Remove the temporary fasteners and install the porous panels with the CR3524-4-02 Rivets,MS35206-246 Screws, and NAS1515H08L Washers (screws on 13102-75 Vertical StabilizerPorous Panel only).

CAUTION: Always use P840294 Tape or equivalent low-residue masking material to make surethat unapproved materials do not touch the porous panels.

CAUTION: You must allow the sealant to cure before you remove the strips of tape and theratcheting straps from the porous panels.

S. After the panels are cured in position, remove the ratchet straps or tape that you used to applypressure to the porous panels.

T. (Refer to Figure 15) Fillet seal around the edges of the porous panels with U470638 Sealant. (Referto the 208 Maintenance Manual, Chapter 20, Fuel, Weather, and High - Temperature Sealing -Maintenance Practices.

U. Remove the masking tape from around the perimeter of the porous panels.

V. Make sure that the maximum resistance value of the electrical bond between the porous panelsand the structure is no more than 0.005 ohms. If the maximum resistance value is more than 0.005ohms, you must contact Cessna Customer Service at 316-517-5800. (Refer to the 208 MaintenanceManual, Chapter 20, Electrical Bonding - Maintenance Practices.)

21. Fay seal each horizontal and vertical stabilizer access panel with U544035S Sealant.

22. Install the access panels on the horizontal and the vertical stabilizers. Do not install the wing accesspanels at this time.

23. (Refer to Figure 31.) Install the four 4D2007 Vortex Generators (VG) on the left flap and the four 4D2007Vortex Generators (VG) on the right flap. (Refer to the Model 208 Maintenance Manual, Chapter 57, Flaps- Maintenance Practices and Flap Vortex Generator Boots Removal/Installation.)

A. To make sure that you keep an equal distance between the vortex generators, you can trim therubber mats of the 4D2007 before you attach them to the flaps.

B. (Refer to Figure 31, Detail C.) Fillet seal in area shown with black paint.

24. (Refer to Figure 31, View A-A.) Install the gurney flaps on the wings as follows:

A. Match drill 17 Number 27 holes in the flap on the left wing and 17 Number 27 holes in the flapon the right wing.

B. Apply Alodine to bare metal.

C. With U470637 Sealant, fay seal the 2625000-31 Left Gurney Flap to the left wing flap and the2625000-32 Right Gurney Flap to the right wing flap.

D. With 34 S2456-4-1 Rivets, attach the 2625000-31 Left Gurney Flap and the 2625000-32 RightGurney Flap to the wing flaps.

25. (Refer to Figure 14, View A-A and View B-B.) Move the installation position of the stall vane to alignwith the cutout in the 13102-63 Left Mid-Wing Porous Panel and install the kept 799-1 Lift Transduceras follows:

A. Increase the forward length of the slots in the leading edge skin no more than 0.20 inch to get the0.03-inch dimension shown.

B. Put the 799-1 Lift Transducer in position at the most forward position in the holes on the wing andmeasure to see if you must add NAS1149FN816P Washer(s) and/or NAS1149FN832P Washer(s) tomake the forward edge of the 799-1 Lift Transducer flush with the outer surface of the 13102-63 LeftMid-Wing Porous Panel. The forward edge of the 799-1 Lift Transducer must be flush with the outersurface of the 13102-63 Left Mid-Wing Porous Panel or inset no more than 0.010 inch.

C. With the two MS24694-S6 Screws, two MS24694-S5 Screws, NAS1149FN816P and/orNAS1149FN832P Washer(s) as necessary, and four MS21044N08 Nuts and NAS1149FN832P

SK208-178Page 39


Washers (installed under the nut), install the 799-1 Lift Transducer in the most forward position inthe holes.

D. Make sure that the 799-1 Lift Transducer is at the most forward position in the holes, that the 799-1Lift Transducer is flush with the outer surface of the 13102-63 Left Mid-Wing Porous Panel, andthat the top edge of the 799-1 Lift Transducer is flush with the outer surface of the 13102-63 LeftMid-Wing Porous Panel or inset no more than 0.010 inch.

E. (Refer to Figure 14, Detail A.) Inject and fillet seal all around the mounting plate of the 799-1 LiftTransducer with U470642 Sealant. The sealant must not extend above the outermost line of themounting plate face.

26. (Refer to Figure 16 and Figure 19.) Do the electrical installation as follows:

A. Remove the two adel clamps that hold the static drain on the circuit breaker panel.

B. Find the large JD003 connector and the smaller JD004 connector on the TKS wire bundle.

C. At the two bulkhead holes that were drilled, prepare the surface of the skin below the floorboardsbetween the pilot and copilot seat for an electrical bond.

D. Electrically bond the JD003 and JD004 bulkhead connectors and the doubler, and make sure thatthe maximum resistance value is no more than 0.0025 ohms after the connectors are installed.(Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.)

E. (Refer to Figure 19, Detail A.) Install the JD003 bulkhead connector with four MS35206-228Screws and one M85528/2-12-A Mounting Flange and the JD004 bulkhead connector with fourMS35206-215 Screws and one M85528/2-16-B Mounting Flange.

F. (Refer to Figure 16.) In the low-profile TKS fairing, install the connectors from the TKS fluid andequipment pack to JD003 and JD004.

G. (Refer to Figure 16.) Do the installation of the wires.

H. Inside the cabin and from the JD003 connector, do the routing of the three wires aft along existingwire bundles and supports to the tailcone proportioning unit and PT003.

I. Inside the cabin and from the JD003 and JD004 connectors, do the routing of the applicable newwires forward along existing wire bundles and supports and up through the floor along the right sideof the cabin and across the top beneath the glareshield to the CB box PC011 connector, left switchpanel PI003 connector and GC001 ground connector.

J. (Refer to Figure 16 and Figure 19, View B-B.) Install one S1232-505 Circuit Breaker (HC015)and one S1232-502 Circuit Breaker (HC016) as the face nut and use the knurled nut as the basenut adjacent to the circuit breaker body. (Refer to the 208 Wiring Diagram Manual, Chapter 20,Standard Practices - Airframe.)

K. Install one S1232-505 Circuit Breaker (HC005) in #1 Bus Bar. Use the hex nut provided with thecircuit breaker as the face nut and use the knurled nut as the base nut adjacent to the circuit breakerbody.

L. Wire circuit breakers with existing wire in accordance with Figure 16.

M. (Refer to Figure 19, View D-D.) If not already installed, install the S2034-1 Mount as follows:

(1) Make one Number 30 (0.128-inch diameter) hole in the structure.


(3) With one MS20470AD4-3A Rivet, install one S2034-1 Mount on the structure.

(4) Attach the TKS wire assembly to the S2034-1 Mount with one S2209 Tie.

N. (Refer to Figure 19, View A-A.) Install the MS24524-23 BACKUP Switch (S1024) and the C15GreenTip on the 9910616-5 LED LAA Switch Plate Assembly.

O. Install the MS24524-27 MAX FLOW Switch (S1023) and the C15Green Tip on the 9910616-5 LEDLAA Switch Plate Assembly.

SK208-178Page 40


P. Install the MS27407-1 PRIMARY Switch (S1022) and the C15Green Tip on the 9910616-5 LEDLAA Switch Plate Assembly.

Q. (Refer to Figure 16.) Install the wires from the switches to the PI003 (L SW Panel) connector.

R. (Refer to Figure 16 and Figure 19.) Make sure that the TKS Cable Assembly is connected correctlyat all positions.

27. Accomplish SK208-180 Low Airspeed Awareness System Installation for Airplanes with TKS.

NOTE: Part Number SK208-180 is a separate item and is not included with SK208-178 TKS IceProtection System.

28. Decrease the up angle of the elevators to 18 degrees, +1 degree or −1 degree, as follows: (Refer to theModel 208 Maintenance Manual, Chapter 27, Elevator - Maintenance Practices.)

A. Replace the up stop bolt with an NAS428H4A14 Bolt.

B. Set the elevator to 17 to 19 degrees on the UP mark on the elevator rigging protractor.

C. Do the adjustment of the up stop bolt as necessary.

29. (Refer to Figure 28.) Install the necessary placards for the TKS anti-ice system installation as follows:

A. (Refer to Figure 28, View A-A and View B-B.) Install one 7000-03 Solvent Caution Placard on thebottom of each wing and one 7000-03 Solvent Caution Placard on the bottom of each horizontalstabilizer as follows:

(1) Clean areas where placard is to be installed with isopropyl alcohol. (Refer to the MaintenanceManual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.)

(2) Install the four 7000-03 Solvent Caution Placards on the left and the right wings and on theleft and the right horizontal stabilizers in the positions shown.

(3) Edge seal the 7000-03 Solvent Caution Placards with clear polyurethane enamel topcoat.(Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.)

B. (Refer to Figure 28, Detail A.) Install the 2605076-14 Placard-TKS Filler Cap on the left side of thefuselage as follows:

(1) Clean area where placard is to be installed with isopropyl alcohol. (Refer to the MaintenanceManual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.)

(2) Install the 2605076-14 Placard-TKS Filler Cap on the left side of the fuselage in the positionshown.

(3) Edge seal the 2605076-14 Placard-TKS Filler Cap with clear polyurethane enamel topcoat.(Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.)

C. (Refer to Figure 28, View C-C.) Install the 2105015-7 Operational Limitations Placard adjacentto the overhead console as follows:

(1) Remove the installed operational limitations placard that is adjacent to the overhead console.

(2) Clean the area where the new placard is to be installed with isopropyl alcohol. (Refer to theMaintenance Manual, Chapter 20, Solvents, Sealants and Adhesives - Maintenance Practices.)

(3) Install the 2105015-7 Operational Limitations Placard adjacent to the overhead console inthe approximate position shown.

D. (Refer to Figure 28, View D-D.) Install the 2605070-10 Icing Conditions Placard on the instrumentpanel as follows:

(1) Remove the installed icing conditions placard that is on the instrument panel.


(3) Install the 2605070-10 Icing Conditions Placard on the instrument panel in the position shown.

SK208-178Page 41


E. (Refer to Figure 28, View D-D.) Install the 7000-26 Windshield Anti-Ice Placard on the instrumentpanel as follows:


(2) Install the 7000-26 Windshield Anti-Ice Placard on the instrument panel in the position shown.

F. (Refer to Figure 28, View D-D.) Install the 2605076-5 TKS Operational Limit Placard on the pilot sideof the instrument panel as follows:


(2) Install the 2605076-5 TKS Operational Limit Placard on the pilot side of the instrument panel inthe position shown.

G. (Refer to Figure 28, Detail B.) Install the 2605076-4 TKS Operational Limit Placard on the side ofthe low-profile TKS fairing as follows:


(2) Install the 2605076-4 TKS Operational Limit Placard on the side of the low-profile TKS fairingin the position shown.

(3) Edge seal the 2605076-4 TKS Operational Limit Placard with clear polyurethane enameltopcoat. (Refer to the Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting.)

30. Clean, electrically bond, and do a resistance check of the ice protection system. (Refer to the 208Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.)

A. Clean and electrically bond the 2601553-3 TKS Filter Pallet and the 2601553-14 TKS AccessoryPallet, and make sure that the maximum resistance value at the two pallets is no more than 0.5 ohms.(Refer to the 208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.)

B. Install the MS25083-2BB16 Bonding Jumper on the 2601553-3 TKS Filter Pallet mounting screwwhich is the shortest distance from the closest mounting screw on the 2601553-14 TKS AccessoryPallet. Measure the resistance value to make sure that it is no more than 0.5 ohms. (Refer to the208 Maintenance Manual, Chapter 20, Electrical Bonding - Maintenance Practices.)

31. Review and incorporate the Pilot's Operating Handbook Supplement 208PHBUS-S1-00 Ice ProtectionSystem, or later revision.

32. Do the operational tests necessary to make sure that all of the systems that you changed or workedin while you installed this TKS system operate correctly. (Refer to the applicable chapters of the 208Maintenance Manual.)

33. Make sure that the stall warning margin is set correctly and do an operational check of the lift transducer.(Refer to the 208 Maintenance Manual, Chapter 27, Stall Warning System - Maintenance Practices.)

34. Do a visual inspection for correct installation of the TKS system tubes and connections and the electricalconnections.

A. Look at the system nylon tubing in the fuselage (cabin and tailcone), engine compartment, wing, wingstrut, horizontal stabilizer, and vertical stabilizer to make sure that there are no kinks or sharp bends.

B. Make sure that the tubing connections are attached correctly in all areas. Make sure that you checkthe tubing connections in the engine compartment.

C. Make sure that the electrical connections are attached correctly.

35. Do a test of the wiring for the circuit breaker panel as follows:

A. Disengage one circuit breaker.

B. Make sure that power is removed from the system the circuit breaker is a part of.

SK208-178Page 42


C. Engage the circuit breaker.

(1) Make sure that there is power to the system.

(a) For systems that have switches and that are easily visible (cockpit lights or vent blowersfor example), you can use visual or tactile information to make sure that the systemoperates correctly.

(b) For systems that start automatically or when operation cannot be seen (stall heat or pitotheat for example), you can look at the instrument panel ammeter for changes in currentdraw to make sure that the system operates correctly

D. Repeat Step 35A thru 35C(1)(b) for each circuit breaker, one circuit breaker at a time.

36. Update the TKS software configuration as follows:

A. Do the configuration of the software as follows:

(1) Make sure that all electrical power to the airplane is off and remove the database cards from allthree of the displays.

(2) Disengage the PFD1, PFD2, and MFD circuit breakers.

(3) Push and hold the ENT key down on the PFD2 display while you engage the PFD2 circuitbreaker.

(4) Release the ENT key when INITIALIZING SYSTEM shows on the PFD2 display.

(5) Push and hold the ENT key down on the MFD display while you engage the MFD circuitbreaker.

(6) Release the ENT key when INITIALIZING SYSTEM shows on the MFD display.

(7) Put the G1000 software SD loader card (from the POH plastic sleeve) in the top slot of thePFD1 display unit.

(8) Push and hold the ENT key down on the PFD1 display while you engage the PFD1 circuitbreaker.

(9) Release the ENT key when INITIALIZING SYSTEM shows on the PFD1 display.

(10) When UPDATE USER SETTINGS shows on the PFD1 display, select NO.

(11) Use the FMS knob and the ENT key to go to the SYSTEM UPLOAD.

(12) Use the FMS knobs and the ENT key to select INSTALLATION OPTIONS in the AIRFRAMEfield.

(13) Use the FMS knob and the ENT key to select the Cessna Caravan - TKS Low Profile TankInstallation Option from the option list.

(14) Push the LOAD soft key and wait until the upload process is complete.

(15) Push the ENT key.

(16) Push the UPDT CFG and the ENT soft keys to update the PFD1 Configuration module.

(17) Wait until the upload process is complete and then push the ENT key.

(18) Remove power from the system.

(19) Remove the G1000 SD loader card from the PFD1 display.

(20) Install the three G1000 SD database cards into their correct displays.

(21) Apply power to the system and bring the three displays up in NORMAL mode.

B. Do a check of the software configuration as follows:

(1) Put the EXTERNAL POWER switch to the BUS position.

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(2) Put the AVIONICS 1 switch to the ON position.

(3) Put the AVIONICS 2 switch to the ON position.

(4) After PFD’s have stabilized, pull down the MFD circuit breaker on the Avionics Circuit BreakerPanel to remove power from the MFD.

(5) After ten seconds, apply power.

(6) When the splashscreen is displayed, push MFD soft keys 1, 2, 3, and 1 in sequence to enterMaintenance Mode.

(7) Push ENT to exit the splashscreen.

(8) Make sure that the ADVISORY soft keys on the PFDs begin to flash.

(9) Push either of the ADVISORY soft keys.

(10) Make sure that the message “MAINTENANCE MODE – Cycle Power to Exit” is displayed inthe ALERTS window.

(11) Make sure that the message “CHECK TKS CONFIG – TKS Install Option does not match TKSTank” does NOT appear in the ALERTS window. If this message does appear, troubleshootas follows:

(a) Make sure that there is a ground present at 61PI002 with tank assembly and wiringinstalled. Wring out between 61PI002 and *cJD003.

(b) Load the G1000 baseline configuration again and then do Steps 36A(1) thru 36A(22)(TKS Low Profile Tank Option configuration) of this Service Kit again.

(c) When you reload the baseline software, all other software options will be erased andyou must load them again.

(12) Put the AVIONICS 1 switch to the OFF position.

(13) Put the AVIONICS 2 switch to the OFF position.

(14) Put the EXTERNAL POWER switch to the OFF position.

37. Do the leakage and functional tests.

A. Do the preparation for the leakage and functional tests as follows:

(1) Make sure that the airplane is level. (Refer to the Model 208 Maintenance Manual, Chapter 8,Leveling - Maintenance Practices.)

(2) Engage the applicable circuit breakers as shown in Table 1:

TABLE 1: TKS CIRCUIT BREAKERS

TKS Circuit Breaker Reference Designator

PRIMARY ANTI-ICE (HC005)

W/S ANTI-ICE (HC016)

BACKUP ANTI-ICE (HC015)

ENG INTFC (HI013)

(3) Set initial conditions in accordance with Table 2.

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TABLE 2 INITIAL CONDITIONS

Name Position

Ground Power Supply 28, +0.5 VDC or −0.5 VDC

External Power OFF

Battery (DC Power) Switch OFF

Fluid Control - Primary OFF

Fluid Control - Max Flow OFF

Fluid Control - Backup OFF

TKS Fluid Tank Empty

(4) (Refer to Figure 2, View N-N and View P-P.) Disconnect the left and the right wing 0.50-inchfluid supply lines from the wing connection point on each proportioning unit.

(5) Connect the test lines to the left and the right wing supply lines.

NOTE: You can make test lines of unused TKS tubing. Shutoff valves or nylon balls and nutsas recorded in the Material Information Section of this Service Kit can be used tomodulate flow through the test lines. It is necessary to install a 0-200 psi fluid gauge inthe empennage test line only.

(6) Open the shutoff valves (or remove the nylon ball/nut caps if you used them) and put theends of the test lines in five-gallon buckets.

(7) Find the windshield and propeller supply lines on the lower right side of the engine firewall.

(8) Disconnect the propeller and the windshield fluid supply lines at the firewall and connect thewindshield and propeller test lines to the bulkhead fittings.

(9) Open the shutoff valve for the propeller test tube and put the ends of the two test lines ina five-gallon bucket.

NOTE: You can keep the windshield test line shutoff valve closed, or put a cap on the end.No fluid should flow from this line during this initial test.

(10) (Refer to Figure 4, Detail B.) Disconnect the empennage 0.50-inch fluid supply line from theempennage connection point on the tailcone proportioning unit and connect the test line, withthe union and the pressure gage, to the supply line.

(11) Open the shutoff valve and put the other end of the test line in a five-gallon bucket.

(12) Make sure that the EXTERNAL POWER switch on the pilot's switch panel is in the OFF position.

(13) Make sure that the PRIMARY switch on the ANTI-ICE switch panel is in the OFF position.

(14) Get access to the two low pressure switches for the left and the right horizontal porous panelsfound in the upper section of the tailcone.

(15) Disconnect the connectors to the two low pressure switches.

(16) Put a five-gallon bucket below the TKS fluid tank and equipment pack drain line (under thelow-profile fairing on the left side of the airplane) and open the drain valve on the tank to makesure that all residual fluid has been drained. Close the drain valve when all fluid is drained.

B. Do the fluid indication systems check as follows:

(1) Put the external power switch to the BUS position.

(2) Put the AVIONICS SWITCHES #1 and #2 to the ON position.

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(3) Make sure that the fluid quantity readout on the MFD is green and reads “A-ICE GAL 0.0”. Putthe FLUID CONTROL PRIMARY switch to the NORM position.

(4) Make sure that the the fluid quantity readout on the MFD is flashing red and reads “A-ICEGAL 0.0”.

(5) Make sure that the annunciation on the PFD is flashing amber and reads “A-ICE FLUID LO”.

(6) Put the FLUID CONTROL PRIMARY switch to the OFF position.

(7) Add 11.00 gallons (41.63 liters) of TKS fluid to the tank and wait no less than one minute.(Refer to the 208 Maintenance Manual, Chapter 12, TKS Anti-Ice System - Servicing.)

(8) With the minimum dispatch mark at eye level, make sure that the bottom of the float ball in thefluid sight glass is not above the top of the minimum dispatch mark.

(9) Make sure that the fluid quantity readout on the MFD is green.

(10) Put the FLUID CONTROL PRIMARY switch to the NORM position.

(11) Make sure that the fluid quantity readout on the MFD is green.

(12) Make sure that the annunciation on the PFD is white and reads A-ICE NORM.


(14) Fill the tank with fluid until the fluid level ball is just above the minimum dispatch quantity line.

(15) Do a check for accuracy of the fluid quantity indication and make sure that it shows within1.50 gallons of 11.7.

(a) If the indication is within 1.50 gallons of 11.7, go to Step 34C.

(b) If the indication is not within 1.50 gallons of 11.7, do the steps that follow to recalibrate thelevel sender:

NOTE: The level sender is mounted on the top of the TKS fluid tank. The FULLadjustment screw is labeled on the level sender.

1 Disengage the ENG INTFC circuit breaker (HI013).

NOTE: The ENG INTFC circuit breaker (HI013) is on the instrument panel justleft of the control yoke.

CAUTION: Make sure that you do not cause a short when you hook up the leadsof the voltmeter.

2 Connect one lead of the voltmeter to the SEND post and the other lead of thevoltmeter to the NEG post of the level sender.

3 Engage the ENG INTFC circuit breaker (HI013).

4 Remove the protective coating from the FULL adjustment screw on the left side (leftside of the airplane) of the level sender.

5 With a screwdriver, turn the FULL adjustment screw until 3.45 VDC, +0.1 or −0.1VDC, shows on the voltmeter.

6 Disengage the ENG INTFC circuit breaker (HI013).

7 Disconnect the leads of the voltmeter from the level sender.

8 Put torque putty on the adjustment screw.

9 Engage the ENG INTFC circuit breaker (HI013).

10 Do a check for the accuracy of the fluid quantity indication to make sure that itshows within 1.50 gallons of 11.7.

C. Do the pump operation systems check as follows:

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CAUTION: During this check, if you see leakage of fluid at one or more connections in thesystem, turn the anti-ice system off, repair connections, and remove all leakage.

(1) Make sure that the shutoff valves are open and that the other ends of the two test lines are infive-gallon buckets.

(2) Make sure that the EXTERNAL POWER switch is at the BUS position.

(3) Put the FLUID CONTROL PRIMARY switch to the HIGH position and let the metering pump#1 operate until fluid flows into each bucket.

(a) If a flow does not come out of the hoses, you must do as follows:

1 Put the FLUID CONTROL PRIMARY switch to the OFF position.

2 Remove the 0.50-inch diameter line that goes into the fuselage from the filter palletand put it in a bucket.

3 Put the FLUID CONTROL PRIMARY switch to the HIGH position.

4 After the fluid begins to flow out, put the FLUID CONTROL PRIMARY switch tothe OFF position.

5 Put the FLUID CONTROL BACKUP switch to the ON position.

6 After the fluid begins to flow out again, put the FLUID CONTROL BACKUP switch tothe OFF position.

7 Connect the 0.50-inch diameter line.

8 Put the FLUID CONTROL PRIMARY switch to the HIGH position and let themetering pump #1 operate until fluid flows into each bucket.

(b) If fluid does not flow from every test line, or if fluid flows only from the empennage testline do as follows:

1 With the FLUID CONTROL PRIMARY switch in the HIGH position, close the shutoffvalve in the empennage test line to force fluid out of the other test lines.

2 Work from the rear to the front and close the shutoff valve in the left.

3 After you have made sure that fluid has flowed from each test line, open all of thetest line shutoff valves and continue with the functional test.

(4) Collect fluid that comes out of the lines for one minute and make sure that the fluid youcollected is 34 ounces, −3.38 ounces or +6.76 ounces (1000 ml, −100 ml or +200 ml).

NOTE: During this test, it is possible that fluid will not flow equally out of all of the test lines

(5) Make sure that the white A-ICE HIGH message is on.

(6) Disengage the PRIMARY ANTI-ICE circuit breaker.

(7) Make sure that the pump goes off.


(9) Engage the PRIMARY ANTI-ICE circuit breaker.

(10) Put the FLUID CONTROL BACKUP switch to the ON position and let the metering pump#2 operate until fluid flows into each bucket.

NOTE: During this test, it is possible that fluid will not flow equally out of all of the test lines

(11) Collect the fluid that comes out of the lines for one minute and make sure that the fluid youcollected is 34 ounces, −3.38 ounces or +6.76 ounces (1000 ml, −100 ml or +200 ml).

(12) Disengage the BACKUP ANTI-ICE circuit breaker and make sure that the pump shuts off.

(13) Put the FLUID CONTROL BACKUP switch to the OFF position.

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(14) Engage the BACKUP ANTI-ICE circuit breaker.

(15) Put the FLUID CONTROL PRIMARY switch to the NORMAL position and start the timer.

(16) Make sure that the two metering pumps are on for 20 seconds +3 seconds or −3 seconds andthen off for 100 seconds +10 seconds or −10 seconds.

(17) When the two pumps turn off, wait 30 seconds and then put the MAX FLOW switch to theAIRFRAME position and release the spring-loaded switch.

(18) Make sure that the two pumps operate at the same time for 120 seconds +10 seconds or−10 seconds.


(20) Unplug the windshield pump line and put the line in a bucket.

(21) Put the MAX FLOW switch to the WINDSHIELD position and release the spring-loaded switch.

(22) Make sure that the windshield pump makes the fluid flow while the switch is in theWINDSHIELD position and for 4 seconds +2 seconds or −2 seconds after you release thespring-loaded switch.

(23) Disengage the W/S ANTI-ICE circuit breaker.

(24) Put the MAX FLOW switch to the WINDSHIELD position and hold the switch.

(25) Make sure that the windshield pump is off.

(26) Release the MAX FLOW switch.

(27) Engage the W/S ANTI-ICE circuit breaker.

D. Do the test of the low pressure switch as follows:

WARNING: During this test the TKS system operation pressure will go above 80 psig.


(2) Put the FLUID CONTROL PRIMARY switch to the HIGH position.

(3) After the metering pump operates for no less than 15 seconds, connect the right side lowpressure switch connector.

NOTE: This connector is in the tailcone at the horizontal.

(4) Make sure that the red A-ICE PRESS LOW annunciator comes on.

(5) Disconnect the right side low pressure switch connector.


(6) Make sure that the red A-ICE PRESS LOW annunciator goes off.

(7) Connect the left side low pressure switch connector.



(9) Disconnect the left side low pressure switch connector.



(12) Put the FLUID CONTROL BACKUP switch to the ON position.

(13) After the metering pump operates for no less than 15 seconds, connect the right side lowpressure switch connector.


SK208-178Page 48


(15) Disconnect the right side low pressure switch connector.






(21) Put the FLUID CONTROL BACKUP switch to the OFF position.

(22) Connect the two low pressure switches in the tailcone at the horizontal.

E. Do the leak test and high pressure switch test as follows:

NOTE: It is possible that the red A-ICE PRESS LOW annunciator will come on momentarily duringthis test. This is okay.

(1) Close the shutoff valves in the wings and in the propeller test tube assemblies.

(2) Make sure that the empennage test tube assembly is open.



(5) Limit fluid flow through the empennage shutoff valve until the pressure gage shows 60 psi+15 psi or −15 psi.

(6) Do an inspection for leaks of the pressurized fluid lines and connections in the airplane.

(7) If there are leaks, you must put the FLUID CONTROL PRIMARY switch in the OFF position,release the pressure in the lines, and repair the leaks before you continue with this test.

(8) Close the empennage shutoff valve.

(9) When the pressure gage shows more than 150 psi, put the FLUID CONTROL PRIMARYswitch to the OFF position.

(10) Make sure that the amber A-ICE HIGH comes on.

(11) Once again, do an inspection for leaks of the pressurized fluid lines and connections in theairplane. If there are leaks, you must release the pressure in the lines and repair the leaksbefore you continue with this test.

(12) Slowly open all of the test tube shutoff valves to release the fluid pressure.


(14) Disconnect all of the five test tube assemblies.

(15) Install new sealing rings and seals (three 101-013-8810 Seals at the proportioning units, oneS2800-942 Sealing Ring at the propeller supply line, and one S2800-943 Sealing Ring at thewindshield supply line) and connect the five fluid supply lines to their correct connections onthe proportioning units and engine firewall.

CAUTION: Before you begin the panel purge, you must make sure that the fay seal cures for 72 hoursand you must make sure that the fillet seal is no longer tacky.

38. Do the panel purge and complete system functional test as follows:

A. Put a label on each wing tube assembly to make sure that you attach it to the correct relatedproportioning tube port after you complete the functional test. Refer to Table 3.

SK208-178Page 49


TABLE 3: TKS PANEL / RELATED PROPORTIONING UNIT PORT

TKS Panels Proportioning Unit Port

Left Inboard Wing Panel 1, 5

Left Mid Wing Panel 2

Left Outboard Wing Panel 3, 4

Left Wing Strut Panel 6, 7

Right Inboard Wing Panel 1, 5

Right Outboard Wing Panel 3, 4

Right Wing Strut Panel 6, 7

Right Mid Wing Panel 2

B. Purge the panels as follows:

NOTE: It is not necessary to use electrical power for the purge of the panels.

(1) Remove the P840294 Protective Tape from the surface of the porous panels.

(2) (Refer to Figure 17.) In Figure 17, look for examples of fluid flow through the porous panelsthat is sufficient and of fluid flow that is not sufficient. You must know how to tell if fluid flowthrough the porous panels is sufficient before you accomplish this panel purge operation. Ifyou need help to know how to tell if a panel is purged correctly, contact Cessna CustomerService at 316-517-5800.

WARNING: During this test the TKS system operation pressure will be as high as 75 psig.

(3) Attach the fluid collector system (plastic guttering) below the area of the panels.

(4) Fill the TKS system test cart reservoir with approximately 5.50 gallons (20.82 liters) of TKSfluid and attach the cart to an air source. Do not fill the reservoir until it is full.

NOTE: You will fill the reservoir more than once as you do this procedure.

(5) Follow the operation and safety instructions that are supplied with the test cart, found in the"Panels Installed on Aircraft TKS Panel Test section of the TKS Ice Protection Panel FlowCheck Procedure Using TKS System Test Cart" publication.

(6) Disconnect the two left inboard wing porous panel supply lines from ports 1 and 5 of thewing proportioning unit.

NOTE: The inboard and outboard wing panels have two supply tubes. It is necessary todisconnect the second tube and put a cap or plug in the tube end to keep sufficientpressure in the panel.

(7) Connect the test cart supply tube to the left inboard wing porous panel as near to the panel asyou can.

(8) Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks.

(9) Apply pressure of 20 psi to slowly start the fluid flow through the panel.

(10) Let the system run for two minutes.

(11) Apply pressure of 40 psi to make sure that there is a steady flow of fluid through the panels.


(13) Wait until the fluid starts to come out all the holes at the same rate along the full length of thepanel and increase the pressure to 60 psi.


SK208-178Page 50


(15) (Refer to Figure 17.) Continue the fluid purge until the panel is correctly purged in accordancewith Figure 17 and Table 4.

TABLE 4: Panel Purge Flow Troubleshooting - Work Through Table as Necessary UntilThere Are Correct Flow Characteristics

Is there enough fluid in the test cart? Add fluid to the test cart as necessary

Wipe leading edge with paper towel to evenout the fluid flow

If flow still uneven, use an approvedprocedure to clean the dry spots

Are there correct flow characteristics for theporous panel? If no,

Do the panel purge again

Does the fluid leave the test cart correctly?If no,

Repair or replace the test cart as necessary

Are there kinks or objects in the tubing thatblock the flow? If yes,

Replace the tubing as necessary

Do a water panel purge as follows:

1. Attach a water line to the water inletport and a shop air line to the air inletport on the purge cart

2. Connect the purge tank lines to thepanel you will purge

3. Turn the selector lever to the WATERposition on the purge cart

4. Turn the water valvecounterclockwise until the pressuregauge shows 50 psi

5. After water begins to flow fromthe panel, let the water flow for 30minutes

6. Turn the purge cart selector lever toAIR

7. Adjust the air pressure to 15 psi

8. Purge the entire system with the airfor 10 to 15 minutes to dry out thepanels

Are there correct flow characteristics for theporous panel? If still no,

Do the panel purge of the porous panel withthe TKS fluid again

Are there correct flow characteristics for theporous panel? If still no,

Replace the porous panel

NOTE: To get an even flow over the panel it may be necessary to lightly run a dry cloth orpaper towel over the leading edge and/or the dry spots of the panel during purging.

(16) Make sure that there is no leakage at the tube connections and around the perimeter of thepanel.

(17) Stop the fluid supply.

(18) Wait until the fluid pressure is released.

SK208-178Page 51


(19) Slowly disconnect the test cart fluid supply tube from the left inboard wing porous panel.

(20) Install new sealing rings (two S2800-942 Sealing Rings) and connect the two left inboard wingpanel supply lines to ports 1 and 5 on the wing proportioning unit.

(21) Disconnect the center TKS panel supply line from port 2 on the wing proportioning unit.

(22) Connect the purge tank line to the left mid wing TKS panel as near to the panel as you can.


(24) Apply pressure of 20 psi to slowly start the fluid flow through the left mid wing panel.




(28) Wait until the fluid starts to come out all the holes at the same rate along the full length of theleft mid wing panel and increase the pressure to 60 psi.

(29) Let the system run for no less than 10 minutes.





(33) Slowly disconnect the test cart fluid supply tube from the left mid wing panel.

(34) Install a new S2800-942 Sealing Ring and connect the left mid wing panel supply line to port2 on the wing proportioning unit.

(35) Disconnect the left outboard wing TKS panel supply lines from ports 3 and 4 on the wingproportioning unit.

(36) Connect the purge tank line to the outboard wing TKS panel as near to the panel as you can.












(47) Slowly disconnect the test cart fluid supply tube from the left outboard wing TKS panel.

SK208-178Page 52


(48) Disconnect the two wing strut TKS panel supply lines from ports 6 and 7 on the wingproportioning unit.

(49) Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid bythe line that was attached to port 6.

NOTE: The strut panel has two membranes (upper and lower). Each membrane has a fluidsupply tube. You can install a tee fitting and connect the test cart supply tube toeach membrane.












(60) Disconnect the purge tank lines.

(61) Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid bythe line that was attached to port 7.













(72) Disconnect the purge tank lines.

SK208-178Page 53


(73) Install new sealing rings (one S2800-942 Sealing Ring at port 6 and one S2800-943 SealingRing at port 7) and connect the wing strut TKS supply lines to ports 6 and 7 on the wingproportioning unit.

(74) Disconnect the two right inboard wing porous panel supply lines from ports 1 and 5 of thewing proportioning unit.

NOTE: The inboard and outboard wing panels have two supply tubes. It is necessary todisconnect the second tube and put a cap or plug in the tube end to keep sufficientpressure in the panel.

NOTE: If your airplane is equipped with the weather radar system, the airplane has only oneaccess panel to get to the right wing proportioning unit. You can disconnect the panelfeed lines at the body of the proportioning valve and then safety them with safety wirewhen you connect them again, or you can remove the radar to get access.

(75) Connect the test cart supply tube to the inboard panel as near to the panel as you can.












(86) Slowly disconnect the test cart fluid supply tube from the inboard panel.

(87) Install new sealing rings (two S2800-942 Sealing Rings) and connect the two right inboardwing panel supply lines to ports 1 and 5 on the wing proportioning unit.

(88) Disconnect the center TKS panel supply line from port 2 on the wing proportioning unit.

(89) Connect the purge tank line to the center TKS panel as near to the panel as you can.







(96) Let the system run for no less then 10 minutes.

SK208-178Page 54






(100)Slowly disconnect the test cart fluid supply tube from the inboard panel.

(101)Install a new S2800-942 Sealing Ring and connect the center TKS inboard wing panel supplyline to port 2 on the wing proportioning unit.

(102)Disconnect the right outboard wing TKS panel supply lines from ports 3 and 4 on the wingproportioning unit.

(103)Connect the purge tank line to the outboard TKS panel as near to the panel as you can.

(104)Apply pressure of 10 psi, do a check for leaks in the line, and repair all leaks.

(105)Apply pressure of 20 psi to slowly start the fluid flow through the panel.

(106)Let the system run for two minutes.

(107)Apply pressure of 40 psi to make sure that there is a steady flow of fluid through the panels.


(109)Wait until the fluid starts to come out all the holes at the same rate along the full length of thepanel and increase the pressure to 60 psi.

(110)Let the system run for no less than 10 minutes.



(112)Stop the fluid supply.

(113)Wait until the fluid pressure is released.

(114)Slowly disconnect the test cart fluid supply tube from the left outboard wing TKS panel.

(115)Disconnect the two wing strut TKS panel supply lines from ports 6 and 7 on the wingproportioning unit.

(116)Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid bythe line that was attached to port 6.




(119)Let the system run for two minutes





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(124)(Refer to Figure 17.) Continue the fluid purge until the panel is correctly purged in accordancewith Figure 17 and Table 4.




(127)Disconnect the purge tank lines.

(128)Connect the purge tank line to the section of the wing strut TKS panel that supplies fluid bythe line that was attached to port 7.














(140)Install new sealing rings (one S2800-942 Sealing Ring at port 6 and one S2800-943 SealingRing at port 7) and connect the wing strut TKS supply lines to ports 6 and 7 on the wingproportioning unit.

(141)Disconnect the left horizontal stabilizer TKS panel supply line from the tailcone proportioningunit.

NOTE: The empennage proportioning unit is part of the tail bracket assembly on the floor ofthe tailcone forward of the tailcone access panel.

(142)Connect the purge tank lines to the left horizontal stabilizer TKS panel as near to the panel asyou can.






SK208-178Page 56









(154)Install a new S2800-942 Sealing Ring and connect the left horizontal stabilizer TKS supply lineto the tailcone proportioning unit.

(155)Disconnect the right horizontal stabilizer TKS panel supply line from the tailcone proportioningunit.

(156)Connect the purge tank lines to the right horizontal stabilizer TKS panel as near to the panel asyou can.













(168)Install a new S2800-942 Sealing Ring and connect the right horizontal stabilizer TKS supplyline to the tailcone proportioning unit.

(169)Disconnect the vertical stabilizer TKS panel supply line from the tailcone proportioning unit.

(170)Connect the vertical stabilizer TKS panel supply line directly to the purge cart.






SK208-178Page 57









(182)Install a new S2800-942 Sealing Ring and connect the vertical stabilizer TKS supply lineto the tailcone proportioning unit.

C. Complete the system operational test as follows:

NOTE: On days when the ambient temperature is very high, the rate of flow of the TKS fluid fromthe vertical porous panel TKS fluid may not be as high as on cooler days.

(1) Make sure that the circuit breakers that follow in Table 5 are engaged:

TABLE 5

TKS Circuit Breaker Reference Designator

PRIMARY ANTI-ICE (HC003)

W/S ANTI-ICE (HC016)

BACKUP ANTI-ICE (HC015)

ENG INTFC (HI013)

(2) Make sure that conditions are in accordance with Table 6.

TABLE 6 INITIAL CONDITIONS

Name Position

Ground Power Supply 28, +0.5 VDC or −0.5 VDC

External Power OFF

Battery (DC Power) Switch OFF

Fluid Control - Primary OFF

Fluid Control - Max Flow OFF

Fluid Control - Backup OFF

(3) Put a five-gallon bucket below the prop slinger. Put one blade of the prop vertical and downand put the bucket under that blade.

(4) Add TKS fluid to the tank as necessary until the indicator in the sight glass is above theminimum departure mark.


(6) Put the AVIONICS SWITCHES #1 and #2 to the ON position.

SK208-178Page 58



(8) Wait until the fluid starts to come out all the holes along the full length of the panel.

(9) Make sure that the fluid comes out of all of the panels and the propeller slinger.

NOTE: Actual fluid flow from the porous panels during this test will be different at differenttimes as the ambient temperature changes. If there is no indication of fluid flow onone or more panels, that panel must be purged again.

(10) Turn the propeller until each blade (one at a time) is vertical and down and make sure that fluidcomes out of the feed tube at each blade.


(12) Discard the TKS fluid from the buckets you collected it in during the fluid purge.


(14) Let the system operate for five minutes.


(16) Measure the quantity of fluid that you collected from the left wing side of the airplane (leftinboard wing panel, left mid wing panel, left outboard wing panel, and left wing strut panel).

(17) Measure the quantity of fluid that you collected from the right wing side of the airplane (rightinboard wing panel, right mid wing panel, right outboard wing panel, and right wing strut panel).

(18) To make sure that there is the same flow from one wing to the other, make sure that youcollected 52 ounces +20 or −10 ounces, (1550 ml +600 ml or −300 ml) from each wing. Thequantity of fluid collected from one side of the airplane should be within 20 ounces (600 ml)of the quantity collected from the other side of the airplane.


CAUTION: Do not operate the windshield pump for more than 10 seconds continuously andthere must be no less than 10 seconds between pump operations.

(20) Put the MAX FLOW switch to the WINDSHIELD position and release the spring-loaded switch.

(21) Make sure that the fluid flows out of the windshield spray collection tube.

NOTE: If the fluid does not flow out of the windshield spray collection tube, you can move theMAX FLOW switch to and from the WINDSHIELD position three or four times.


(23) Disconnect external power from the airplane.

(24) Open the TKS fluid tank drain valve and let the tank drain completely.

(25) Close the TKS fluid tank drain valve.

(26) Clean TKS fluid and remove collection equipment from the airplane as necessary.

D. Do a test of the windshield ice detect light, wing inspection lights, and nav lights as follows:

(1) Make sure that the WING ICE DET LIGHT (HC027) and the NAV LIGHT (HC036) circuitbreakers are engaged.

(2) Connect external power and put the EXTERNAL POWER switch in the BUS position.

(3) Move the WING LIGHT (S1021) to the ON position and make sure that you can see the lightfrom the wing inspection light on the leading edge of the left wing.

(4) Move the WING LIGHT to OFF.

(5) Move the NAV (S1017) switch light to ON.

SK208-178Page 59


(6) Make sure the navigations lights on both wings and the tail come on.

(7) Make sure that you can see the light from the windshield ice detect light on the windshield fromthe top of the glareshield.

(8) Move the NAV light switch to OFF.

(9) If one or more of the lights do not operate correctly, troubleshoot the wiring in accordance withFigure 16 and the wiring diagram manual. (Refer to the 208 Wiring Diagram Manual.)

39. Install all of the equipment and upholstery that you removed for access. (Refer to the Model 208Maintenance Manual.)

A. (Refer to Figure 29, View A-A.) Install the 2613498-2 Aft Fairing Assembly as follows:

(1) Install the 2613498-2 Aft Fairing Assembly with the 36 AN525-10R8 Screws.

(2) With U470644 Sealant, fillet seal all around the flange edge of the 2613498-2 Aft FairingAssembly where it is adjacent to the fuselage.

B. Install the radar and the radome. You may have to trim the radar pod assembly to preventinterference with the porous panel. (Refer to the 208 Maintenance Manual, Chapter 34, GarminGWX-68 Weather Radar - Maintenance Practices.)

C. Apply sealant to all of the access plates and panels on the bottoms of the wings with U544053SSealant and petrolatum parting agent. (Refer to the 208 Maintenance Manual, Chapter 6, AccessPlates and Panels Identification - Description and Operation, and Chapter 20, Fuel, Weather, andHigh-Temperature Sealing - Maintenance Practices.)

D. Install all of the wing inspection panels and access plates that you removed from both wings. (Referto the 208 Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Descriptionand Operation.)

40. Remove maintenance warning tags and connect the airplane battery.

41. Make sure that the airplane is level. (Refer to the Model 208 Maintenance Manual, Chapter 8, Leveling -Maintenance Practices.)

42. Weigh the airplane and calculate a final weight and balance. (Refer to the current applicable PilotsOperating Handbook and the Model 208 Maintenance Manual Chapter 8, Leveling and Weighing.)

43. Do the TKS anti-ice equipment preflight check that follows:

A. To make sure of the condition and the security of all the components of the TKS system, do thePREFLIGHT INSPECTION checklist from the Known Icing Equipment Supplement.

WARNING: Do not run the TKS ice protection system in dry, cold air. The ice protection fluidis designed to mix with water that impinges on the surface of the airplane duringnormal operation. If you run the system during dry, cold air conditions, the fluidbecomes a gel that takes much time to clear, particularly from the windshield.

B. With the airplane level and the TKS tank filled where the fluid level ball is just above the minimumdispatch quantity line, do a check for the accuracy of the fluid quantity indication.

C. Remove the airplane from jacks. (Refer to the Model 208 Maintenance Manual, Chapter 8, Leveling- Maintenance Practices.)

D. Turn the BACKUP switch to ON.

NOTE: During the initial operation of the TKS system, the low pressure WARN annunciator mayinitially come ON and then should go out as the system begins to flow and to build pressure.

E. Walk around the airplane and make sure that there is a fluid flow to each porous panel that goesthe full length of the panel.

NOTE: At fluid temperatures that are above 59 °F (15 °C), fluid viscosity is such that the operatingpressure may not cancel the low pressure WARN annunciator. At these fluid temperatures,

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you must make sure visually of the full-length fluid flow to each porous panel to make sure ofcorrect operation of the system. After initial operation, the low pressure WARN annunciatorshould not come ON during in-flight system operation with the outside air temperature(OAT) below 46 °F (8 °C).

44. Touch-up paint as necessary. (Refer to the Model 208 Maintenance Manual, Chapter 20, ExteriorFinish - Cleaning/Painting.)

45. Make an entry in the airplane logbook stating this service kit has been installed.

46. After the accomplishment of this Service Kit you must do Corrosion Prevention and Control Inspectionsbased on the intervals specified for airplanes equipped with the TKS system. (Refer to the Model 208Maintenance Manual, Chapter 5, Corrosion Prevention and Control Inspections (Airplanes with TKSAnti-Ice System.)

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Figure 1. TKS Installation (Sheet 1)

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Figure 2. Left Wing Tube Routing (All Airplanes), Right Wing Tube Routing (Airplanes without Bendix/KingWeather Radar) (Sheet 1)

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Figure 3. Right Wing Tube Routing (Airplanes with Bendix/King Weather Radar) (Sheet 1)

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Figure 4. Fuselage Tubing Removal (Sheet 1)

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Figure 5. Fuselage Modification - TKS Fairing Tank (Sheet 1)

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Figure 6. Tailcone Modification (Sheet 1)

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Figure 6. Tailcone Modification (Sheet 2)

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Figure 7. Vertical Stabilizer and Horizontal Stabilizer Porous Panel Installation (Sheet 1)

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Figure 8. Left Wing and Left/Right Wing Strut Porous Panel Installation (Sheet 1)

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Figure 9. Right Wing (Airplanes with Bendix/King Weather Radar) Porous Panel Installation (Sheet 1)

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Figure 10. Right Wing (Airplanes without Bendix/King Weather Radar) Porous Panel Installation (Sheet 1)

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Figure 11. Correct Tubing Coupling Procedures (Sheet 1)

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Figure 12. Low-Profile Tank Installation (Sheet 1)

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Figure 13. Porous Panel Location (Sheet 1)

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Figure 14. Lift Transducer Modification (Sheet 1)

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Figure 14. Lift Transducer Modification (Sheet 2)

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Figure 15. Sealer Application (Sheet 1)

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Figure 15. Sealer Application (Sheet 2)

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Figure 16. Wiring Modification (Sheet 1)

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Figure 16. Wiring Modification (Sheet 2)

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Figure 17. Fluid Flow During Purge Operation (Sheet 1)

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Figure 18. Protective Tape Application (Sheet 1)

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Figure 19. Electrical Equipment Installation (Sheet 1)

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Figure 20. Fuel Sump Installation (Sheet 1)

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Figure 21. Porous Panel Hole Location (Sheet 1)

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Figure 22. TKS Fairing Nutplate Installation (Sheet 1)

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Figure 23. Equipment Pack Installation for the Low-Profile Tank (Sheet 1)

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Figure 23. Equipment Pack Installation for the Low-Profile Tank (Sheet 2)

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Figure 24. XPDR Antenna Installation (Sheet 1)

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Figure 24. XPDR Antenna Installation (Sheet 2)

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Figure 25. Vent Tube Installation (Sheet 1)

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Figure 25. Vent Tube Installation (Sheet 2)

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Figure 26. Filler Tube Installation (Sheet 1)

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Figure 27. Low Profile Tank Strap Installation (Sheet 1)

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Figure 27. Low Profile Tank Strap Installation (Sheet 2)

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Figure 28. Placards Installation (Sheet 1)

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Figure 29. Tank Fairing Installation (Sheet 1)

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Figure 30. Fuselage Tubing Installation (Sheet 1)

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Figure 31. Flap VG and Gurney Installation (Sheet 1)

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