Export Control
EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.Copyright
© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).Applicability
All
Common Information
TASK 72-00-32-450-013 LPC/Intermediate Case Module Components - Install The Fuel Diverter And Return Valve 4018KS, Installation-020
General
This TASK gives the procedure to install the fuel diverter and return valve (FDRV) to the engine.
Fig/item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.
For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the item number.
Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-039 ENGINE OIL, unless other lubricants are referred in the procedure.
For the torque tightening procedures, refer to the SPM TASK 70-41-00-400-501 and the SPM TASK 70-41-01-400-501.
For the lockwire data and procedures refer to the SPM TASK 70-42-05-400-501.
To identify, lubricate and install seal rings refer to the SPM TASK 70-44-01-400-501.
For safety cable data and procedures refer to the SPM TASK 70-42-08-400-501.
Safety the threaded fasteners in the ATA Chapter/Section/Subject 71-51-41 as applicable with CoMat 02-274 SAFETY CABLE KIT or CoMat 02-275 SAFETY CABLE KIT.
The engine must be isolated from starting air supply, fuel supply and electrical power source while you do this procedure.
NOTE
Preliminary Requirements
Pre-Conditions
NONESupport Equipment
NONEConsumables, Materials and Expendables
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| CoMat 01-002 SOLVENT, DELETED. | 0AM53 | CoMat 01-002 | ||
| CoMat 01-124 ISOPROPYL ALCOHOL | LOCAL | CoMat 01-124 | ||
| CoMat 02-099 LINT-FREE CLOTH | LOCAL | CoMat 02-099 | ||
| CoMat 02-147 LOCKWIRE | LOCAL | CoMat 02-147 | ||
| CoMat 02-274 SAFETY CABLE KIT | LOCAL | CoMat 02-274 | ||
| CoMat 02-275 SAFETY CABLE KIT | LOCAL | CoMat 02-275 | ||
| CoMat 10-038 PETROLEUM JELLY | LOCAL | CoMat 10-038 | ||
| CoMat 10-039 ENGINE OIL | LOCAL | CoMat 10-039 | ||
| CoMat 02-126 LOCKWIRE | LOCAL | CoMat 02-126 |
Spares
Safety Requirements
NONEProcedure
Refer to Figure.
Make a clean lint free cloth moist with CoMat 01-124 ISOPROPYL ALCOHOL cleaning fluid.
Clean the FCOC pad.
Lubricate the sealing rings with CoMat 10-038 PETROLEUM JELLY.
Install the new Fuel Diverter and Return Valve (73-13-42, 01-135) sealing ring 1 off and the new Fuel Diverter and Return Valve (73-13-42, 01-145) sealing ring 1 off.
Attach the FDRV and safety with the two bolts Fuel Diverter and Return Valve (73-13-42, 01-120) and washers Fuel Diverter and Return Valve (73-13-42, 01-125) and the two bolts Fuel Diverter and Return Valve (73-13-42, 01-110).
Attach the FDRV to the FCOC.
SUBTASK 72-00-32-420-148 Install the FDRV to the Fuel Cooled Oil Cooler (FCOC)
Refer to Figure.
Lubricate the sealing rings with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 02-498) sealing rings 2 off to the LP fuel element to FDRV fuel tube.
Install the fire shield Control Fuel Tubes (73-11-49, 02-475) and the seal housing Control Fuel Tubes (73-11-49, 02-485) on to the fuel tube.
SUBTASK 72-00-32-420-149 Install the Sealing Rings, the Fire Shield and the Seal Housing

WARNING
WHEN YOU USE COMAT 01-002 TRICHLOROETHANE INHIBITED AND STABILIZED YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.Clean the pin Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-115) and its mating faces on the FCOC with CoMat 01-002 SOLVENT, DELETED..
Safety the assembly to the brackets with the pin Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-115) and the bolt Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-110). Tighten the bolt lightly.
Safety the assembly to the brackets with the bush Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-440), the bolt Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-435) and the nut Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-430). Tighten the nut lightly.
Safety the assembly to the link with the bolt Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-595) and the nut Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-590). Tighten the nut lightly.
Safety the assembly to the brackets and the link.

WARNING
WHEN YOU USE COMAT 01-002 TRICHLOROETHANE INHIBITED AND STABILIZED YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.Clean the bonding strap connector Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-350), its mating faces on the FCOC and the bonding strap connector Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-250) with CoMat 01-002 SOLVENT, DELETED..
Connect the bonding strap Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-250) to the pin with the bolt Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-254), the washer Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-253) and the nut Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-251). Tighten the nut lightly.
Connect the bonding strap Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-350) to the FCOC with the bolt Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-355), the washer Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-392) and the nut Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-351). Tighten the nut lightly.
Torque the nuts Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-430) and Fuel Cooled Oil Cooler (FCOC) (01-590) to 180 to 200 lbf.in (20.34 to 22.60 Nm).
Torque the bolt Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-110) to 36 to 40 lbf.in (4.07 to 4.52 Nm).
Torque the nuts Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-251) and Fuel Cooled Oil Cooler (FCOC) 01-351) to 85 to 95 lbf.in (9.60 to 10.73 Nm).
Torque the bolts and the nuts.
SUBTASK 72-00-32-420-150 Install the Assembly of the FCOC and the FDRV
Refer to Figure.
Lubricate the sealing rings with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 05-108) sealing ring 1 off and the new Control Fuel Tubes (73-11-49, 05-116) sealing ring 1 off to the fuel tube.
Attach the fuel tube to the FCOC and the HP fuel pump with the three bolts Control Fuel Tubes (73-11-49, 05-106) and the four bolts Control Fuel Tubes (73-11-49, 05-114).
SUBTASK 72-00-32-420-151 Install the FCOC to HP Pump Fuel Tube
Refer to Figure.
Lubricate the packing with CoMat 10-039 ENGINE OIL.
Install the new FUEL SYSTEM TUBES (RIGID)-POWER PLANT (73-11-47, 02-108)packing1 off to the FDRV to aircraft fuel tube.
Attach the fuel tube to the FDRV with the three bolts FUEL SYSTEM TUBES (RIGID)-POWER PLANT (73-11-47, 02-101).
Connect the FDRV to aircraft fuel tube to the FDRV.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 02-516) sealing ring 1 off to the seal housing Control Fuel Tubes (73-11-49, 02-485).
Attach the fuel tube, the fire shield Control Fuel Tubes (73-11-49, 02-475) and the seal housing to the FDRV with the two bolts Control Fuel Tubes (73-11-49, 02-514).
Connect the LP fuel pump element to FDRV fuel tube to the FDRV.
Safety the nut with CoMat 02-147 LOCKWIRE.
Connect the FDRV to drain fuel tube to the FDRV.
SUBTASK 72-00-32-420-152 Connect the FDRV to Aircraft Fuel Tube, the LP Fuel Pump Element to FDRV Fuel Tube and the FDRV to Drain Fuel Tube
Refer to Figure.
Make sure that the restrictor Control Fuel Tubes (73-11-49, 02-090) and the retaining ring Control Fuel Tubes (73-11-49, 02-088) are installed in the fuel tube.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install Control Fuel Tubes (73-11-49, 02-108) sealing ring 1 off to the fuel tube.
Attach the fuel tube to the FCOC with the three bolts Control Fuel Tubes (73-11-49, 02-106).
Connect the fuel tube to the FCOC.
SUBTASK 72-00-32-420-153 Connect the FCOC to LP Fuel Pump Element Fuel Tube
Refer to Figure.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new OIL-PRESSURE OIL TUBES-ENGINE (79-21-49, 03-496) sealing ring 1 off to the oil outlet tube.
Attach the oil outlet tube to the FCOC with the three bolts OIL-PRESSURE OIL TUBES-ENGINE (79-21-49, 03-506).
Connect the oil outlet tube to the FCOC.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new OIL-PRESSURE OIL TUBES-ENGINE (79-21-49, 03-098) sealing ring 1 off to the oil inlet tube.
Attach the oil inlet tube to the FCOC with the three bolts OIL-PRESSURE OIL TUBES-ENGINE (79-21-49, 03-114).
Connect the oil inlet tube to the FCOC.
SUBTASK 72-00-32-420-154 Connect the Oil Outlet Tube and the Oil Inlet Tube to the FCOC
Lubricate the sealing rings with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 26-098) sealing rings 2 off and the new Control Fuel Tubes (73-11-49, 26-108) sealing ring 1 off to the fuel tube.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 26-116) sealing ring 1 off to the seal housing Control Fuel Tubes (73-11-49, 26-085).
Attach the fuel tube and the seal housing to the FDRV and the FMU with the two bolts Control Fuel Tubes (73-11-49, 26-114) and the three bolts Control Fuel Tubes (73-11-49, 26-106). Torque the five bolts to 85 to 95 lbf.in (9.60 to 10.73 Nm).
Make sure that the clip nut Control Fuel Tubes (73-11-49, 26-180) is engaged with the bracket.
Install the bolt Control Fuel Tubes (73-11-49, 26-173) and the washer Control Fuel Tubes (73-11-49, 26-174).
Assemble the clip position 1072.
Install the bolts EEC Fan Harness (71-51-41, 01-870) and EEC Fan Harness (01-878), the washers EEC Fan Harness (71-51-41, 01-871 and EEC Fan Harness 01-879) and the nuts EEC Fan Harness (71-51-41, 01-877 and EEC Fan Harness 01-885).
Assemble the clip positions 0789 and 0790.
Install the bolt Control Fuel Tubes (73-11-49, 26-157), the washer Control Fuel Tubes (73-11-49, 26-158) and the nut Control Fuel Tubes (73-11-49, 26-164).
Assemble the clip position 0921.
Install the bolt Control Fuel Tubes (73-11-49, 26-165), the washer Control Fuel Tubes (73-11-49, 26-166) and the nut Control Fuel Tubes (73-11-49, 26-172).
Assemble the clip position 0922.
Make sure that the clip nut Control Fuel Tubes (73-11-49, 05-140) is engaged with the bracket.
Install the bolt Control Fuel Tubes (73-11-49, 05-133), the washer Control Fuel Tubes (73-11-49, 05-134) and the spacers Control Fuel Tubes (73-11-49, 05-138 and Control Fuel Tubes 05-139).
Assemble the clip position 0795.
SUBTASK 72-00-32-420-155 Install the FMU to FDRV Fuel Tube
Refer to Figure.
Lubricate the sealing rings with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 03-498) sealing rings 2 off and the new Control Fuel Tubes (73-11-49, 03-508) sealing ring 1 off to the fuel tube.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new Control Fuel Tubes (73-11-49, 03-508) sealing ring 1 off to the seal housing Control Fuel Tubes (73-11-49, 03-085).
Attach the fuel tube, the seal housing and the bracket Control Fuel Tubes (73-11-49, 03-470) to the FDRV and the IDG FCOC with the two bolts Control Fuel Tubes (73-11-49, 03-514) and the three bolts Control Fuel Tubes (73-11-49, 03-506). Torque the five bolts to 85 to 95 lbf.in (9.60 to 10.73 Nm).
SUBTASK 72-00-32-420-156 Install the IDG FCOC to FDRV Fuel Tube
Refer to Figure.
Safety the nuts of tubes with CoMat 02-147 LOCKWIRE.
SUBTASK 72-00-32-420-157 Connect the Servo Feed FMU to FDRV Fuel Tube and the Servo Return to FDRV Fuel Tube
Refer to Figure
SUBTASK 72-00-32-420-158 Connect the Electrical Connectors
Refer to Figure.
Connect the 4017KS-A electrical connector to the fuel temperature thermocouple FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-100), refer to the view on E.
SUBTASK 72-00-32-420-281-A00 -A1 Series : Connect the Electrical Connector 4017KS-A to the Fuel Temperature Thermocouple
Refer to Figure.
Connect the 4017KS-A electrical connector to the fuel temperature thermocouple FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-100), refer to the view on E.
SUBTASK 72-00-32-420-281-B00 -A5 Series : Connect the Electrical Connector 4017KS-A to the Fuel Temperature Thermocouple (Pre SBE 73-0071 and Pre SBE 71-0183)
Refer to Figure.
Remove the two bolts FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-110) that secure the thermocouple to the FCOC Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-100).

WARNING
WHEN YOU USE CoMat 01-002 SOLVENT, DELETED. YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.Remove the grease, the fingerprints and the unwanted material from the mating surfaces of the ground terminals and thermocouple earth positions with CoMat 01-002 SOLVENT, DELETED.. Use a clean lint free cloth moistened with the solvent.
Install the harness ground terminal connectors to the two bolts FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-110). Install the two bolts FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-110) to secure the thermocouple to the FCOC and torque the bolts to between 85 and 105 lbf.in (10 to 12 Nm). Refer to Figure, view E.

CAUTION
YOU MUST NOT EXCEED THE RECOMMENED TORQUE VALUES. OVER TORQUING CAN RESULT IN FRACTURE OF THE THERMOCOUPLE STUDS.Install channel A and B thermocouple lead assemblies EEC Fan Harness (71-51-41, 04-900) to the fuel temperature thermocouple studs. Install the two nuts FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-140) to the top studs and torque to between 18 and 22 * lbf.in (2.03 to 2.48 Nm). Install the two nuts FUEL TEMPERATURE THERMOCOUPLE (73-35-15, 01-130) to the bottom studs and torque to between 15 and 18 * lbf.in (1.69 to 2,03 Nm). Refer to Figure.
Adjust the harness in the datumn clip position 0295 as necessary to obtain the correct clearance and drip loop. Torque the clip bolt to 36 to 45 lbf.in (4 to 5 Nm), refer to TASK 72-00-32-420-004-B00 (INSTALLATION-004, CONFIG-02.
Connect the terminal connectors to the fuel temperature thermocouple FUEL TEMPERATURE THERMOCOUPLE(73-35-15,01-100), refer to the view at E.
SUBTASK 72-00-32-420-281-C00 -A5 Series : Connect the Electrical Terminal Connector 4017KS-A to the Fuel Temperature Thermocouple (SBE 73-0071 and SBE 71-0183)
Refer to Figure.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-149) sealing ring 1 off to the fuel drain plug Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-147).
Safety the fuel drain plug with CoMat 02-147 LOCKWIRE.
Install the fuel drain plug.
Lubricate the sealing ring with CoMat 10-039 ENGINE OIL.
Install the new Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-159) sealing ring 1 off to the oil drain plug Fuel Cooled Oil Cooler (FCOC) (79-21-43, 01-157).
Safety the fuel drain plug with CoMat 02-147 LOCKWIRE.
Install the oil drain plug.
SUBTASK 72-00-32-420-159 Install the Fuel Drain Plug and the Oil Drain Plug
Refer to Figure.
Make sure that all the applicable backshells and cable clamps are safetied with CoMat 02-126 LOCKWIRE. Refer to the SPM TASK 70-42-05-400-501.
SUBTASK 72-00-32-210-069 Visually Inspect the Electrical Backshells and Cable Clamps
NOTE
Use this procedure to safety the EEC harness backshells and cable clamps with safety cable.Refer to Figure.
Make sure that all the EEC harness backshells and cable clamps are safetied. Safety with CoMat 02-274 SAFETY CABLE KIT or with CoMat 02-275 SAFETY CABLE KIT. Refer to the SPM TASK 70-42-08-400-501.
SUBTASK 72-00-32-210-070 Visually Inspect the EEC Harness (01-005) Electrical Backshells and Cable Clamps (SBE 70-0813)
Figure: Install the FDRV to the FCOC
Install the FDRV to the FCOC

Figure: Connect the fuel tubes
Connect the fuel tubes

Figure: Install the assembly of the FCOC and FDRV
Install the assembly of the FCOC and FDRV

Figure: Install the assembly of the FCOC and the FDRV
Install the assembly of the FCOC and the FDRV

Figure: Connect the oil tubes
Connect the oil tubes

Figure: Install the clips of the FMU to FDRV fuel tube
Install the clips of the FMU to FDRV fuel tube

Figure: Install the clips of the FMU to FDRV fuel tube
Install the clips of the FMU to FDRV fuel tube

Figure: Install the drain plugs and the electrical connectors
Install the drain plugs and the electrical connectors

Figure: Install the drain plugs and the electrical connectors SBE 73-0071 : (A5 Series) Install the electrical connector 4017KS-A
Install the drain plugs and the electrical connectors SBE 73-0071 : (A5 Series) Install the electrical connector 4017KS-A

Figure: Connect the fuel tubes
Connect the fuel tubes

Figure: Visually inspect the backshells and cable clamps
Visually inspect the backshells and cable clamps

