Removal of the Exhaust Nozzle Assembly [PW11]

TASK 78-11-01-000-801-A
Removal of the Exhaust Nozzle Assembly

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: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS NECESSARY.

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: 3801KM1 ** ON A/C NOT FOR ALL
FIN: 3801KM2 ** ON A/C NOT FOR ALL

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	AR	COVER - PROTECTION
636-4000-22GSE	1	EXHAUST DOLLY
636-4250-21GSE	1	NOZZLE LIFTING AID

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL, 452AR, 473AL, 473AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR, 483AL, 483AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
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 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
Exhaust Nozzle Assembly
Exhaust Nozzle Lifting Aid
Exhaust Dolly

3. Job Set-up
Subtask 78-11-01-941-050-A ** ON A/C NOT FOR ALL

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

Subtask 78-11-01-010-050-A ** ON A/C NOT FOR ALL

B. 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
(2) Put an ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE in position.

Subtask 78-11-01-040-050-A ** ON A/C NOT FOR ALL

C. Deactivation of the Thrust Reverser 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 78-11-01-010-051-A ** ON A/C NOT FOR ALL

D. 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

Subtask 78-11-01-010-068-A ** ON A/C NOT FOR ALL

E. On the pylon, open the following access panels:
(1) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
473AL, 473AR
(2) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
483AL, 483AR

4. Procedure
Subtask 78-11-01-020-050-A ** ON A/C NOT FOR ALL

A. Removal of the Exhaust Nozzle Assembly

WARNING: MAKE SURE THAT THE NOZZLE ASSEMBLY IS SUFFICIENTLY SUPPORTED DURING REMOVAL OR INSTALLATION. THE NOZZLE ASSEMBLY WEIGHS APPROXIMATELY 39 LB (17.7 KG). IF IT IS NOT SUFFICIENTLY SUPPORTED, INJURY TO PERSONNEL AND/OR DAMAGE TO THE COMPONENTS CAN OCCUR.

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

(1) Attach the 636-4250-21GSE NOZZLE LIFTING AID to the exhaust nozzle assembly (4):
(a) Put the 636-4250-21GSE NOZZLE LIFTING AID below the exhaust nozzle assembly (4).
(b) Lift the 636-4250-21GSE NOZZLE LIFTING AID until it holds the weight of the exhaust nozzle assembly (4). Refer to the instructions of the manufacturer.
(c) Attach the 636-4250-21GSE NOZZLE LIFTING AID to the exhaust nozzle assembly (4). Refer to the instructions of the manufacturer.
(2) Remove the 20 bolts (3), the 20 washers (2) and the 20 nuts (1) that attach the exhaust nozzle assembly (4) to the turbine exhaust case.

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE PYLON SEAL ON THE PYLON WHEN YOU REMOVE/INSTALL THE NOZZLE ASSEMBLY FROM/ON THE TURBINE EXHAUST CASE.

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE FORWARD OR AFT CENTERBODY IF INSTALLED WHEN YOU REMOVE/INSTALL THE NOZZLE ASSEMBLY FROM/ON THE TURBINE EXHAUST CASE.

(3) Move the exhaust nozzle assembly (4) away from the pylon and the turbine exhaust case. Use the 636-4250-21GSE NOZZLE LIFTING AID. Refer to the instructions of the manufacturer.
(a) Carefully move the exhaust nozzle assembly (4) aft until it is immediately aft of the points of the alignment pins.
(b) Lower the 636-4250-21GSE NOZZLE LIFTING AID until the pylon seal on the exhaust nozzle assembly (4) does not touch the pylon.
(c) Move the exhaust nozzle assembly (4) aft until it is aft of the forward and aft center bodies, if they are there.
(d) Lower the exhaust nozzle assembly (4) away from the pylon and the turbine exhaust case.
(e) Put the exhaust nozzle assembly (4) on the 636-4000-22GSE EXHAUST DOLLY. Refer to the instructions of the manufacturer.
(4) Installation of the protection covers:

CAUTION: INSTALL PROTECTION COVERS ON ALL THE OPENINGS IMMEDIATELY TO PREVENT DAMAGE TO THE ENGINE.

(a) Make sure that you install COVER - PROTECTION as necessary to prevent damage to the engine.

[Rev.10 from 2021] 2026.04.01 03:30:20 UTC