Installation of the Pylon Duct Assembly

TASK 36-11-49-400-825-A
Installation of the Pylon Duct Assembly

WARNING: MAKE SURE THAT THE PNEUMATIC SYSTEM IS DEPRESSURIZED BEFORE YOU START WORK. PRESSURIZED AIR CAN CAUSE INJURY TO PERSONNEL.

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: ALWAYS USE APPLICABLE GLOVES TO TOUCH HOT PARTS. HOT PARTS CAN CAUSE INJURY TO PERSONS.

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

CAUTION: BE VERY CAREFUL WHEN YOU DO WORK ON OR NEAR THE AIR-CONDITIONING DUCTS. THE DUCTS ARE MADE OF THIN MATERIAL AND YOU CAN EASILY BREAK THEM.

ZONE: 410
ZONE: 420
ZONE: 450
ZONE: 460

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	1	ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE
No specific	1	FOIL - ALUMINUM
No specific	1	HAMMER - FIBER
No specific	AR	PLUG - BLANKING
No specific	2	SHIM - ALUMINUM OR PLASTIC
No specific	AR	WARNING NOTICE(S)
No specific	1	WATER - SOAPY SOLUTION
No specific	Torque wrench: range to between 0.48 and 0.37 m.daN (42.48 and 32.74 lbf.in )
No specific	Torque wrench: range to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )
98D27803000000	AR	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
98L12003001000	1	HARNESS,SAFETY

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.14QEB1)	Wire-Locking Dia: 0.6 mm CRES Nickel Alloy -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
410	ENG 1 PYLON BOX AND FORWARD FAIRING
420	ENG 2 PYLON BOX AND FORWARD FAIRING
450	ENG 1 THRUST REVERSER & EXHAUST SECTION
460	ENG 2 THRUST REVERSER & EXHAUST SECTION
191DB
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451AL, 452AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461AL, 462AR
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
413BT, 413CT, 413DT
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
423BT, 423CT, 423DT

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
3	SEAL	AIPC 36-11-86-01-020
30	GLASS-FIBER YARN BRAID	AIPC 36-11-86-01-150
18	SEAL	AIPC 36-11-86-01-240

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-00-00-481-002-A	Installation of the Wingrip
TASK 20-23-22-910-001-A	Marking of the Unions after Application of Standard or Specific Tightening Torque
TASK 24-41-00-861-002-A	Energize the Aircraft Electrical Circuits from the External Power
TASK 24-41-00-861-002-A-01	Energize the Aircraft Electrical Circuits from the APU
TASK 24-41-00-862-002-A	De-energize the Aircraft Electrical Circuits Supplied from the External Power
TASK 24-41-00-862-002-A-01	De-energize the Aircraft Electrical Circuits Supplied from the APU
TASK 27-00-00-480-002-A	Installation of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 36-11-49-000-826-A	Removal of the Sense Line between the Bleed-Air Precooler Exchanger (Upstream) and the Bleed Differential Pressure-Transducer
TASK 36-11-49-400-826-A	Installation of the Sense Line between the Bleed-Air Precooler Exchanger (Upstream) and the Bleed Differential Pressure-Transducer
TASK 36-12-00-860-802-A	Pressurization of the Bleed System with the APU
TASK 36-12-00-860-803-A	Pressurization of the Bleed System through the HP Ground Connector
TASK 36-22-15-000-802-A	Removal of the Pylon Overheat Sensing-Elements
TASK 36-22-15-400-802-A	Installation of the Pylon Overheat Sensing-Elements
TASK 49-00-00-860-009-A	APU Shutdown by External Power (131-9(A))
TASK 49-00-00-860-009-A-01	APU Shutdown by Batteries (131-9(A))
TASK 54-52-11-000-805-A	Removal of the Access Skin Panels
TASK 54-52-11-400-805-A	Installation of the Access Skin Panels
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-00-51-000-802-A	Removal of the Power Plant (Bootstrap Method)
TASK 71-00-51-000-802-A-01	Removal of the Power Plant (JacXson Method)
TASK 71-00-51-400-802-A	Installation of the Power Plant (Bootstrap Method)
TASK 71-00-51-400-802-A-01	Installation of the Power Plant (JacXson Method)
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
Transversal Fairing Support
Pylon Duct Assembly

3. Job Set-up
Subtask 36-11-49-860-122-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Make sure that the aircraft electrical circuits are energized (Ref. AMM TASK 24-41-00-861-002) or (Ref. AMM TASK 24-41-00-861-002).
(2) In the cockpit, on AIR COND panel 30VU:
(a) Make sure that the ENG 1(2) BLEED pushbutton switch is released (the OFF legend is on).
(b) Make sure that the APU BLEED pushbutton switch is released (the ON legend is off).
(c) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the pneumatic system.
(3) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).
(4) On access door 191DB, on the HP ground connector:
(a) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the pneumatic system.
(5) Put on and attach a 98L12003001000 HARNESS,SAFETY before you start work in the work area (Ref. AMM TASK 12-00-00-481-002).
(6) On FLAPS panel 114VU:

Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is in position on the flap/slat control lever (Ref. AMM TASK 27-00-00-480-002).
Make sure that the WARNING NOTICE(S) is in position on the flap/slat control lever to tell persons not to operate the flap/slat controls.

(7) Make sure that the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in position above the pylon.

Subtask 36-11-49-865-190-A ** ON A/C NOT FOR ALL

B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENG 1)
49VU	ENGINE/1/FADEC A/AND EIU 1	2KS1	A04
49VU	AIR BLEED/ENG 1/CTL	2HA1	D11
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG1/FADEC B/AND EIU 1	4KS1	R41
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG1/FADEC B/AND EIU 1	4KS1	R40
** ON A/C NOT FOR ALL
122VU	AIR BLEED/ENG 1/MONG	3HA1	Z23
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENG 2)
49VU	ENGINE/2/FADEC A/AND EIU 2	2KS2	A05
49VU	AIR BLEED/ENG 2/MONG	3HA2	D12
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG2/FADEC B/AND EIU2	4KS2	Q40
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG2/FADEC B/AND EIU2	4KS2	R41
** ON A/C NOT FOR ALL
122VU	AIR BLEED/ENG 2/CTL	2HA2	Z22

Subtask 36-11-49-010-225-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802).
(a) FOR [1000EM1] (ENGINE-1)
437AL and 438AR.
(b) FOR [1000EM2] (ENGINE-2)
447AL and 448AR.

Subtask 36-11-49-040-194-A ** ON A/C NOT FOR ALL

D. Deactivation of the Thrust-Reverser for Maintenance

WARNING: MAKE THE THRUST REVERSER UNSERVICEABLE (INSTALL AND SAFETY THE ICU LOCKOUT PIN) BEFORE YOU DO WORK ON OR AROUND THE THRUST REVERSER. IF YOU DO NOT INSTALL AND SAFETY THE ICU LOCKOUT PIN, YOU CAN CAUSE ACCIDENTAL OPERATION OF THE THRUST REVERSER AND INJURY TO PERSONS AND/OR DAMAGE TO THE EQUIPMENT.

(1) Make the thrust reverser unserviceable for maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 36-11-49-010-316-A ** ON A/C NOT FOR ALL

E. Get Access
(1) Make sure that these access panels are removed (Ref. AMM TASK 54-52-11-000-805):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
413BT, 413CT and 413DT.
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
423BT, 423CT and 423DT.

Subtask 36-11-49-010-314-A ** ON A/C NOT FOR ALL

F. Get Access
(1) Make sure that the thrust-reverser doors are open (Ref. AMM TASK 78-36-00-010-802).
(a) FOR [1000EM1] (ENGINE-1)
451AL and 452AR.
(b) FOR [1000EM2] (ENGINE-2)
461AL and 462AR.
(2) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position below the pylon.

Subtask 36-11-49-010-226-A ** ON A/C NOT FOR ALL

G. Removal of the Components
(1) If you use the APU to energize the electrical circuits, stop the APU:

For GTCP 36-300 APU (Ref. AMM D/O 49-00-00-86)
For APS 3200 APU (Ref. AMM D/O 49-00-00-86)
For 131-9(A) APU
(Ref. AMM TASK 49-00-00-860-009).

(2) In the cockpit, on the SD bleed page:
(a) Make sure that the pressure and the temperature of the bleed-air duct system are in ambient conditions.

WARNING: MAKE SURE THAT THE PNEUMATIC SYSTEM IS DEPRESSURIZED BEFORE YOU START WORK. PRESSURIZED AIR CAN CAUSE INJURY TO PERSONNEL.

WARNING: DO NOT TOUCH THE UNIT UNTIL IT IS SUFFICIENTLY COOL TO PREVENT BURNS WHEN YOU DO THE MAINTENANCE TASK(S).

(3) Make sure that the engine is removed (Ref. AMM TASK 71-00-51-000-802).
(4) Make sure that the related pylon-overheat sensing-elements are removed (Ref. AMM TASK 36-22-15-000-802).
(5) Make sure that the sense line between the bleed-air precooler exchanger (upstream) and the bleed differential pressure-transducer is removed (Ref. AMM TASK 36-11-49-000-826).
(6) Make sure that the support of overheat sensing elements (1), the closing rib (6) and the transversal fairing support (2) are removed.

Transversal Fairing Support ** ON A/C NOT FOR ALL

4. Procedure
Subtask 36-11-49-420-137-A ** ON A/C NOT FOR ALL

A. Installation of the Pylon Duct Assembly
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the PLUG - BLANKING from the bleed-air precooler exchanger (19) and the duct (1).
(3) Install a new AIPC 36-11-86-01-020 SEAL (3) on the elbow (8).
(4) Install a new AIPC 36-11-86-01-240 SEAL (18) on the bleed-air precooler exchanger (19).
(5) Install the elbow (8):
(a) Install the elbow (8) between the two supports (7).
1 Install the bushing (6), washer (5), bolt (4), bushing (9) and the nut (10) on the elbow (8) and the support (7).
2 Install the washer (13), bolt (14), bushing (12) and the nut (11) on the elbow (8) and the support (7).
3 Tighten the bolts (4) and (14).
(6) Install the duct (1):
(a) Install the duct (1) in the pylon.
(b) Make sure that the upper bellow of the duct (1) is not engaged with the bleed-air precooler exchanger (19).
(7) Install the lateral supports (24) and (25):
(a) Install the lateral supports (24) and (25) on the supports (26) and the duct (1).
(b) Install two temporary 3 mm (0.12 in.) SHIM - ALUMINUM OR PLASTIC (opposite to each other to keep a space of 3 mm (0.12 in.) between the duct and the precooler) between the flanges of the duct (1) and the precooler exchanger (19), on the outer side area.
(c) Install the washers (21) and the screws (20) with the minimum quantity of threads:
1 Do not torque the screws (20) at this time.
(d) Install the washers (22) and the screws (23) in sequence to make sure that the supports (24) and (25) are at symmetric location on the supports (26).
(e) Tighten the screws (23).
(f) Install the coupling (2) that attaches the elbow (8) to the duct (1):
1 Do not torque the coupling (2) at this time.
(g) Remove two temporary 3 MM (0.12 IN.) SHIM - ALUMINUM OR PLASTIC between the flanges of the duct (1) and the precooler exchanger (19), on the outer side area (shims are used as a tool and they must not stay on the aircraft).
(8) Install the coupling (17):
(a) Install the coupling (17) that attaches the bleed-air precooler exchanger (19) to the duct (1).
(b) Turn the clamp nut of the coupling (17) for the best tool access:
1 TORQUE the nut of the coupling (17) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
2 Tap around the outer surface of the coupling (17) with a HAMMER - FIBER.
3 TORQUE the nut of the coupling (17) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
4 Tap around the outer surface of the coupling (17) with a HAMMER - FIBER.
5 TORQUE the nut of the coupling (17) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
(c) Identify the tightened nut of the coupling (17) with a red line (Ref. AMM TASK 20-23-22-910-001).
(d) Tighten the screws (20).
(9) Torque the coupling (2):
(a) TORQUE the nut of the coupling (2) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
(b) Tap around the outer surface of the coupling (2) with a HAMMER - FIBER.
(c) TORQUE the nut of the coupling (2) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
(d) Tap around the outer surface of the coupling (2) with a HAMMER - FIBER.
(e) TORQUE the nut of the coupling (2) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
(f) Identify the tightened nut of the coupling (2) with a red line (Ref. AMM TASK 20-23-22-910-001).
(10) Install the half-plates (28) and (32) on the flange (33), as follows:
(a) Install the half-plates (32).
(b) Install the washers (31) and the fixing axes (29):
1 TORQUE the fixing axes (29) to between 0.48 and 0.37 m.daN (42.48 and 32.74 lbf.in )

.
(c) Install a new AIPC 36-11-86-01-150 GLASS-FIBER YARN BRAID (30) between the half-plates (32) and the duct (1).
(d) Compress the glass-fiber yarn braid (30) with the half-plates (28).
(e) Hold the half-plates (28) and install the nuts (27):
1 TORQUE the nuts (27) to between 0.48 and 0.37 m.daN (42.48 and 32.74 lbf.in )

.
(11) Tighten the bolts (16) to lock the duct (1) on the flange (15).

Subtask 36-11-49-410-180-A ** ON A/C NOT FOR ALL

B. Installation of the Components
(1) Install the transversal fairing support (2), the closing rib (6) and the support of overheat sensing-elements (1).

Transversal Fairing Support ** ON A/C NOT FOR ALL

(a) Install the transversal fairing support (2):
1 Install the transversal fairing support (2) on the pylon attach fittings (3).
2 Install the four bolts (13) and nuts (14).
a Tighten the four bolts (14).
(b) Install the closing rib (6):
1 Install the closing rib (6) on the pylon attach fittings (3) and the transversal fairing support (2).
2 Install the eight washers (7), bolts (8) and nuts (12) on the pylon attach fittings (3) and closing rib (6).
a Tighten the eight bolts (8).
3 Install the two washers (10), bolts (9) and nuts (11) on the transversal fairing support (2) and closing rib (6).
a Tighten the two bolts (9).
(c) Install the support of the overheat sensing elements (1):
1 Install the support of the overheat sensing elements (1) on the pylon attach fittings (2).
2 Install the two washers (4) and bolts (5) on the closing rib (6) and support of the overheat sensing elements (1).
3 Tighten the two bolts (5).
(2) Install the related pylon-overheat sensing-elements (Ref. AMM TASK 36-22-15-400-802).
(3) Attach the harnesses to the support of the overheat sensing elements (1) with a lacing tapes.
(4) Install the sense line between the bleed-air precooler exchanger (upstream) and the bleed differential pressure-transducer (Ref. AMM TASK 36-11-49-400-826).
(5) Install the engine (Ref. AMM TASK 71-00-51-400-802).

Subtask 36-11-49-720-101-A ** ON A/C NOT FOR ALL

C. Do this test:
(1) Pressurize the bleed system through the HP ground connector (Ref. AMM TASK 36-12-00-860-803) or with the APU (Ref. AMM TASK 36-12-00-860-802).
(2) 0n AIR COND panel 30VU, put the X-BLEED selector switch in the OPEN position.
(3) If you pressurize the bleed system through the HP ground connector, make sure that the supplied pressure 30 psi (2.07 bar) is stable.
(4) Make sure that there are no leaks at the junctions of the duct (1), elbow (8), duct (1) and the bleed-air precooler exchanger (19).

NOTE: There are two procedures to do a leak check at the connections of the bleed air ducts (duct joint, flexible connections).

(a) Soap solution procedure:

Leaks are permitted if the WATER - SOAPY SOLUTION stays on the joint line with the continuous series of bubbles.
Leaks are not permitted if the air pressure (from the air source) blows the soap solution from the joint line and prevents the continuous series of bubbles.

(b) Aluminum foil procedure.

NOTE: We recommend that you do this procedure when you do a leak check with hot air.

1 Wind the FOIL - ALUMINUM one time on the joint.
2 Twist the seam of the foil wrap to make it tight.
3 Make the foil wrap as tight as possible on the tube but do not cause damage to the foil wrap.

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

4 Attach the foil wrap with the two sides of the pneumatic joint with 14QEB1Wire-Locking Dia: 0.6 mm CRES Nickel Alloy -.
5 Do a leak check:

If there is a leak, the foil installed on the duct breaks or becomes too hot.

5. Close-up
Subtask 36-11-49-410-181-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Put the aircraft back to its initial configuration.
(2) Make sure that the work area is clean and clear of tools and other items.
(3) Install the access panels (Ref. AMM TASK 54-52-11-400-805):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
413BT, 413CT and 413DT.
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
423BT, 423CT and 423DT.
(4) Remove the access platform(s).
(5) Close the thrust-reverser cowl doors (Ref. AMM TASK 78-36-00-410-802).
(a) FOR [1000EM1] (ENGINE-1)
451AL and 452AR.
(b) FOR [1000EM2] (ENGINE-2)
461AL and 462AR.
(6) On FLAPS panel 114VU:

Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the flap/slat control lever.

Subtask 36-11-49-410-235-A ** ON A/C NOT FOR ALL

B. Close Access
(1) Close the fan cowl doors
(a) FOR [1000EM1] (ENGINE-1)
437AL and 438AR.
(b) FOR [1000EM2] (ENGINE-2)
447AL and 448AR.

Subtask 36-11-49-440-137-A ** ON A/C NOT FOR ALL

C. Make the thrust-reverser serviceable after maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 36-11-49-865-191-A ** ON A/C NOT FOR ALL

D. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENG 1)
49VU	ENGINE/1/FADEC A/AND EIU 1	2KS1	A04
49VU	AIR BLEED/ENG 1/CTL	2HA1	D11
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG1/FADEC B/AND EIU 1	4KS1	R41
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG1/FADEC B/AND EIU 1	4KS1	R40
** ON A/C NOT FOR ALL
122VU	AIR BLEED/ENG 1/MONG	3HA1	Z23
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENG 2)
49VU	ENGINE/2/FADEC A/AND EIU 2	2KS2	A05
49VU	AIR BLEED/ENG 2/MONG	3HA2	D12
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG2/FADEC B/AND EIU2	4KS2	Q40
** ON A/C NOT FOR ALL
121VU	ENGINE/ENG2/FADEC B/AND EIU2	4KS2	R41
** ON A/C NOT FOR ALL
122VU	AIR BLEED/ENG 2/CTL	2HA2	Z22

Subtask 36-11-49-862-109-A ** ON A/C NOT FOR ALL

E. Aircraft Maintenance Configuration
(1) Remove the WARNING NOTICE(S).
(2) De-energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-862-002) or (Ref. AMM TASK 24-41-00-862-002).

[Rev.10 from 2021] 2026.04.01 01:11:29 UTC