Installation of the Variable Stator Vane (VSV) Actuators [CFMI]

A. Installation of the VSV actuators:
   (1) Remove the blanking plugs from the ports of the actuator as follows:
     (a) Remove all the blanking plugs from the head-end, rod-end and actuator drain ports.
   (2) Lubricate the new AIPC 75-32-10-01-130 O-RING (120) and AIPC 75-23-10-01-130 O-RING (190) with vaseline (Material No.CP5070) and install them on the nipples (130, 200).
   (3) Install the nipples (130) into the head-end and rod-end ports of the actuator. TORQUE the nipples (130) to between 150 and 135 lbf.in (1.70 and 1.53 m.daN ) .
   (4) Install the nipple (200) in the drain port of the actuator located at the two o'clock position.
   (5) Install the plug (210) into the drain port of the actuator located at the 8:00 o'clock position.
   (6) TORQUE the nipple (200) and the plug (210) to between 150 and 135 lbf.in (1.70 and 1.53 m.daN ) .
   (7) Wirelock the plug (210) with CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia.
   (8) Install the actuator as follows:

CAUTION: MAKE SURE THAT BOTH OF THE ACTUATORS ON AN ENGINE ARE OF THE SAME PISTON SIZE, REF. CFM56-5 SERVICE BULLETIN 72-120. DO NOT MIX THE ACTUATORS ON AN ENGINE, (PRE AND POST SERVICE BULLETIN 72-120). THE INCORRECT MIX OF THE ACTUATORS WILL CAUSE DAMAGE TO THE ENGINE HARDWARE. LOOK IN THE ENGINE ILLUSTRATED PARTS CATALOG AND THE SERVICE BULLETIN 72-120 TO MAKE SURE THAT THE ACTUATORS ARE THE SAME. DO A TEST WITH A MAGNET, BETWEEN THE PORTS ON THE ACTUATORS, TO MAKE SURE THAT BOTH OF THE ACTUATOR BODIES ARE MADE OF STEEL OR ALUMINUM. BOTH OF THE ACTUATORS MUST BE THE SAME.

     (a) Remove the blanking plugs from the shroud drain tubes, fuel tubes and actuator drain tube.
     (b) Install the sleeve (170) into the actuator boss at the head-end of the actuator.
     (c) Attach the actuator, with sleeve (170) installed, to the bellcrank assembly at the head-end with the bolt (160) and nut (180).

NOTE: Put the head of the bolt (160) forward.

     (d) Attach the rod-end of the actuator to the bellcrank assembly with the bolt (110) and nut (100).

NOTE: Put the head of the bolt (110) outboard.

     (e) TORQUE the nut (180) at the head-end actuator boss to between 70 and 55 lbf.in (0.79 and 0.62 m.daN ) .
     (f) TORQUE the nut (100) at the rod-end actuator boss to between 120 and 100 lbf.in (1.36 and 1.13 m.daN ) .
     (g) Install the clevis link (90) in the actuator clevis. Install the bolt (80), bushing (70), washer (60) and nut (50).

NOTE: Put the head of the bolt (80) outboard.

     (h) TORQUE the nut (50) to between 70 and 55 lbf.in (0.79 and 0.62 m.daN ) .
     (i) Attach the actuator clevis, with the clevis link (90) installed, to the bellcrank assembly with the bolt (40), bushing (30), washer (20) and nut (10).

NOTE: Put the head of the bolt (40) outboard.

     (j) TORQUE the nut (10) to between 70 and 55 lbf.in (0.79 and 0.62 m.daN ) .
     (k) Lubricate the new AIPC 75-23-10-01-020 O-RINGS (140) with vaseline (Material No.CP5070) and install them on the head-end and the rod-end fuel tubes.
     (l) Lubricate the new AIPC 75-23-10-01-010 O-RINGS (150) with vaseline (Material No.CP5070) and install them in the head-end and the rod-end drain shrouds.
     (m) Connect the fuel tubes to the nipples (130) on the actuators at the head-end and the rod-end ports.
     (n) TORQUE the fuel tube nuts to between 150 and 135 lbf.in (1.70 and 1.53 m.daN ) .

NOTE: Do not connect the head-end and the rod-end drain shrouds at this time.

     (o) For the right actuator, connect the actuator drain tube to the actuator drain port.
     (p) TORQUE the drain tube nut to between 150 and 135 lbf.in (1.70 and 1.53 m.daN ) .
     (q) Remove the blanking cap and plug from the electrical connector.
     (r) Connect the electrical connector. Tighten the coupling ring by hand plus one-eighth of a turn. If necessary, use PLIERS - NOSE, SOFT, LONG.

B. Leak check of the VSV actuators:
   (1) Do a leak check of the actuator fuel tube connections as follows:

WARNING: DO NOT APPLY MORE THAN 300 PSI (20.7 BAR) TO AVOID DAMAGE TO THE ACTUATOR.

     (a) Remove the blanking caps from the head-end and rod-end flex-hoses at the HMU.
     (b) Install the reducers supplied with the 856A1084 CART-STATOR ACTUATOR (856A1084G02 or 856A1084G04) to the rod-end and head-end flex-hoses at the HMU.
     (c) Connect a source of dry, regulated air, nitrogen, or argon to the reducers.
     (d) Apply 250 +50 -50 psi (17.3 +3.45 -3.45 bar) to the head-end and rod-end flex-hoses.
     (e) Apply leak-tek 160X (Material No.CP2170) to each fuel tube connection at the VSV actuator. Then, look for leaks. No leaks are permitted.
     (f) Stop the source of dry, regulated air, nitrogen or argon.
     (g) Disconnect the head-end and rod-end flex-hoses at the HMU from the source of dry, regulated air, nitrogen, or argon. Then, remove the reducers from the ends of the head-end and rod-end flex-hoses at the HMU.
     (h) Install the head-end flex-hose to the HMU. TORQUE the coupling nut to between 550 and 450 lbf.in (6.22 and 5.09 m.daN ) .
     (i) Install the rod-end flex-hose to the HMU. TORQUE the coupling nut to between 300 and 270 lbf.in (3.39 and 3.05 m.daN ) .
     (j) Wirelock the fuel tube nut to the nipples (130) with CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia.
   (2) Connect the head-end and rod-end shrouds as follows:
     (a) Connect the head-end and rod-end knurled connection nuts and tighten them by hand.
     (b) Connect the drain tubes to the shrouds. TORQUE to between 150 and 135 lbf.in (1.70 and 1.53 m.daN ) .
     (c) Wirelock the head-end and rod-end knurled connection nuts with CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia.
   (3) Do a leak check of the head-end and rod-end drain shrouds as follows:
     (a) Remove the blanking cap from the drain tube tap.

NOTE: The drain tube tap is the first tap aft of the 6 o'clock tube bundle junction box.

     (b) Connect a source of dry, regulated air, nitrogen or argon to the tap.
     (c) Apply between 20 psi (1.4 bar) and 25 psi (1.7 bar) to the drain tube.
     (d) Stop the supply of dry, regulated air, nitrogen or argon.
     (e) Monitor the pressure. The pressure cannot decrease more than 10 psi (0.7 bar) in 2 minutes.
     (f) If the pressure decreases more than the limit, apply leak-tek 160X (Material No.CP2170) to all of the couplings on the drain manifold. Then, look for leaks.
     (g) If you find leakage, make sure the coupling nuts are tightened to the correct torque. Or, tighten the knurled nut connections by hand until the leaks stop.
     (h) If the leakage continues, remove and replace the O-rings in the area of the leak.
     (i) Do the leak check again if you replaced an O-ring.
     (j) Remove the source of dry, regulated air, nitrogen or argon.
     (k) Install the blanking cap on the drain tube tap aft of the 6 o'clock tube bundle. TORQUE the blanking cap to between 150 and 135 lbf.in (1.70 and 1.53 m.daN ) .

C. Close Access
   (1) Make sure that the work area is clean and clear of tools and other items.
   (2) Close thrust reverser cowl doors : (Ref. AMM TASK 78-36-00-410-040)
     (a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
     (b) FOR [1000EM2] (ENGINE-2)
461AL 462AR
   (3) Remove the access platform(s).
   (4) Remove the WARNING NOTICE(S).