Installation of the Exhaust Nozzle Assembly [PW11]

TASK 78-11-01-400-801-A
Installation 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.

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

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	1	WRENCH - STANDARD
No specific	1	WRENCH - TORQUE
No specific	Torque wrench: range to between 130 and 125 lbf.in (1.47 and 1.41 m.daN )
636-4250-21GSE	1	NOZZLE LIFTING AID

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.PU3-0025)	sealant, tamper proof
(Material No.PU5-0003)	anti-seize compound

C. 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

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
3	BOLT	EIPC 78-11-86-01-030
1	NUT	EIPC 78-11-86-01-050

E. 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 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 78-11-01-400-803-A	Installation of the Exhaust Nozzle Alignment Pin
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
Exhaust Nozzle Assembly
Exhaust Nozzle Lifting Aid
Exhaust Dolly

3. Job Set-up
Subtask 78-11-01-941-051-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833)

Subtask 78-11-01-010-052-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR
(2) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position.

Subtask 78-11-01-040-051-A ** ON A/C NOT FOR ALL

C. 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) Make sure that you did the deactivation of the thrust reverser system for maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 78-11-01-010-053-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Make sure that the thrust reverser cowl-doors are open (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 78-11-01-010-069-A ** ON A/C NOT FOR ALL

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

Subtask 78-11-01-420-053-A ** ON A/C NOT FOR ALL

F. Make sure that the alignment pins are installed (Ref. AMM TASK 78-11-01-400-803).

4. Procedure
Subtask 78-11-01-420-050-A ** ON A/C NOT FOR ALL

A. Installation of the Exhaust Nozzle Assembly

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

(1) Removal of the protection covers:

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Make sure that you remove all the necessary COVER - PROTECTION to prevent damage to the engine.
(2) Remove the exhaust nozzle assembly (4) from the 636-4000-22GSE EXHAUST DOLLY. Refer to the instructions of the manufacturer.
(3) Attach the 636-4250-21GSE NOZZLE LIFTING AID on the exhaust nozzle assembly (4). Refer to the instructions of the manufacturer.
(4) Lift the exhaust nozzle assembly (4):

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.

(a) Lift the exhaust nozzle assembly (4) with the 636-4250-21GSE NOZZLE LIFTING AID and put the exhaust nozzle assembly (4) in position on the turbine exhaust case. Refer to the instructions of the manufacturer.
(b) Make sure that the alignment pins on the turbine exhaust case align with the holes on the exhaust nozzle assembly (4).
(5) Apply the anti-seize compound (Material No.PU5-0003) to the shanks and threads of the bolts (3).

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE EXHAUST FIRESEAL ON THE NOZZLE ASSEMBLY WHEN YOU INSTALL THE NOZZLE ASSEMBLY ON THE TURBINE EXHAUST CASE.

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE CROSSFLOW BLOCKERS ON THE NOZZLE ASSEMBLY WHEN YOU INSTALL THE NOZZLE ASSEMBLY 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.

(6) Move the exhaust nozzle assembly (4):
(a) With the exhaust nozzle assembly (4) away from the aft pylon fairing, move the exhaust nozzle assembly (4) until the front of the assembly is about to touch the points of the alignment pins.
(b) Carefully lift the exhaust nozzle assembly (4) until you align the alignment pins with the holes in the exhaust nozzle assembly (4).
(c) Make sure that the exhaust fire seal compresses correctly on the aft pylon fairing.
(d) Move the exhaust nozzle assembly (4) forward into position with the alignment pins in the appropriate holes.
(7) Install the exhaust nozzle assembly (4) on the turbine exhaust case with the 20 bolts (3), the 20 washers (2) and the 20 nuts (1).
(a) Do not torque the nuts (1) at this time. Keep a small space under the nuts (1).
(8) Hold the bolts (3) with a WRENCH - STANDARD.
(9) Engage each nut (1) until one bolt thread protrudes from the top of the nut (1).
(10) Turn each nut (1) a small distance with a WRENCH - TORQUE.
(11) Measure the maximum torque to turn each nut. If the torque is less than 3.5 lbf.in (0.04 m.daN), replace the nut (1) and the related bolt (3).
(12) Repeat steps 4.A.(8) thru 4.A.(11) with the new EIPC 78-11-86-01-050 NUT (1) and the new EIPC 78-11-86-01-030 BOLT (3).

NOTE: The maximum torque is usually found immediately before the nut starts to turn.

(13) TORQUE the nuts (1) in opposite pairs to between 130 and 125 lbf.in (1.47 and 1.41 m.daN )

.
(a) Make sure that you install all the bolts (3), the washers (2) and the nuts (1) before you begin to torque the nuts.
(14) Paint torque stripes on the 20 nuts (1) and the adjacent surfaces with the PU3-0025sealant, tamper proof.
(15) Remove the 636-4250-21GSE NOZZLE LIFTING AID from the exhaust nozzle assembly (4). Refer to the instructions of the manufacturer.

5. Close-up
Subtask 78-11-01-410-050-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) On the pylon, close the following access panels:
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
473AL, 473AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
483AL, 483AR
(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 78-11-01-440-050-A ** ON A/C NOT FOR ALL

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

Subtask 78-11-01-410-051-A ** ON A/C NOT FOR ALL

C. 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 access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 03:30:21 UTC