Installation of the Exhaust Nozzle [CFML]

TASK 78-12-40-400-801-A
Installation of the Exhaust Nozzle

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

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

WARNING: BEFORE YOU INSTALL/REMOVE THE GSE TOOL, READ THE MANUFACTURER'S INSTRUCTIONS, AND, WHILE YOU OPERATE THIS TOOL, CAREFULLY OBEY THEM. IF YOU DO NOT DO THIS, INJURY TO PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.

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: 210
ZONE: 400

1. Reason for the Job
Two persons are necessary to do this task.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 1M(3 FT)
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - TORQUE, DIAL TYPE
No specific	Torque wrench: range to between 1.4 and 1.2 m.daN (123.89 and 106.19 lbf.in )
98N7810H001-000	1	EXHAUST DOLLY
98N7810H004-000	1	EXHAUST SHOCK ABSORBER

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.CPNCL00378)	Never-seez pure nickel special
(Material No.CPNCL02069)	Textile - lint free cotton
(Material No.CPNCL02589)	Diestone DLS
(Material No.CPNCL02640)	Loctite 8009

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, ENGINE 1)
437AL, 438AR, 451AL, 452AR, 473AL, 473AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR, 461AL, 462AR, 483AL, 483AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
4	NUT	AIPC 78-11-41-05-030
8	FLOATING NUT	AIPC 78-11-41-10-070
10	RIVET	AIPC 78-11-41-10-080

E. Referenced Information

REFERENCE	DESIGNATION
TASK 54-56-00-000-803-A	Removal of the Aft Pylon Fairing (APF)
TASK 54-56-00-400-803-A	Installation of the Aft Pylon Fairing (APF)
TASK 70-60-00-910-802-A	Standard Practices
TASK 71-13-00-010-803-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-803-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-807-A	Deactivation of the Thrust Reverser System for Nacelle Maintenance (ICU)
TASK 78-30-00-440-807-A	Reactivation of the Thrust Reverser System after Nacelle Maintenance (ICU)
TASK 78-36-00-010-806-A	Opening of the Thrust Reverser Cowl Doors
TASK 78-36-00-410-806-A	Closing of the Thrust Reverser Cowl Doors
Exhaust Nozzle

3. Job Set-up
Subtask 78-12-40-941-051-A

A. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
(c) Make sure that the WARNING NOTICE(S) are in position to tell persons not to operate:

The ENG/MODE selector switch, and
The ENG/MASTER 1(2) control switch.

(2) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton switch is off.
(b) Make sure that the WARNING NOTICE(S) is in position to tell persons not to energize FADEC 1(2).

Subtask 78-12-40-010-052-A

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR
(2) Make sure that the ACCESS PLATFORM 1M(3 FT) is in position.

Subtask 78-12-40-040-051-A

C. Deactivation of the Thrust Reverser System for Nacelle 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 nacelle maintenance (Ref. AMM TASK 78-30-00-040-807).

Subtask 78-12-40-010-053-A

D. Get Access
(1) Make sure that the thrust reverser cowl-doors are open (Ref. AMM TASK 78-36-00-010-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL 462AR
(2) Make sure that the left and right Aft Pylon Fairings are removed (Ref. AMM TASK 54-56-00-000-803).
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
473AL 473AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
483AL 483AR

4. Procedure
Subtask 78-12-40-420-050-A

A. Installation of the Exhaust Nozzle
(1) Clean the bolts (2), the two washers (3) and the nuts (4) with a Textile - lint free cotton (Material No.CPNCL02069) made moist with Diestone DLS (Material No.CPNCL02589) .
(2) Make sure that the finish on the threads of the bolts (2) and the washers (3), the contact surfaces of the washers (3) and nuts (4) are not damaged.
(3) Apply Loctite 8009 (Material No.CPNCL02640) or Never-seez pure nickel special (Material No.CPNCL00378) on the threads, barrel and the head bottom face of each bolt (2) head.
(a) Check of the condition of the floating nut (8):
1 Do a check for the maximum locking torque for each floating nut (8):
a Turn the bolt (2) with your hand until the self-locking device is engaged.
b Turn the fastener until the self-locking device is fully engaged.
c Use a WRENCH - TORQUE, DIAL TYPE to measure the maximum locking torque value of the bolt (2).

NOTE: A minimum of one and a half threads of the bolt (2) must extend more than the floating nut (8) to record the locking torque value.

d Make sure that the maximum locking torque value of the bolt (2) is not more than 0.339 m.daN (30.00 lbf.in).
e If the maximum locking torque value is not in the limits, replace the floating nut (8) by a new AIPC 78-11-41-10-070 FLOATING NUT (8) with AIPC 78-11-41-10-080 RIVET (10) (Ref. AMM TASK 70-60-00-910-802).
2 Do a check for the minimum breakaway torque for each floating nut (8):
a Use a WRENCH - TORQUE, DIAL TYPE to loosen the bolt (2).

NOTE: A minimum of one and a half threads of the bolt (2) must extend more than the floating nut (8) to record the breakaway torque value.

b Make sure that the minimum breakaway torque value necessary to turn the bolt (2) is more than 0.04 m.daN (3.54 lbf.in).
c If the minimum breakaway torque value is not in the limits, replace the floating nut (8) by a new AIPC 78-11-41-10-070 FLOATING NUT (8) with AIPC 78-11-41-10-080 RIVET (10) (Ref. AMM TASK 70-60-00-910-802).
(4) Clean the nozzle (1) and engine flange with a Textile - lint free cotton (Material No.CPNCL02069) made moist with Diestone DLS (Material No.CPNCL02589) .
(5) Make sure that the 98N7810H004-000 EXHAUST SHOCK ABSORBER (9) is installed on the front plug.
(6) Put the nozzle (1) in position:

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE ADJACENT PARTS DURING REMOVAL/INSTALLATION OF THE NOZZLE.

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE FINGER SEALS DURING INSTALLATION OF THE NOZZLE.

(a) Remove the nozzle (1) from the 98N7810H001-000 EXHAUST DOLLY or transportation box.

NOTE: Start by inserting one of the 2 upper spigots. Then one mechanic push under the nozzle (1) to compress the finger seals while the other mechanic centre and insert the second upper spigot.

(b) Put the nozzle (1) in position on the exhaust engine flange carefully to align the centering spigot (7).
(c) Check that the nozzle finger seal is fully engaged under the aft pylon fairing. If not, engage it manually.

WARNING: MAKE SURE THAT TWO MECHANICS ARE AVAILABLE FOR THIS OPERATION. ONE MECHANIC MUST HOLD THE NOZZLE TO PREVENT ITS FALL BEFORE THE OTHER MECHANIC INSTALLS THE FIRST FASTENERS. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

(7) Installation of the fasteners on the nozzle (1):

NOTE: SAFRAN Nacelles recommend to replace the removed nut (4) with a new nut (4).

NOTE: If the airline's decision is to use the removed nut (4) again, refer to Para. 4.A.(7)(a) to do a check of the condition of the removed nut (4).

(a) Do a check of the condition of the nuts (4) to be installed:

NOTE: Do this check only if you use the removed nut (4) again.

1 Do the check for the maximum locking torque for each nut (4):
a Turn the bolt (2) with your hand until the self-locking device is engaged.
b Turn the fastener until the self-locking device is fully engaged.
c Use a WRENCH - TORQUE, DIAL TYPE to measure the maximum locking torque value of the nut (4) before you push the assembly.

NOTE: A minimum of one and a half threads of the bolt (2) must extend more than the nut (4) to record the locking torque value.

d Make sure that the maximum locking torque value of the nut (4) is not more than 0.339 m.daN (30.00 lbf.in).
e If the maximum locking torque value is not in the limits, discard the nut (4) and install a new AIPC 78-11-41-05-030 NUT (4).
2 Do a check for the minimum breakaway torque for each nut (4):
a Use a WRENCH - TORQUE, DIAL TYPE to loosen the nut (4).

NOTE: A minimum of one and a half threads of the bolt (2) must extend more than the nut (4) to record the breakaway torque value.

b Make sure that the minimum breakaway torque value necessary to turn the nut (4) is more than 0.04 m.daN (3.54 lbf.in).
c If the minimum breakaway torque value is not in the limits, discard the nut (4) and install a new AIPC 78-11-41-05-030 NUT (4).
(b) Install the two washers (3), bolts (2) and nuts (4) at positions 37, 13, 36 and 12.
(c) Install the two washers (3), bolts (2) and nuts (4) at positions 42, 31 to 27, 22 to 18 and 7.

CAUTION: MAKE SURE THAT THE TEN PADS ARE CORRECTLY INSTALLED. IF ONE OR MORE PADS ARE MISSING OR INCORRECTLY INSTALLED, DAMAGE TO THE AFT CORE COWL CAN OCCUR.

(8) Installation of the pads (5) and (6) and the fasteners on the nozzle (1):

NOTE: SAFRAN Nacelles recommend to replace the removed nut (4) with a new nut (4).

NOTE: If the airline's decision is to use the removed nut (4) again, refer to Para. 4.A.(7)(a) to do a check of the condition of the removed nut (4).

(a) Install the pads (5) and (6), washers (3), bolts (2) and the nuts (4) at positions 41 to 38, 35 to 32, 26 to 23, 17 to 14 and 11 to 8.

NOTE: Install the pads (6) between positions 41, 40 and 24, 23 to let the centering spigot (7) through it.

NOTE: Pads (6) must be in contact with the engine flange at positions 41, 40 and 24, 23.

NOTE: Pads (5) must be in contact with the nozzle (1) flange at positions 39 to 38, 35 to 32, 26 to 25, 17 to 14 and 11 to 8.

(9) Install the washers (3) and bolts (2) at positions 48 to 43 and 6 to 1.
(10) Torque procedure:

CAUTION: BEFORE YOU DO THE TORQUE PROCEDURE, MAKE SURE THAT YOU CORRECTLY ALIGN THE CENTERING SPIGOT. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO THE EQUIPMENT.

(a) TORQUE the bolts (2) at position 12, 36, 13, 37, 48 and 24 to between 1.4 and 1.2 m.daN (123.89 and 106.19 lbf.in )

.
(b) TORQUE the bolts (2) at the remaining positions to between 1.4 and 1.2 m.daN (123.89 and 106.19 lbf.in )

in the Counter Clockwise (CCW) direction.
(c) Loosen and immediately TORQUE all the bolts (2) to between 1.4 and 1.2 m.daN (123.89 and 106.19 lbf.in )

in the CCW direction.
(11) Make sure that one and a half threads of the bolt (2) extend more than the nut (4). If not, repeat the Para. 4.A.(11).
(12) Remove the 98N7810H004-000 EXHAUST SHOCK ABSORBER (9) from the front plug.
(13) Remove the 98N7810H001-000 EXHAUST DOLLY or transportation box.

5. Close-up
Subtask 78-12-40-410-050-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the left and right Aft Pylon Fairings (Ref. AMM TASK 54-56-00-400-803).
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
473AL 473AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
483AL 483AR
(3) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL 462AR

Subtask 78-12-40-440-050-A

B. Do the reactivation of the thrust reverser system after nacelle maintenance (Ref. AMM TASK 78-30-00-440-807).

Subtask 78-12-40-410-051-A

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 03:34:32 UTC