Installation of the Variable Stator Vane (VSV) Actuator [IAE]

TASK 75-32-41-400-010-A
Installation of the Variable Stator Vane (VSV) Actuator

WARNING: BE CAREFUL NOT TO GET AIRCRAFT FUEL IN YOUR MOUTH OR IN YOUR EYES. IF YOU GET FUEL ON YOUR SKIN OR ON YOUR CLOTHES, FLUSH IT IMMEDIATELY WITH WATER. IF NECESSARY, GET MEDICAL HELP. AIRCRAFT FUEL IS POISONOUS.

WARNING: BE CAREFUL DURING THE REMOVAL/INSTALLATION OF THE VARIABLE STATOR VANE ACTUATOR. IT WEIGHS 10lb (4.5kg).

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

CAUTION: DO NOT LET ENGINE FUEL OR OIL FALL ON THE ENGINE. UNWANTED FUEL OR OIL MUST BE REMOVED IMMEDIATELY WITH A CLEAN LINT FREE CLOTH. THE FUEL OR OIL CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO SOME PARTS.

ZONE: 453
ZONE: 454
FIN: 4022KS ** ON A/C NOT FOR ALL

1. Reason for the Job
This task is for all A1 engines with Post SBE 72-0398 configuration and for all A5 engines with Pre SBE 75-0122 configuration (Type 1685 or 2607 Series VSVA).
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	BRUSH 0,75 IN (19 MM) WIDE - BRISTLED, MEDIUM
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - STANDARD
No specific	AR	WRENCH 15/16 IN - CROWFOOT, BI-HEX
No specific	Torque wrench: range to between 45 and 36 lbf.in (0.51 and 0.41 m.daN )
No specific	Torque wrench: range to between 177 and 159 lbf.in (2.00 and 1.80 m.daN )
No specific	Torque wrench: range to between 220 and 180 lbf.in (2.49 and 2.03 m.daN )
No specific	Torque wrench: range to between 220 and 205 lbf.in (2.49 and 2.32 m.daN )
No specific	Torque wrench: range to between 310 and 283 lbf.in (3.50 and 3.20 m.daN )
No specific	Torque wrench: range to between 370 and 290 lbf.in (4.18 and 3.28 m.daN )
No specific	Torque wrench: range to between 475 and 425 lbf.in (5.37 and 4.80 m.daN )
IAE1R18254	1	PIN RIGGING
IAE1R18282	1	PIN, RIGGING
IAE1R18891	1	PIN, RIGGING

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.V02-126)	lockwire
(Material No.V04-004)	jointing compound
(Material No.V04-005)	jointing compound
(Material No.V04-020)	jointing compound

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
453	HOT SECTION
454	HOT SECTION
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451AL
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461AL

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
10	PACKING	AIPC 75-32-41-80-060
3	PACKING	AIPC 75-32-41-80-060
4	PACKING	AIPC 75-32-41-80-060
8	PACKING	AIPC 75-32-41-80-060

E. Referenced Information

REFERENCE	DESIGNATION
TASK 70-11-50-100-802-A	Local Swab or Wipe Cleaning with Solvent
TASK 70-23-11-911-013-A	General Torque Tightening Techniques
TASK 70-23-13-911-010-A	Procedures for the Installation of Preformed Packings
TASK 70-23-15-912-010-A	Connection of Electrical Connectors
TASK 70-40-11-911-014-A	Locking Devices General Information
TASK 71-00-00-710-012-B	Test No.3 : Idle Leak Check
TASK 71-00-00-710-013-C	Test No.11 : High Power Assurance Test
TASK 71-00-00-710-045-A	Test No.1 : Dry Motor Leak Check
TASK 71-13-00-010-010-A	Opening of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 71-13-00-410-010-A	Closing of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 78-30-00-040-012-A	Deactivation of the Thrust Reverser Hydraulic Control Unit (HCU) for Ground Maintenance
TASK 78-30-00-440-012-A	Re-activation of the Thrust Reverser Hydraulic Control Unit (HCU) after Ground Maintenance
TASK 78-32-00-010-010-A	Opening of the Thrust Reverser Halves
TASK 78-32-00-410-010-A	Closing of the Thrust Reverser Halves
Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122)
VSV and Drains System HP Fuel Tubes
VSV and Drains System LP Fuel Tubes

3. Job Set-up
Subtask 75-32-41-860-050-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) On the center pedestal, on ENG panel 115VU, make sure that a WARNING NOTICE(S) is in position to tell persons not to start the engine.
(2) On overhead maintenance panel 50VU, make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off.
(3) Make sure that a WARNING NOTICE(S) is in position to tell persons not to energize FADEC 1(2).

Subtask 75-32-41-010-052-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Make sure that the fan cowl doors are open: (Ref. AMM TASK 71-13-00-010-010)
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR
(2) Make sure that the left thrust reverser half is open: (Ref. AMM TASK 78-32-00-010-010)
(a) FOR [1000EM1] (ENGINE-1)
451AL
(b) FOR [1000EM2] (ENGINE-2)
461AL

Subtask 75-32-41-040-051-A ** ON A/C NOT FOR ALL

C. Deactivation of the thrust reverser

WARNING: MAKE SURE THAT THE THRUST REVERSER HYDRAULIC CONTROL UNIT (HCU) IS DEACTIVATED BEFORE YOU DO WORK ON OR AROUND THE THRUST REVERSER. IF THE HCU IS NOT DEACTIVATED, THERE IS A RISK OF UNWANTED THRUST REVERSER OPERATION WHICH CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Make sure that the thrust reverser Hydraulic Control Unit (HCU) is deactivated (Ref. AMM TASK 78-30-00-040-012).

Subtask 75-32-41-110-050-A ** ON A/C NOT FOR ALL

D. Clean the mating surfaces of the actuator and compressor

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

(1) Use The local swab or wipe cleaning with solvent procedure to clean these parts (Ref. AMM TASK 70-11-50-100-802):

The mating faces of the actuator
The mating faces of the HP compressor case
The support bracket and clip point bracket
The bolts (21), (24) and (28)
The washers (23) and (29).

4. Procedure
Subtask 75-32-41-280-050-A ** ON A/C NOT FOR ALL

A. Make sure that the Actuator has sufficient clearance before installation

CAUTION: DO NOT LET THE VSVS MOVE THROUGH THE LOW OR HIGH SPEED POSITIONS WHEN THE CRANKSHAFT IS TURNED. THE ENGINE CAN BE DAMAGED INTERNALLY.

(1) Before the installation of the VSVA, use an applicable wrench on the flats of the crankshaft and move the VSV system from the low-speed to the high-speed position.

Subtask 75-32-41-630-050-A ** ON A/C NOT FOR ALL

B. Remove the caps from the openings

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

(1) Remove the caps from the electrical connectors (2), (3), (4) and (5) and their receptacles on the actuator (1).
(2) Remove the caps from the openings on the actuator (1).

Subtask 75-32-41-420-050-A ** ON A/C NOT FOR ALL

C. Installation of the actuator

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

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.

(1) Put a piece of lockwire (Material No.V02-126) through the lockwire hole in the actuator case adjacent to the fuel supply tube (7).

NOTE: It is very difficult to put the lockwire in position when the actuator is installed on the compressor case.

(2) Install the actuator.

NOTE: If jointing compound is not available at the time of actuator installation, it is permitted to operate a maximum of 100 flight cycles (or) 2 months, whichever comes first, with no compound applied.

(a) Use the BRUSH 0,75 IN (19 MM) WIDE - BRISTLED, MEDIUM to apply jointing compound (Material No.V04-004) , jointing compound (Material No.V04-005) (or) jointing compound (Material No.V04-020) to these parts:
1 The mating faces on the HP compressor case
2 The mating faces on the support bracket and the clip point bracket
3 The mating faces on the actuator
4 The bolts (20), (21), (24) and (28)
5 The washers (23) and (29).
(b) Let the jointing compound (Material No.V04-004) (or) jointing compound (Material No.V04-005) dry for at least 10 minutes. Drying jointing compound (Material No.V04-020) is not required if applied.
(c) Put the actuator in position on the HP compressor case. Make sure that the two dowels engage fully in the actuator mounting faces.

NOTE: The washers (23) and (29) are D-shaped washers with a 45-degree chamfer on the flat side. The flats of the washers must face the main body of the VSVA and the 45-degree chamfer on the washer flats must be facing away from the heads of the bolts.

(d) Install the two bolts (24) and (28) and washers (23) and (29).
(e) TORQUE the bolts (24) and (28) to between 220 and 180 lbf.in (2.49 and 2.03 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
(f) Put the support bracket in position and install the bolt (21). Tighten the bolt with your hand.
(g) Install the two bolts (20) through the clip point bracket and support bracket.
(h) TORQUE the bolts (20) and (21) to between 220 and 180 lbf.in (2.49 and 2.03 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
(i) After at least two minutes, TORQUE the bolts (24), (28), (20) and (21) to between 220 and 180 lbf.in (2.49 and 2.03 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

NOTE: The bolts can become loose because the jointing compound beds in after the initial assembly.

(j) Install the bolt (17) with the washer (18) through the tube clip and in the clipnut (19).
(k) TORQUE the bolt (17) to between 45 and 36 lbf.in (0.51 and 0.41 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

Subtask 75-32-41-820-052-A ** ON A/C NOT FOR ALL

D. Lock the actuator and the crank assembly

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

(1) Move the actuator ram to the high-speed position (ram retracted) so that the fork end is against the high-speed stop.

NOTE: Use a WRENCH - STANDARD on the flats on the crank to move the VSVs to the high-speed position.

NOTE: The Post-SB 75-0122 rig pin housing is on the rear side of ram when you look at it from the front of the engine.

(2) Position the ram to align the rig pin slot in the fork end with the hole in the rig pin housing, as in Detail B.
(3) Installation of the rig pin

CAUTION: YOU MUST MAKE SURE THAT RIG PIN IAE1R18282 OR IAE1R18891 IS FULLY AND CORRECTLY INSTALLED IN THE VSV ACTUATOR WHEN YOU INSTALL THE BOLT. IF IT IS NOT, DAMAGE TO THE ENGINE CAN OCCUR.

(a) Install the IAE1R18891 PIN, RIGGING or IAE1R18282 PIN, RIGGING through the rig pin housing and in the actuator ram fork end, as in Detail B.

NOTE: Move the actuator ram fork end to align the rig pin slot in the fork end and the rig pin hole in the housing if the rig pin cannot be fully installed.

Visually inspect to ensure the correct rig pin engagement into the fork end slot, the pin must be fully engaged.

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

(4) Make sure that the IAE1R18254 PIN RIGGING (44) is installed in the crank assembly.

Subtask 75-32-41-420-051-B ** ON A/C NOT FOR ALL

E. Install the control rod

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

CAUTION: YOU MUST MAKE SURE THAT RIG PIN IAE1R18282 OR IAE1R18891 IS FULLY AND CORRECTLY INSTALLED IN THE VSV ACTUATOR WHEN YOU INSTALL THE BOLT. IF IT IS NOT, DAMAGE TO THE ENGINE CAN OCCUR.

CAUTION: YOU MUST MAKE SURE THAT THE BOLT IS CORRECTLY INSTALLED TO THE VSV ACTUATOR FORK. IF YOU DO NOT DO THIS, EXTENSIVE DAMAGE TO THE ENGINE CAN OCCUR.

(1) Put the end of the control rod (26) in position and install the bolt (27), the washer and the nut (25).

NOTE: Make sure that the D-head bolt (27) is installed in the correct orientation to the VSV actuator fork. The D-head bolt straight face aligns with the location feature on the mating actuator fork.

(2) If the bolt (27) cannot be easily installed, adjust the length of the control rod (26) to align with the actuator ram.

(a) Remove and discard the lockwire that safeties the locknuts (41).
(b) Loosen the two locknuts (41).
(c) Adjust the length of the control rod until the bolt (27) can be easily installed.
(d) Install the bolt (27), washer and nut (25).
(3) TORQUE the nut (25) to between 370 and 290 lbf.in (4.18 and 3.28 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

NOTE: The correct installation of the bolt (27) makes sure that the nut (25) can be torqued correctly.

Subtask 75-32-41-820-050-A ** ON A/C NOT FOR ALL

F. Make sure that the control rod is aligned correctly

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

(1) Make sure that the control rod-end(s) is(are) aligned to less than five degrees.
(2) Make sure that the control rod-end(s) is(are) in safety.

Subtask 75-32-41-420-052-A ** ON A/C NOT FOR ALL

G. Tighten the locknut(s)
(1) TORQUE the locknut(s) (41) to between 220 and 205 lbf.in (2.49 and 2.32 m.daN )

.
(2) Safety the locknut

(a) Safety the locknut(s) (41) to the control rod-end(s) with the lockwire (Material No.V02-126) (Ref. AMM TASK 70-40-11-911-014).

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

Subtask 75-32-41-080-050-B ** ON A/C NOT FOR ALL

H. Remove the rigging pins
(1) Remove the two rigging pins IAE1R18254 PIN RIGGING and IAE1R18891 PIN, RIGGING or IAE1R18282 PIN, RIGGING.

Subtask 75-32-41-420-053-A ** ON A/C NOT FOR ALL

I. Connection of the fuel tubes and the electrical connectors

CAUTION: DURING REMOVAL AND INSTALLATION OF THE HP SUPPLY TUBE AND LP RETURN TUBE, TWO OPEN JAW OR BI-HEX CROWSFOOT SPANNERS MUST BE USED TO ENSURE THE UNION BETWEEN THE TUBE AND THE VSVA BODY REMAINS STATIONARY.

(1) Connect the fuel tubes.

VSV and Drains System HP Fuel Tubes ** ON A/C NOT FOR ALL

VSV and Drains System LP Fuel Tubes ** ON A/C NOT FOR ALL

Variable Stator Vane Actuator (V2500-A1 or V2500-A5 and A5 SelectOne Retrofit PRE SB 75-0122) ** ON A/C NOT FOR ALL

NOTE: The unions for Pre SB 75-0122 for the HP supply and LP return at the VSVA are 1" wrench flats. The tube fittings are 15/16" wrench flats.

(a) Connect the LP return fuel tube (9).
1 Install a new AIPC 75-32-41-80-060 PACKING (10) (Ref. AMM TASK 70-23-13-911-010).
2 Connect the fuel tube (9) to the actuator.
3 TORQUE the union to between 475 and 425 lbf.in (5.37 and 4.80 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
4 Safety the union

a Safety the union to the actuator case with lockwire (Material No.V02-126) (Ref. AMM TASK 70-40-11-911-014).
(b) Connect the fuel drain tube (6).
1 Connect the fuel drain tube (6).
2 TORQUE the connector to between 177 and 159 lbf.in (2.00 and 1.80 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
3 Safety the connector to the actuator case with lockwire (Material No.V02-126) (Ref. AMM TASK 70-40-11-911-014).
(c) Connect the HP supply fuel tube (7).
1 Install a new AIPC 75-32-41-80-060 PACKING (8) (Ref. AMM TASK 70-23-13-911-010).
2 Connect the fuel tube (7) to the actuator.
3 TORQUE the union to between 475 and 425 lbf.in (5.37 and 4.80 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

NOTE: A WRENCH 15/16 IN - CROWFOOT, BI-HEX is necessary to tighten this fuel tube union.

4 Safety the connector to the actuator case with the lockwire (Material No.V02-126) (Ref. AMM TASK 70-40-11-911-014) that was put in position before the actuator was installed.
(d) Connect the union (1)

1 Install a new AIPC 75-32-41-80-060 PACKING (3) (Ref. AMM TASK 70-23-13-911-010).
2 Connect union (1) to the T-connector (12).
3 TORQUE the connector to between 310 and 283 lbf.in (3.50 and 3.20 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
4 Safety the union with lockwire (Material No.V02-126) (Ref. AMM TASK 70-40-11-911-014).
(e) Connect the union (2)

1 Install a new AIPC 75-32-41-80-060 PACKING (4) (Ref. AMM TASK 70-23-13-911-010).
2 Connect the union (2) to the T-connector (11).
3 TORQUE the connector to between 310 and 283 lbf.in (3.50 and 3.20 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
4 Safety the union with lockwire (Material No.V02-126) (Ref. AMM TASK 70-40-11-911-014).
(2) TORQUE the clamps loosened to allow for fuel tube movement to between 45 and 36 lbf.in (0.51 and 0.41 m.daN )

.
(3) Connect the electrical connectors (Ref. AMM TASK 70-23-15-912-010).
(a) Connect the electrical connectors (2), (3), (4) and (5) to the actuator (1).

5. Close-up
Subtask 75-32-41-410-050-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the left thrust reverser half (Ref. AMM TASK 78-32-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
451AL.
(b) FOR [1000EM2] (ENGINE-2)
461AL.

Subtask 75-32-41-440-050-A ** ON A/C NOT FOR ALL

B. Activate the thrust reverser HCU (Ref. AMM TASK 78-30-00-440-012).

Subtask 75-32-41-410-051-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowls (Ref. AMM TASK 71-13-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR.
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR.
(2) Remove the WARNING NOTICE(S).

Subtask 75-32-41-720-050-B ** ON A/C NOT FOR ALL

D. For test requirements:
(1) Do an Idle leak check (Ref. AMM TASK 71-00-00-710-012).

NOTE: A dry motor leak check (Ref. AMM TASK 71-00-00-710-045) may be used to check for leaks, but this must be followed by an idle leak check (Ref. AMM TASK 71-00-00-710-012).

(2) Do a High power assurance test (Ref. AMM TASK 71-00-00-710-013).

[Rev.10 from 2021] 2026.04.01 03:11:54 UTC