Installation of the engine begins with unboxing of the Rotax 915 from it's shipping container.
There are multiple packages inside the container so I completed a quick inventory:
Rotax 915 engine - ✅ Fuel pump assembly - ✅ Rotax Fuse Box - ✅ Oil Reservoir - ✅
Engine CPU - ✅ Wired Harness kit - ✅ Engine Maintenance booklet - ✅
Coolant Flange - ✅
With all of the accessories out of the way I could unwrap and inspect the engine.
Surprisingly multiple stores in my area didn't actually have any in-stock so I had to drive to a store in downtown Seattle to collect my prizes.
Several hours later...
With the lift fully assembled I was ready to lift the engine out of the container.
I didn't purchase the Rotax approved lifting hardware, which I think is ridiculous that it's not included with the engine.
I modified some shackles to fit the lift points on the intake manifold.
In the photo above I had to grind down one side of the shackle so that it would not bind against the intake manifold. Both shackles needed one side heavily ground down in order to fit.
I am sure there are multiple ways or different parts one could use, but this was what I had on hand and I made it work for me.
Tip #1
The manual calls for this step later in the engine installation but I opted to pre-install the Sling provided coolant flange. Start by removing the 90 degree flange that ships with the engine and install the replacement part provided in the firewall forward kit.
With the engine stabilized with the load spreader, I unbolted the engine from the base of the shipping container.
There are (4) 17mm bolts holding the engine to the shipping container.
The engine is stable on the mounting hardware and probably was not at risk of tipping over but I didn't want to take any chances.
Tip #2
After removing the mounting hardware (heavy steal plates) attached to the engine, there is a shipping nut that needs to be removed prior to mounting the engine to the firewall.
The shipping nut is held in place with a welded plate and a rivet as shown,
I drilled the rivet out and with a little persuasion (hammer and screwdriver) the shipping nut was removed and the installation could move forward.
