Installation of the Pylons

TASK 54-50-00-400-803-A
Installation of the Pylons

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

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: DO NOT GET FUEL IN YOUR MOUTH, EYES OR ON YOUR SKIN. DO NOT BREATHE THE FUMES FROM THE FUEL. KEEP THE FUEL AWAY FROM SPARKS, FLAME AND HEAT. FUEL IS POISONOUS AND FLAMMABLE, WHICH CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT.

WARNING: OBEY THE HYDRAULIC SAFETY PROCEDURES. WORK ON THE HYDRAULIC SYSTEMS CAN BE DANGEROUS.

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

CAUTION: BEFORE YOU INSTALL/REMOVE THE GSE-TOOL, READ THE INSTRUCTIONS IN THE APPLICABLE GSE INSTRUCTION MANUAL. WHILE YOU OPERATE THIS TOOL, CAREFULLY OBEY THEM. IF YOU DO NOT OBEY THE INSTRUCTIONS, DAMAGE TO EQUIPMENT CAN OCCUR.

CAUTION: THIS PART IS A REMOVABLE STRUCTURAL COMPONENT (RSC), WHICH CAN BE MOVED BETWEEN AIRCRAFT. THUS IT CAN HAVE DIFFERENT OPERATION CONDITIONS AND A DIFFERENT LIFE RECORD (FLIGHT HOURS/FLIGHT CYCLES/CALENDAR) FROM THE AIRCRAFT IT IS INSTALLED ON OR REMOVED FROM. THE OPERATOR IS RESPONSIBLE FOR THE SPECIFIC TRACKING AND CONTINUED AIRWORTHINESS OF REMOVABLE STRUCTURAL COMPONENTS. INCORRECT MAINTENANCE OF THESE COMPONENTS CAN CAUSE A RISK FOR THE FLIGHT SAFETY.

ZONE: 400
FIN: 4020KM1
FIN: 4020KM2

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

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE
No specific	AR	CONTAINER 2 L (0.53 USGAL)
No specific	AR	CONTAINER 3 L(3/4 USGAL)
No specific	1	CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB)
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 0.47 and 0.37 m.daN (41.59 and 32.74 lbf.in )
No specific	Torque wrench: range to between 12 and 1 m.daN (1061.95 and 88.50 lbf.in )
No specific	Torque wrench: range to between 5 and 4 m.daN (36.87 and 29.50 lbf.ft )
98A54003117000	1	TROLLEY-PYLON STORAGE
98D54403006000	1	R/I PYLON
98D54403007000	1	PYLON HANDLING FOR PW AND CFM
98D54503000001	1	PYLON R/I WRENCH SET

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03FAB1)	Mineral Oil base Grease-- Vaseline or Petrolatum -
(Material No.03GBC1)	Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14QDC1)	Wire-Locking Dia: 0.5 mm (0.020 inch) CRES -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
195BB, 413ET, 414AR, 414BR, 423ET, 424AR, 424BR, 424CR, 471AL, 471BL, 471CL, 472AR, 472BR, 481AL, 481BL, 482AR, 482BR, 482CR, 521BT, 521EB, 621BT, 621EB
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR, 461AL, 462AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
11	O-RINGS	AIPC 28-21-86-50-120
24	O-RINGS	AIPC 28-21-86-50-120
13	RETAINING RINGS	AIPC 28-21-86-50-150
26	RETAINING RINGS	AIPC 28-21-86-50-150
12	O-RINGS	AIPC 28-21-86-50-160
25	O-RINGS	AIPC 28-21-86-50-160
11	O-RINGS	AIPC 28-21-86-51-120
24	O-RINGS	AIPC 28-21-86-51-120
13	RETAINING RINGS	AIPC 28-21-86-51-150
26	RETAINING RINGS	AIPC 28-21-86-51-150
12	O-RINGS	AIPC 28-21-86-51-160
25	O-RINGS	AIPC 28-21-86-51-160
27	SEAL	AIPC 36-11-86-50-300
27	SEAL	AIPC 36-11-86-51-290
76	COTTER PINS	AIPC 54-51-87-31-010
73	TAB WASHERS	AIPC 54-51-87-31-040
70	COTTER PINS	AIPC 54-51-87-31-090
67	TAB WASHERS	AIPC 54-51-87-31-170
76	COTTER PINS	AIPC 54-51-87-32-010
73	TAB WASHERS	AIPC 54-51-87-32-040
70	COTTER PINS	AIPC 54-51-87-32-090
67	TAB WASHERS	AIPC 54-51-87-32-170

E. Referenced Information

REFERENCE	DESIGNATION
TASK 05-57-00-200-001-B	Aircraft Stability
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 26-21-41-400-001-F	Installation of the Engine Fire-Extinguisher Bottle
TASK 28-00-00-910-001-A	Fuel Safety Procedures
TASK 28-16-42-400-001-A	Installation of the Fuel Recirculation Check-valve
TASK 28-21-00-790-001-A	Leak Test of the Main Fuel-Pump-System Pipelines
TASK 29-00-00-910-002-A	Safety Procedures of the Hydraulic System
TASK 29-10-00-864-001-A	Depressurize the Green Hydraulic System
TASK 29-10-00-864-002-A	Depressurize the Yellow Hydraulic System
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 54-52-11-000-807-A	Removal of the Access Skin Panels
TASK 54-52-11-400-807-A	Installation of the Access Skin Panels
TASK 54-53-11-000-806-A	Removal of the Pylon-to-Wing Access Panels and Doors
TASK 54-53-11-400-806-A	Installation of the Pylon-to-Wing Access Panels and Doors
TASK 54-54-00-400-803-A	Installation of the Rear Pylon Fairing (RPF)
TASK 54-56-00-400-803-A	Installation of the Aft Pylon Fairing (APF)
TASK 57-41-37-000-004-A	Removal of the Pressure Relief Panels
TASK 57-41-37-000-009-A	Removal of the Access Panel
TASK 57-41-37-400-009-A	Installation of the Access Panel
TASK 71-00-51-400-803-A	Installation of the Power Plant with 2D Bootstrap
TASK 71-13-11-400-806-A	Installation of the Fan Cowl Doors
TASK 78-30-00-440-807-A	Reactivation of the Thrust Reverser System after Nacelle Maintenance (ICU)
TASK 78-32-11-400-803-A	Installation of the Thrust Reverser Cowl Doors
Pylon-to-Wing Aft Attach-Fitting at RIB10
Pylon-to-Wing Forward Attach-Fitting at RIB5
Clearance Check and Adjustment of the Pylon
Spigot at RIB6 - Electrical Bonding
Electrical System - Feeder Cable
Electrical System - Electrical Connectors
Electrical System - Connections at the Wing Closing Rib
Hydraulic Lines - Pylon-to-Wing Junction
Pneumatic System - Bleed-Air Duct Junction
Fuel System - Pylon-to-Wing Junction

3. Job Set-up
Subtask 54-50-00-941-070-A

A. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
(c) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the ENG/MODE selector switch and the ENG/MASTER 1(2) control switch.
(2) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton switch is off.
(b) Make sure that the WARNING NOTICE(S) is in position to tell persons not to energize FADEC 1(2).
(3) On the overhead panel, on AIR COND panel 30VU:
(a) Make sure that the APU BLEED pushbutton switch is released (the ON legend is off).
(b) Make sure that the ENG 1(2) BLEED pushbutton is released (the OFF legend is on).
(c) Make sure that the WARNING NOTICE(S) is in position to tell persons not to push the APUBLEED and ENG 1(2) BLEED pushbutton switches.
(4) On the center pedestal, on FLAPS panel 115VU:
(a) Make sure that the slap and flat control lever is in the "0" (fully retracted) position.
(b) Make sure that the WARNING NOTICE(S) is in position to tell persons not to move the slat and flap control lever.
(5) Make sure that you obeyed the instructions of the fuel safety procedure (Ref. AMM TASK 28-00-00-910-001).
(6) Make sure that you obeyed the instructions of the hydraulic safety procedure (Ref. AMM TASK 29-00-00-910-002).
(7) On the overhead panel, on the HYD section of control panel 40VU:
(a) Make sure that the ENG 1(2) PUMP pushbutton switches are released (the OFF legend is on).
(b) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the applicable hydraulic system:
1 On HYD/FUEL panel 40VU
2 On the ground service panel of the applicable hydraulic system.
(8) Make sure that a WARNING NOTICE(S) is in position on access door 195BB to tell persons not to pressurize the reservoirs of the applicable hydraulic system.
(9) Make sure that the aircraft is stable (Ref. AMM TASK 05-57-00-200-001).

Subtask 54-50-00-865-063-A

WARNING: MAKE SURE THAT YOU OPEN THE CIRCUIT BREAKERS AS FOLLOWS:

1JH AND 3JH1 BEFORE 2KS1
1JH AND 3JH2 BEFORE 2KS2.

IF YOU DO NOT OBEY THIS SEQUENCE, THERE IS A RISK OF ELECTROCUTION. THIS IS BECAUSE YOU WILL START CONTINUOUS IGNITION IF YOU OPEN CIRCUIT BREAKER 2KS1 OR 2KS2 FIRST.

WARNING: MAKE SURE THAT THE PROBE HEATER AND WINDOW HEATER CIRCUIT-BREAKERS ARE OPEN BEFORE YOU OPEN THE PHC AND WHC CIRCUIT BREAKERS. IF YOU DO NOT OBEY THIS SEQUENCE:

THE PROBES WILL BECOME TOO HOT.
THIS CAN CAUSE INJURY TO MAINTENANCE PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
49VU	ENGINE/1 AND 2/IGN/SYS A	1JH	A03
49VU	ANTI ICE/PROBES/AOA/1	4DA1	D04
49VU	ANTI ICE/PROBES/PHC/1	2DA1	D03
49VU	ANTI ICE/PROBES/PITOT/1	3DA1	D02
49VU	ANTI ICE/RAIN/RPLNT/CAPT	1DB1	D01
49VU	COM/CVR/SPLY	23RK	E14
49VU	COM/CVR/CTL	26RK	E13
121VU	RCDR/DFDR	7TU	K39
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N31
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL2/SQUIB/B	2WE1	Q43
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL1/SQUIB/A	1WE1	Q42
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL1/SQUIB/B	2WE2	Q41
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL2/SQUIB/A	1WE2	Q40
122VU	ANTI ICE/WINDOWS/R	4DG2	W14
122VU	ANTI ICE/WHC/2	5DG2	W13
122VU	ANTI ICE/RAIN/RPLNT/F/O	1DB2	W11
122VU	ANTI ICE/ENG/2	1DN2	W10
122VU	ANTI ICE/WINDOWS/L	4DG1	X14
122VU	ANTI ICE/WHC/1	5DG1	X13
122VU	ANTI ICE/PROBES/PHC/3	2DA3	Y16
122VU	ANTI ICE/PROBES/2/TAT	1DA2	Y15
122VU	ANTI ICE/PROBES/2/PITOT	3DA2	Y14
122VU	ANTI ICE/PROBES/2/AOA	4DA2	Y13
122VU	ANTI ICE/PROBES/PHC/2	2DA2	Y12
122VU	ANTI ICE/PROBES/2/STATIC	5DA2	Y11
122VU	ANTI ICE/PROBES/3/PITOT	3DA3	Z16
122VU	ANTI ICE/PROBES/3/AOA	4DA3	Z15
122VU	ANTI ICE/PROBES/3/STATIC	5DA3	Z14
122VU	ANTI ICE/PROBES/1/STATIC	5DA1	Z13
122VU	ANTI ICE/PROBES/1/TAT	1DA1	Z12
123VU	Y HYD/ELEC/PUMP	3802GX	AB06
123VU	Y HYD/ELEC/ELEC PUMP/NORM	3801GX	AB03
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENGINE 1)
49VU	FUEL/LP VALVE/MOT1/ENG1	1QG	A08
49VU	ENGINE/1/FIRE DET/LOOP A	7WD1	A06
49VU	ENGINE/1/FADEC A/AND EIU 1	2KS1	A04
49VU	ENGINE/1/HP FUEL SOV	1KC1	A01
49VU	HYDRAULIC/G HYD/PUMP ENG1/CTL	1701GK	H12
121VU	FUEL/LP VALVE/MOT2/ENG1	3QG	M25
121VU	ENGINE/IGN/ENG1/SYS B	3JH1	P41
121VU	ENGINE/ENG1/FIRE DET/LOOP B	8WD1	Q38
121VU	ENGINE/ENG1/FADEC B/AND EIU 1	4KS1	R40
122VU	ELEC/GCU/1	2XU1	T26
122VU	ANTI ICE/ENG/1	1DN1	X10
122VU	ANTI ICE/PROBES/1/TAT	1DA1	Z12
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENGINE 2)
49VU	FUEL/LP VALVE/MOT1/ENG2	2QG	A09
49VU	ENGINE/2/FIRE DET/LOOP B	8WD2	A07
49VU	ENGINE/2/FADEC A/AND EIU 2	2KS2	A05
49VU	ENGINE/2/HP FUEL SOV	1KC2	A02
121VU	FUEL/LP VALVE/MOT2/ENG2	4QG	M26
121VU	ENGINE/IGN/ENG2/SYS B	3JH2	P42
121VU	ENGINE/ENG2/FIRE DET/LOOP A	7WD2	Q39
121VU	ENGINE/ENG2/FADEC B/AND EIU2	4KS2	R41
122VU	ELEC/GCU/2	2XU2	T27
122VU	ANTI ICE/ENG/2	1DN2	W10

Subtask 54-50-00-864-056-A

C. Depressurization of the Hydraulic Systems

WARNING: MAKE SURE YOU DEPRESSURIZED THE HYDRAULIC SYSTEM. IF YOU LOOSEN A HYDRAULIC TUBE FITTING WHEN THERE IS PRESSURE IN THE HYDRAULIC SYSTEM, YOU CAN CAUSE INJURIES TO PERSONS OR DAMAGE TO EQUIPMENT.

(1) Make sure that the applicable hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-001) or (Ref. AMM TASK 29-10-00-864-002).

NOTE: 4020KM1 (ENG1) supplies the GREEN hydraulic system and 4020KM2 (ENG2) supplies the YELLOW hydraulic system.

(2) Make sure that the reservoirs of the applicable hydraulic system are depressurized (Ref. AMM TASK 29-14-00-614-001).

Subtask 54-50-00-010-060-A

D. Removal of the Panels
(1) Make sure that the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in position:
(a) For the left pylon, in zones 410 and 470
(b) For the right pylon, in zones 420 and 480.
(2) Make sure that the access skin panels are removed: (Ref. AMM TASK 54-52-11-000-807)
(a) For the left pylon: 414AR and 414BR
(b) For the right pylon: 424AR and 424BR.
(3) Make sure that the pylon-to-wing access panels and doors are removed (Ref. AMM TASK 54-53-11-000-806):
(a) For the left pylon: 413ET 471AL 471BL 471CL 472AR and 472BR
(b) For the right pylon: 423ET 481AL 481BL 424CR 482AR 482BR and 482CR.
(4) Make sure that the access panels are removed (Ref. AMM TASK 57-41-37-000-009):
(a) For the left wing: 521BT
(b) For the right wing: 621BT.
(5) Make sure that the pressure-relief panels are removed (Ref. AMM TASK 57-41-37-000-004):
(a) For the left wing: 521EB
(b) For the right wing: 621EB.

Subtask 54-50-00-110-055-A

E. Preparation for Installation
(1) Make sure that the parts retained from the removed component are clean and in the correct condition.
(2) If they are not sufficiently clean, clean the parts retained from the removed component with Non Aqueous Cleaner-General - - (Material No.08BAA9) and Textile-Lint free Cotton - (Material No.14SBA1) .
(3) Do an inspection of the component interfaces and the adjacent area.

4. Procedure
Subtask 54-50-00-480-059-A

A. Installation of the Tool
(1) Put a CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB) in position.
(2) Install the 98D54403007000 PYLON HANDLING FOR PW AND CFM on the CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB) and attach it to the pylon.
(3) Disengage the pylon from the 98A54003117000 TROLLEY-PYLON STORAGE with the 98D54403007000 PYLON HANDLING FOR PW AND CFM.
(4) Put the 98D54403006000 R/I PYLON in position below the pylon.
(5) Attach the pylon to the 98D54403006000 R/I PYLON and remove the 98D54403007000 PYLON HANDLING FOR PW AND CFM from the pylon.
(6) Attach the CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB) to the 98D54403006000 R/I PYLON.
(7) Put the 98D54403006000 R/I PYLON in position below the wing with the CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB).

Subtask 54-50-00-914-054-A

B. Preparation for the Installation of the Spigot Fitting
(1) Clean the friction surfaces and the spigot ball joint with Textile-Lint free Cotton - (Material No.14SBA1) soaked with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
(2) Apply Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. - (Material No.03GBC1) to the spigot ball joint.
(3) Use the CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB) to lift the spigot ball joint and put it in position below the wing with the pylon.
(4) Install the pylon below the wing:
(a) Tilt the front shackles to keep them out of the front shackle housing.
(b) Install the spigot in the pylon ball joint.

Subtask 54-50-00-420-088-A

C. Connection of the Pylon-to-Wing Attach-Fittings

WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.

(1) Install the aft fail-safe pins and the sleeves at RIB10. To do this:

Pylon-to-Wing Aft Attach-Fitting at RIB10

(a) Make sure that the shackles are in the correct position.
(b) Apply Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. - (Material No.03GBC1) to the sleeves (65) and all the friction surfaces.

CAUTION: USE BULLET PINS WHEN YOU INSTALL THE SLEEVES. THIS IS TO PREVENT DAMAGE TO THE THREADS.

(c) Install the sleeves (65).
(d) Install new AIPC 54-51-87-31-170 TAB WASHERS (67) (left) and new AIPC 54-51-87-32-170 TAB WASHERS (67) (right).
(e) Install the nuts (68).
(f) Lock the sleeves (65) with a special wrench from the 98D54503000001 PYLON R/I WRENCH SET.
(g) TORQUE the nuts (68) to between 12 and 1 m.daN (1061.95 and 88.50 lbf.in )

. Use a pin wrench from the 98D54503000001 PYLON R/I WRENCH SET and a torque wrench.
(h) Bend the tab washers (67) to safety the nuts (68).
(i) Install the fail-safe pins (66) with a pin wrench from the 98D54503000001 PYLON R/I WRENCH SET.
(j) Lock the fail-safe pins (66) with a pin wrench from the 98D54503000001 PYLON R/I WRENCH SET.
(k) Install the nuts (69) with a pin wrench from the 98D54503000001 PYLON R/I WRENCH SET.
(l) TORQUE the nuts (69) to between 12 and 1 m.daN (1061.95 and 88.50 lbf.in )

.
(m) Safety the nuts (69) with new AIPC 54-51-87-31-090 COTTER PINS (70) (left) and new AIPC 54-51-87-32-090 COTTER PINS (70) (right).
(2) Install the forward fail-safe pins and the sleeves at RIB5. To do this:

Pylon-to-Wing Forward Attach-Fitting at RIB5

(a) Make sure that the shackles are in the correct position.
(b) Before you install the sleeves (72), make sure that the shackles move freely from the rear to the front.
(c) Apply Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. - (Material No.03GBC1) to the sleeves (72) and all the friction surfaces.

CAUTION: USE BULLET PINS WHEN YOU INSTALL THE SLEEVES. THIS IS TO PREVENT DAMAGE TO THE THREADS.

(d) Install the sleeves (72).

NOTE: For the bottom attachments, the nuts, the cotter pins and the lockwashers are installed on the inner side of the pylons (always symmetrically to the pylon centerline).

(e) Install new AIPC 54-51-87-31-040 TAB WASHERS (73) (left) and new AIPC 54-51-87-32-040 TAB WASHERS (73) (right).
(f) Install the nuts (74).
(g) Lock the sleeves (72) with a special wrench from the 98D54503000001 PYLON R/I WRENCH SET.
(h) TORQUE the nuts (74) to between 5 and 4 m.daN (36.87 and 29.50 lbf.ft )

. Use a pin wrench from the 98D54503000000 PYLON REMOVAL-WRENCH and a torque wrench.
(i) Bend the tab washers (73) to safety the nuts (74).
(j) Install the fail-safe pins (71).
(k) Lock the fail-safe pins (71) with a pin wrench from the 98D54503000000 PYLON REMOVAL-WRENCH.
(l) Install the nuts (75) with a pin wrench from the 98D54503000000 PYLON REMOVAL-WRENCH.
(m) TORQUE the nuts (75) to between 5 and 4 m.daN (36.87 and 29.50 lbf.ft )

.
(n) Safety the nuts (75) with new AIPC 54-51-87-31-010 COTTER PINS (76) (left) and new AIPC 54-51-87-32-010 COTTER PINS (76) (right).

Subtask 54-50-00-220-053-A

D. Clearance Check and Adjustment of the Pylon

Clearance Check and Adjustment of the Pylon

(1) Make sure that clearance A between the pylon-to-wing forward attach-fitting (150) and the tab washer (151) is a minimum of 0.1 mm (0.0039 in.).
(2) Make sure that clearance B between the ball joint (152) and the spigot (153) is 9 +2.5 mm or -4 mm (0.3543 +0.0984 in. or -0.1575 in.).
(3) Make sure that clearance C between the air dam seal support (157) and the wing fairing (156) is 14 +3 mm or -3 mm (0.5512 +0.1181 in. or -0.1181 in.).
(4) If necessary, adjust the air dam seal (159) and the air dam seal support (157) to get clearance C. To do this:
(a) Loosen the nuts (154) and the screws (155) and (158).
(b) Adjust the air dam seal (159) and the air dam seal support (157).
(c) TORQUE the nut (154) and the screws (158) to between 0.47 and 0.37 m.daN (41.59 and 32.74 lbf.in )

Subtask 54-50-00-020-098-A

E. Removal of the Tool
(1) Remove the 98D54403006000 R/I PYLON from:
(a) The forward engine-to-pylon attach-fittings
(b) The aft engine-to-pylon attach-fittings (RIB5).
(2) Lower the 98D54403006000 R/I PYLON to the ground.
(3) Remove the CRANE HEIGHT 5 M (16FT), 1500 KG (3300 LB).

Subtask 54-50-00-420-089-A

F. Connection of the Bonding Straps of the Spigot

Spigot at RIB6 - Electrical Bonding

(1) Do the electrical bonding at the applicable locations of the bonding brackets that are installed on the pylon box at RIB6 (Ref. AMM TASK 20-28-00-912-802).
(2) Put the bonding straps (63) in position on the bonding brackets that are installed on the pylon box at RIB6.
(3) Install the bolts (64) and tighten them.

Subtask 54-50-00-420-090-A

G. Installation of the Electrical Systems

NOTE: It is not permitted to make the electrical cables in the pylon go across each other during the installation.

NOTE: When you assemble the cable supports (31) and (43), the smallest hole diameter 4.9 -0.2 mm or +0.2 mm (0.1929 -0.0079 in. or +0.0079 in.) is in the center.

(1) Remove the CAP-BLANKING from each electrical connector and receptacle.
(2) Make sure that all the electrical connections are clean and in the correct condition.
(3) Put the cables in position on the pylon.
(4) Connect the electrical feeders on the right side of the forward fairing structure:

Electrical System - Feeder Cable

(a) Connect connector 424VC1A (424VC2A).

CAUTION: REFER TO THE MATCH MARKS MADE DURING THE REMOVAL WHEN YOU CONNECT THE ELECTRICAL WIRES. INCORRECT CONNECTION OF THE WIRES WILL CAUSE DAMAGE TO EQUIPMENT.

(b) When you connect the electrical feeders, refer to the match marks made during the removal procedure.
(c) Install the electrical feeders on terminal block 400VT1 (400VT2) (45) with the washers (46) and the nuts (47).

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.

(d) Tighten the nuts (47).
(e) Install the covers (44) on terminal block 400VT1 (400VT2) (45) and safety them with 14QDC1Wire-Locking Dia: 0.5 mm (0.020 inch) CRES -.
(f) Install the cable supports (43), (36) and (31) on the right side of the forward fairing structure:

CAUTION: MAKE SURE THAT YOU INSTALL EACH OF THE SCREWS IN ITS CORRECT POSITION. THE SCREWS HAVE DIFFERENT LENGTHS. IF YOU DO NOT INSTALL EACH OF THE SCREWS IN ITS CORRECT POSITION, YOU CAN CAUSE DAMAGE.

1 Cable supports (43):
a Put and hold the cable supports (43) in the correct position with the clamps (42) on the right side of the forward fairing structure.
b Install the washers (41) and the screws (40).
c Tighten the screws (40).
2 Cable supports (36):
a Put the cable supports (36) in the correct position on the right side of the forward fairing structure.
b Install the washers (38), the screws (39) and the nuts (35).
c Tighten the nuts (35).
d Install the washers (34), the screws (33) and the nuts (37).
e Tighten the nuts (37).
3 Cable supports (31):
a Put the the clampblock plates (32) in the correct position with the cable supports (31) and the clamps (30) on the right side of the forward fairing structure.
b Install the washers (29) and the screws (28)
c Tighten the screws (28).
(5) Remove the CAP-BLANKING from each electrical connector and receptacle.
(6) Connect the electrical connectors to their connections adjacent to RIB8 of the pylon box:

Electrical System - Electrical Connectors

(a) For the left pylon:
471VCA, 473VCA and 475VCA
(b) For the right pylon:
470VCA, 472VCA and 474VCA.

(7) Connect the electrical connectors to their connections at the wing closing rib:

Electrical System - Connections at the Wing Closing Rib

(a) Put and hold the electrical cables and the plate (50) in position at the wing closing rib.
(b) Do the electrical bonding at the applicable locations on the plate (50) (Ref. AMM TASK 20-28-00-912-802).
(c) Install the washers (48) and the bolts (49).
(d) Tighten the bolts (49).
(e) Put the clamp (60) in position.
(f) Install the washer (61) and the screw (62).
(g) Install the washers (59) and the nuts (58).
(h) Tighten the nuts (58).
(i) Put the clamp (55) in position.
(j) Install the spacer (54) above the clamp (55).
(k) Put the clamp (53) above the spacer (54).
(l) Install the washers (52) and the screws (51).
(m) Install the washers (56) and the nuts (57).
(n) Tighten the nuts (57).
(o) Remove the CAP-BLANKING from each electrical connector and receptacle.
(p) Connect the electrical connectors to their connections at the wing closing rib:
1 For the left pylon:
411VCA, 413VCA, 415VCA, 419VCA, 421VCA and 423VCA
2 For the right pylon:
410VCA, 412VCA, 414VCA, 418VCA, 420VCA and 422VCA.

Subtask 54-50-00-420-099-A

H. Connection of the Hydraulic Lines

Hydraulic Lines - Pylon-to-Wing Junction

(1) Make sure that a CONTAINER 2 L (0.53 USGAL) is in position below the hydraulic connections.
(2) Remove the blanking plugs from:
(a) The disconnected ports
(b) The disconnected line ends.
(3) Make sure that the hydraulic connectors are clean and in the correct condition.
(4) Connect the hydraulic connectors (5), (4), (3), (2) and (1) to their connections.
(5) Install the pressure line (18) and the suction line (10) on the wing structure. To do this:
(a) Make sure that the suction line (10) is in position.
(b) Put the bracket (9), the clamp (11) and the bracket (8) in position.
(c) Install the washers (7) and the screws (6).
(d) Tighten the screws (6).
(e) Install the washers (13) and the screws (12).
(f) Tighten the screws (12).
(6) Install the return line (17) on the wing structure. To do this:
(a) Put the clamp (16) in position on the bracket (8).
(b) Install the washers (15) and the screws (14).
(c) Tighten the screws (14).
(7) Install the case drain line (22) and the pressure reservoir line (23) on the wing structure. To do this:
(a) Put the deflector (19) and the clamp blocks (24) in position.
(b) Install the washers (20) and the screws (21).
(c) Tighten the screws (21).
(8) Make sure that clearance J1 between the bracket (9) and the suction line (10) is a minimum of 8 mm (0.3150 in.).

Subtask 54-50-00-420-091-A

I. Connection of the Bleed Air Duct

Pneumatic System - Bleed-Air Duct Junction

(1) Remove the PLUG-BLANKING from each disconnected line end.
(2) Install a new AIPC 36-11-86-50-300 SEAL (27) (left) and a new AIPC 36-11-86-51-290 SEAL (27) (right).
(3) Install the sleeve assembly (25) with the clamps (24) and (26).
(4) Tighten the clamps (24) and (26).
(5) Install the insulation muff on the bleed air duct.
(6) Remove the CAP-BLANKING from each electrical connector and receptacle.
(7) Make sure that all the electrical connections are clean and in the correct condition.
(8) Connect electrical connectors 6HA1-B (6HA2-B) (22) and 6HA1-A (6HA2-A) (23) to the temperature sensors.

Subtask 54-50-00-420-092-A

J. Connection of the Fuel/Defuel System Components

WARNING: EXTREME CARE MUST BE EXERCISED WHEN INSTALLING THE O-RING SEALS. MISALIGNMENT CAN CAUSE DAMAGE WHICH CAN LEAD TO FUEL LEAKS.

(1) Make sure that a CONTAINER 3 L(3/4 USGAL) is in position below the connections.
(2) Connect the fuel line coupling to its connection adjacent to RIB5 of the pylon box. To do this:

Fuel System - Pylon-to-Wing Junction

(a) Remove the blanking caps from the disconnected fuel pipe assemblies (32) and (33).
(b) Apply Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) to:
(c) Install the O-rings (11) and (12) on the fuel pipe assemblies (32) and (33).
(d) Install the pipe (22) on the fuel pipe assemblies (32) and (33). To do this:
1 Remove the PLUG-BLANKING from each disconnected line end.
2 Install the O-rings (24) and (25) on the pipe (22).
3 Install new AIPC 28-21-86-50-150 RETAINING RINGS (26) (left) and new AIPC 28-21-86-51-150 RETAINING RINGS (26) (right) on the pipe (22).
4 Install new AIPC 28-21-86-50-150 RETAINING RINGS (13) (left) and new AIPC 28-21-86-51-150 RETAINING RINGS (13) (right) on the fuel pipe assemblies (32) and (33).
5 Align the pipe (22) with the fuel pipe assemblies (32) and (33).
6 Make sure that clearance A1 between the fuel pipe assembly (32) and the pipe (22) is 5 +3 mm or -3 mm (0.1969 +0.1181 in. or -0.1181 in.).
7 Make sure that the clearance between the fuel pipe assembly (33) and the pipe (22) is 5 +3 mm or -3 mm (0.1969 +0.1181 in. or -0.1181 in.).
8 Install the nuts (16) and (27) on the pipe (22) and the fuel pipe assemblies (32) and (33).
9 Put and hold the connectors (28) in the correct position.
10 Tighten the nuts (16) and (27) with your hand.

11 Safety the nuts (16) and (27) to the connectors (28) with the 14QDC1Wire-Locking Dia: 0.5 mm (0.020 inch) CRES -.
(e) Move the sleeves (29) down.
(f) Put the clamps (14) in position.
(g) Install the washers (30) and the bolts (31).
(h) Install the nuts (15) and tighten them.
(i) Install the clamps (17) on the pipe (22).
(j) Do the electrical bonding at the applicable location on the clamps (17) (Ref. AMM TASK 20-28-00-912-802).
(k) Put the bonding straps (18), (19) and (23) in position.
(l) Install the bolts (20) on the clamps (17).
(m) Install the nuts (21) and tighten them.
(3) Connect the fuel recirculation check-valve to its connection adjacent to RIB7 of the pylon box (Ref. AMM TASK 28-16-42-400-001).

Subtask 54-50-00-420-093-A

K. Installation of the Engine Fire-Extinguisher Bottles
(1) Install the engine fire-extinguisher bottles (Ref. AMM TASK 26-21-41-400-001).

Subtask 54-50-00-420-094-A

L. Installation of the Fairings
(1) Install the Aft Pylon Fairing (APF) (Ref. AMM TASK 54-56-00-400-803).
(2) Install the Rear Pylon Fairing (RPF) (Ref. AMM TASK 54-54-00-400-803).

Subtask 54-50-00-420-095-A

M. Installation of the Components
(1) Install the engines (Ref. AMM TASK 71-00-51-400-803).
(2) Install the thrust-reverser cowl doors (Ref. AMM TASK 78-32-11-400-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL 462AR.
(3) Install the fan cowl doors (Ref. AMM TASK 71-13-11-400-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR.

Subtask 54-50-00-790-050-A

N. Leak Test
(1) Do a leak test of the engine fuel-feed pipeline (Ref. AMM TASK 28-21-00-790-001).

Subtask 54-50-00-210-060-A

O. Visual Inspection of the Pylon-to-Wing Interface Junctions
(1) Remove the ground support and maintenance equipment, the special and standard tools and all other items.
(2) When you do the tests necessary after an engine removal, do an inspection of the system lines/wiring at the pylon-to-wing interface.
This is to make sure that:
(a) There is no hydraulic leakage or fuel leakage.
(b) There is no air leakage from the bleed-air duct connections.
(c) The electrical cables are correctly connected.

5. Close-up
Subtask 54-50-00-410-059-A

A. Installation of the Access Panels and Doors
(1) Install the access skin panels (Ref. AMM TASK 54-52-11-400-807):
(a) For the left pylon: 414BR 414AR
(b) For the right pylon: 424BR 424AR.
(2) Install the pylon-to-wing access panels and doors (Ref. AMM TASK 54-53-11-400-806):
(a) For the left pylon: 413ET 471AL 471BL 471CL 472AR and 472BR
(b) For the right pylon: 423ET 481AL 481BL 424CR 482AR 482BR and 482CR.
(3) Install the access panels (Ref. AMM TASK 57-41-37-400-009):
(a) For the left wing: 521BT
(b) For the right wing: 621BT.
(4) Install the pressure-relief panels (Ref. AMM TASK 57-41-37-000-004):
(a) For the left wing: 521EB
(b) For the right wing: 621EB.

Subtask 54-50-00-860-053-A

B. Put the hydraulic systems back to their initial configuration.

Subtask 54-50-00-440-056-A

C. Reactivation of the Thrust Reverser
(1) Make the thrust reverser serviceable after maintenance (Ref. AMM TASK 78-30-00-440-807).

Subtask 54-50-00-865-064-A

WARNING: CLOSE THE CIRCUIT BREAKERS AS FOLLOWS:

2KS1 BEFORE 1JH AND 3JH1
2KS2 BEFORE 1JH AND 3JH2.

IF YOU DO NOT OBEY THIS SEQUENCE, YOU WILL START CONTINUOUS IGNITION AND THERE IS A RISK OF ELECTROCUTION.

WARNING: CLOSE THE CIRCUIT BREAKERS RELATED TO THE PHC AND WHC AND CIRCUIT BREAKER 4KS1(2) BEFORE YOU CLOSE THE PROBE HEATER AND WINDOW HEATER CIRCUIT-BREAKERS: IF YOU DO NOT OBEY THIS SEQUENCE:

THE PROBES WILL BECOME TOO HOT.
THIS CAN CAUSE INJURY TO MAINTENANCE PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
49VU	ENGINE/1 AND 2/IGN/SYS A	1JH	A03
49VU	ANTI ICE/PROBES/AOA/1	4DA1	D04
49VU	ANTI ICE/PROBES/PHC/1	2DA1	D03
49VU	ANTI ICE/PROBES/PITOT/1	3DA1	D02
49VU	ANTI ICE/RAIN/RPLNT/CAPT	1DB1	D01
49VU	COM/CVR/SPLY	23RK	E14
49VU	COM/CVR/CTL	26RK	E13
121VU	RCDR/DFDR	7TU	K39
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N31
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL2/SQUIB/B	2WE1	Q43
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL1/SQUIB/A	1WE1	Q42
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL1/SQUIB/B	2WE2	Q41
121VU	ENGINE/ENG1 AND 2 FIRE EXTIG/BTL2/SQUIB/A	1WE2	Q40
122VU	ANTI ICE/WINDOWS/R	4DG2	W14
122VU	ANTI ICE/WHC/2	5DG2	W13
122VU	ANTI ICE/RAIN/RPLNT/F/O	1DB2	W11
122VU	ANTI ICE/ENG/2	1DN2	W10
122VU	ANTI ICE/WINDOWS/L	4DG1	X14
122VU	ANTI ICE/WHC/1	5DG1	X13
122VU	ANTI ICE/PROBES/PHC/3	2DA3	Y16
122VU	ANTI ICE/PROBES/2/TAT	1DA2	Y15
122VU	ANTI ICE/PROBES/2/PITOT	3DA2	Y14
122VU	ANTI ICE/PROBES/2/AOA	4DA2	Y13
122VU	ANTI ICE/PROBES/PHC/2	2DA2	Y12
122VU	ANTI ICE/PROBES/2/STATIC	5DA2	Y11
122VU	ANTI ICE/PROBES/3/PITOT	3DA3	Z16
122VU	ANTI ICE/PROBES/3/AOA	4DA3	Z15
122VU	ANTI ICE/PROBES/3/STATIC	5DA3	Z14
122VU	ANTI ICE/PROBES/1/STATIC	5DA1	Z13
122VU	ANTI ICE/PROBES/1/TAT	1DA1	Z12
123VU	Y HYD/ELEC/PUMP	3802GX	AB06
123VU	Y HYD/ELEC/ELEC PUMP/NORM	3801GX	AB03
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENGINE 1)
49VU	FUEL/LP VALVE/MOT1/ENG1	1QG	A08
49VU	ENGINE/1/FIRE DET/LOOP A	7WD1	A06
49VU	ENGINE/1/FADEC A/AND EIU 1	2KS1	A04
49VU	ENGINE/1/HP FUEL SOV	1KC1	A01
49VU	HYDRAULIC/G HYD/PUMP ENG1/CTL	1701GK	H12
121VU	FUEL/LP VALVE/MOT2/ENG1	3QG	M25
121VU	ENGINE/IGN/ENG1/SYS B	3JH1	P41
121VU	ENGINE/ENG1/FIRE DET/LOOP B	8WD1	Q38
121VU	ENGINE/ENG1/FADEC B/AND EIU 1	4KS1	R40
122VU	ELEC/GCU/1	2XU1	T26
122VU	ANTI ICE/ENG/1	1DN1	X10
122VU	ANTI ICE/PROBES/1/TAT	1DA1	Z12
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENGINE 2)
49VU	FUEL/LP VALVE/MOT1/ENG2	2QG	A09
49VU	ENGINE/2/FIRE DET/LOOP B	8WD2	A07
49VU	ENGINE/2/FADEC A/AND EIU 2	2KS2	A05
49VU	ENGINE/2/HP FUEL SOV	1KC2	A02
121VU	FUEL/LP VALVE/MOT2/ENG2	4QG	M26
121VU	ENGINE/IGN/ENG2/SYS B	3JH2	P42
121VU	ENGINE/ENG2/FIRE DET/LOOP A	7WD2	Q39
121VU	ENGINE/ENG2/FADEC B/AND EIU2	4KS2	R41
122VU	ELEC/GCU/2	2XU2	T27
122VU	ANTI ICE/ENG/2	1DN2	W10

Subtask 54-50-00-942-056-A

E. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 01:59:00 UTC