Test No. 18 - Oil System Leak Test (Dye Method) [PW11]

TASK 71-00-00-790-803-A
Test No. 18 - Oil System Leak Test (Dye Method)

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

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

ZONE: 210
ZONE: 400

1. Reason for the Job
Use this procedure to find leaks in the engine oil system with a PS 197 Blue Dye Solution, which contains PWA 521 Engine Oil (P03-001) and PMC 4513 Blue Dye (P05-459), that is applied to the engine oil before the test.
After this test, you must drain the oil with the dye from the engine and add new engine oil to the engine oil system.
This dye leak test method is optional to other leak test procedures.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	2	ACCESS PLATFORM 1M(3 FT)
No specific	AR	FLASHLIGHT

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P03-001)	engine oil
(Material No.P05-459)	blue dye

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
210	CKPT,FWD COMPT BHD TO FLT COMPT BULKHEAD
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
1	PACKING	EIPC 79-11-02-01-140

E. Referenced Information

REFERENCE	DESIGNATION
TASK 70-26-00-910-801-A	PS 197 - Preparation of the Blue Dye Leak Check Solution
TASK 70-27-00-910-801-A	SPOP 1 - Degreasing of the Engine Exterior
TASK 70-27-00-910-804-A	SPOP 208 - Degreasing of Parts by Solvent Wiping
TASK 71-00-00-860-814-A	Shutdown of the Engine
TASK 71-00-00-860-822-A	Start the Engine (Normal Manual Start)
TASK 71-00-00-860-823-A	Start the Engine (Normal Automatic Start)
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-00-00-910-803-A	Engine Operation Limits and Guidelines
TASK 71-00-00-910-804-A	General Warnings and Cautions and Related Safety Data
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing 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
TASK 79-00-00-610-801-A	Check and Fill the Engine Oil
TASK 79-00-00-610-802-A	Change the Engine Oil
TASK 79-00-00-680-801-A	Drain the Engine Oil
TASK 79-21-06-960-801-A	Replace the Oil Filter Element
Engine Oil Leak Check (Dye Method)

3. Job Set-up
Subtask 71-00-00-941-128-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Make sure that all the parts, tools, equipment and loose objects are removed from the engine air intake and the area around the intake.
(2) Make sure that the aircraft is clean and that there are no persons in the dangerous areas.
(3) Obey the engine safety precautions (Ref. AMM TASK 71-00-00-910-804) and the engine operations limits and guidelines procedure (Ref. AMM TASK 71-00-00-910-803).
(4) On the air conditioning panel 30VU, make sure that the engine bleed valves are off (the OFF legend is on).

Subtask 71-00-00-860-194-A ** ON A/C NOT FOR ALL

B. Safety Precautions
(1) Do the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833)

Subtask 71-00-00-010-179-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR.

Subtask 71-00-00-040-101-A ** ON A/C NOT FOR ALL

D. Deactivation of the Thrust Reverser System for Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Do the deactivation of the thrust reverser system for maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 71-00-00-010-180-A ** ON A/C NOT FOR ALL

E. Get Access
(1) Open the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL, 462AR.
(2) Put the ACCESS PLATFORM 1M(3 FT) in position.

4. Procedure

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

Subtask 71-00-00-860-195-A ** ON A/C NOT FOR ALL

A. Preparation for the Test

WARNING: DO NOT REMOVE THE OIL TANK CAP OR DRAIN PLUGS UNTIL 5 MINUTES MINIMUM AFTER THE ENGINE SHUTDOWN. THIS WILL LET THE OIL PRESSURE BLEED OFF. IF YOU DO NOT, YOU CAN CAUSE HOT OIL BURNS TO YOUR EYES AND SKIN.

(1) Add the PS 197 Blue Dye solution to the oil system as follows:
(a) Mix the blue dye (Material No.P05-459) with new engine oil (Material No.P03-001) (Ref. AMM TASK 70-26-00-910-801).

NOTE: The PW1100G-JM engine total oil system volume capacity is approximately 18 USgal (68.1 l).

(b) Drain the engine oil (Ref. AMM TASK 79-00-00-680-801).
(c) Fill the engine oil tank with the blue dye (Material No.P05-459) to the correct level (Ref. AMM TASK 79-00-00-610-802).
(d)

Engine Oil Leak Check (Dye Method) ** ON A/C NOT FOR ALL

1 Use the FLASHLIGHT and find the engine oil level sight glass on the oil tank.
2 Examine the filler cap and replace the EIPC 79-11-02-01-140 PACKING (1), if necessary.
3 Align the cap with the filler neck and push the cap in position.
4 Turn the lever clockwise and push the cap until it is locked.
5 Make sure that the level is in the correct position against the cap and in the locked position.
(2) Clean all the remaining oil from the engine external surfaces, tubes, components and accessories by one of the procedures that follow:
(a) Clean the engine external surfaces by SPOP 1 (Ref. AMM TASK 70-27-00-910-801).
(b) Clean the engine by SPOP 208 (Ref. AMM TASK 70-27-00-910-804).

Subtask 71-00-00-410-168-A ** ON A/C NOT FOR ALL

B. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the fluid drain collector.
(3) Remove the access platform(s).
(4) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL, 462AR.

Subtask 71-00-00-440-095-A ** ON A/C NOT FOR ALL

C. Do the reactivation of the thrust reverser system after the deactivation for maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 71-00-00-410-169-A ** ON A/C NOT FOR ALL

D. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR.
(2) Remove the WARNING NOTICE(S).

Subtask 71-00-00-790-064-A ** ON A/C NOT FOR ALL

E. Do the Leak Test (Idle Power Only - Optional to High Power)

WARNING: DO NOT OPERATE THE ENGINE WITH THE FAN COWLS AND THRUST REVERSER HALVES OPEN. IT IS NOT PERMITTED TO OPERATE THE ENGINE WITH THE FAN COWLS OPEN AT A POWER LEVEL HIGHER THAN IDLE (INJURY TO PERSONNEL AND EQUIPMENT CAN BE THE RESULT).

WARNING: IF THE ENGINE OPERATES WITH THE COWL DOORS OPEN, MAKE SURE THAT THE FIRE DEPARTMENT PERSONS ARE NEAR THE ENGINE. THE AIRCRAFT FIRE EXTINGUISHING SYSTEM DOES NOT OPERATE WITH THE COWL DOORS OPEN. IF YOU DO NOT OBEY THIS PRECAUTION, INJURY TO PERSONS CAN OCCUR.

WARNING: STAY AWAY FROM THE EXHAUST NOZZLE OF THE ENGINE. WHEN AN ENGINE OPERATES, THE ENGINE EXHAUST IS HOT AND OF SUFFICIENTLY HIGH VELOCITY TO CAUSE INJURY. IMMEDIATELY AFTER THE ENGINE IS STOPPED, THE ENGINE EXHAUST PARTS ARE HOT AND CAN CAUSE BURNS.

WARNING: WHEN THE ENGINE OPERATES, MAKE SURE THAT ALL PERSONS WHO DO WORK NEAR THE AIRCRAFT USE EAR PROTECTION. THE LOUD NOISE FROM THE ENGINE CAN CAUSE TEMPORARY OR PERMANENT INJURY TO YOUR EARS. IT CAN ALSO CAUSE DIZZINESS, WHICH CAN MAKE YOU FALL.

WARNING: WHEN YOU GO NEAR A JET ENGINE, BE CAREFUL TO STAY AWAY FROM THE INLET AREA. AN ENGINE HAS SUFFICIENT SUCTION AT THE INLET TO PULL A PERSON UP TO THE INLET OR INTO IT. THIS CAN CAUSE INJURY OR DEATH. THE INLET CAN ALSO PULL HATS, GLASSES, LOOSE CLOTHING, OR RAGS FROM POCKETS. REMOVE OR MAKE SAFE ALL LOOSE ITEMS BEFORE YOU DO WORK AROUND AN ENGINE.

(1) Before you start the engine, obey all the engine safety precautions (Ref. AMM TASK 71-00-00-910-804).
(2) Start the engine:

By normal automatic start (Ref. AMM TASK 71-00-00-860-823), or
By normal manual start (Ref. AMM TASK 71-00-00-860-822).

(3) Make sure that all the engine parameters are in the permitted limits (Ref. AMM TASK 71-00-00-910-803).
(4) Let the engine become stable for five minutes at MIN IDLE.
(5) Do the shutdown of the engine (Ref. AMM TASK 71-00-00-860-814).

Subtask 71-00-00-790-065-A ** ON A/C NOT FOR ALL

F. Do the Leak Test (High Power - Optional to Idle Power)

NOTE: If the leak test (idle power only) is satisfactory to find all the leaks, it is not necessary to do the leak test at high power.

NOTE: It is necessary in this test that engines 1 and 2 be operated at the same time to give a thrust balance on the aircraft.

NOTE: It is possible that more running time is necessary at high power to get the wetting of the leak area. The running time at high power should be kept to a minimum to prevent too much leakage.

(1) Before you start the engine, obey all the engine safety precautions (Ref. AMM TASK 71-00-00-910-804).
(2) Start each engine:

By normal automatic start (Ref. AMM TASK 71-00-00-860-823), or
By normal manual start (Ref. AMM TASK 71-00-00-860-822).

(3) Make sure that all the engine parameters are in the permitted limits for each engine (Ref. AMM TASK 71-00-00-910-803).
(4) Let each engine become stable for five minutes at MIN IDLE.
(5) Slowly move the thrust lever forward to 70 percent N1 for each engine.
(6) Operate only the test engine for leaks at take-off power for 60 seconds.
(7) Move the thrust lever back to MIN IDLE power for each engine and let the engines become stable for five minutes.
(8) Do the shutdown of the engine (Ref. AMM TASK 71-00-00-860-814).

Subtask 71-00-00-790-066-A ** ON A/C NOT FOR ALL

G. Do a leak check of the engine as follows:
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR.
(2) Deactivation of the thrust reverser system for maintenance:

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(a) Do the deactivation of the thrust reverser system for maintenance (Ref. AMM TASK 78-30-00-040-805).
(3) Open the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL, 462AR.
(4) Put the ACCESS PLATFORM 1M(3 FT) in position.
(5) Do a visual inspection of the engine for oil leaks.

NOTE: The leak location is identified by blue fluid at the tube joints or at the components. An amber (brown/yellow) colored leak is from engine assembly fluids.

(6) Examine the seal drains for signs of the blue fluid.
(7) If necessary, repair the joints or components that have leaks. After all the leaks are repaired, examine the oil system again for leaks.

Subtask 71-00-00-680-061-A ** ON A/C NOT FOR ALL

H. Do the servicing of the oil system as follows:
(1) Drain the dyed oil from the oil system and replace the main oil filter element (Ref. AMM TASK 79-00-00-680-801) and (Ref. AMM TASK 79-21-06-960-801).
(2) Change the engine oil (Ref. AMM TASK 79-00-00-610-802).

Subtask 71-00-00-410-170-A ** ON A/C NOT FOR ALL

I. 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) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL, 462AR.

Subtask 71-00-00-440-096-A ** ON A/C NOT FOR ALL

J. Do the reactivation of the thrust reverser system after the deactivation for maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 71-00-00-410-171-A ** ON A/C NOT FOR ALL

K. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR.

Subtask 71-00-00-680-060-A ** ON A/C NOT FOR ALL

L. Start the Engine
(1) Start the engine by normal automatic start (Ref. AMM TASK 71-00-00-860-823), or by normal manual start (Ref. AMM TASK 71-00-00-860-822).
(2) Operate the engine for a minimum time of three minutes at MIN IDLE.
(3) Do the shutdown of the engine (Ref. AMM TASK 71-00-00-860-814).
(4) Do the engine oil check for the correct oil quantity before you return the engine to the service (Ref. AMM TASK 79-00-00-610-801).

5. Close-up
Subtask 71-00-00-860-197-A ** ON A/C NOT FOR ALL

A. Put the aircraft back to its initial configuration.
(1) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 12:57:10 UTC