Preliminary Requirements

Procedure

1. SUBTASK 72-42-61-350-068-001 Remove the Damaged Liner Segments

   1. Refer to Figure.

   2. Loosen the liner segment(s) that are in front of the damaged liner segment. Remove and discard the nuts.

      1. Use IAE 3P16240 Igniter guide segment wrench 1 off to remove the nuts on the liner segments located at the igniters.

         Use IAE 3P16241 Ratchet wrench 1 off to remove the nuts at all other locations.

         NOTE

         In some cases, the lip of the bulkhead segment will obstruct the liner segments in Row 1. Do the procedure that follows to remove the damaged obstructed segment.

2. SUBTASK 72-42-61-350-068-002 Remove Damaged Liner Segments in Row 1 that are Obstructed by the Bulkhead Segments

   NOTE

   You can replace the washers with large area work washers before you cut off the studs to protect the liner shell from damage.

   1. Install masking tape on the liner shell around the stud.

      1. Use CoMat 02-024 MASKING TAPE (CREPE PAPERBACKING).

   2. Cut off the studs as close to the liner shell as possible. Be careful not to damage the shell with the cut-off equipment.

      1. Use a hand rotary tool with a cut-off wheel.

   3. Remove the segment. Make a mark at the location of the segment so you can install a repair segment there.

   4. Replace the washers if they were damaged.

3. SUBTASK 72-42-61-220-127 Examine the Shell for Damage

   1. Examine the shell for cracks, burns and wear.

      1. Use a white light and 3X magnifier.

         If there are any cracks or burns, or if the thickness of the shell is less than 0.030in. (0.762 mm), refer to Repair-003, VRS3091 TASK 72-42-61-300-003.

4. SUBTASK 72-42-61-350-069-001 Install the Replacement Liner Segments

   
   CAUTION
   DO NOT USE CoMat 10-049 MOLYBDENUM DISULFIDE TO LUBRICATE THE NUT THREADS. MOLYBDENUM DISULFIDE CAN CAUSE CORROSION. ENGINE OIL IS NOT NECESSARY FOR THIS ASSEMBLY PROCESS.
   
   CAUTION
   DO NOT USE ENGINE OIL AND CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER ON THE SAME STUDS.
   
   CAUTION
   IT IS REQUIRED TO USE CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER ON ROW 1 LINER SEGMENTS AFTER FINAL TORQUE THE NUTS. DO NOT USE CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER ON ALL THE STUD THREADS DURING INSTALLATION.
   
   CAUTION
   CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER IS OPTIONAL ON OTHER LINER SEGMENTS (ROWS 2 THRU 5), HOWEVER, DO NOT USE CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER IF ENGINE OIL WAS ALREADY APPLIED ON THE STUD THREADS.
   
   CAUTION
   IF CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER WAS USED IN LINER SEGMENTS, LIGHTLY USE A STAINLESS STEEL WIRE BRUSH TO REMOVE LOOSE DEBRIS BEFORE NEW COATING.

   1. Refer to Figure, Figure and Figure.

   2. Manually blend the panel and the rail to remove the coating overspray.

      1. Make sure the end rail width is a minimum of 0.025 in. (0.635 mm).

         NOTE

         You can remove the coating overspray from the panel and rails. This will reduce the risk of chipping the coating from the functional panel surface during installation.

   3. Install the replacement liner segments from back to front with washers and new nuts. Replace the nuts on the segment you loosened with new nuts. If the washers have damage, use new washers.

      1. Install oval-shaped washers with dimple facing to the liner shell and seated in slot.

         If engine oil is preferred on Rows 2 thru 5 liner segments, apply engine oil on the stud threads. Do not use engine oil on Row 1 liner segment stud threads.

         Install the nuts with IAE 3P16238 Angle box wrench 1 off.

         Use IAE 3P16240 Igniter guide segment wrench 1 off to install the liner segments at the igniter locations.

         Torque the segment's center stud first followed by the two adjacent studs then the segment's two outer-most studs. Tighten nuts down on the stud between 40 to 50 lbfin (4.519 o 5.649 Nm) of torque and make sure that the washer is not free to move. Back the nut off one-half turn, then use IAE 3P16239 Ratchet wrench 1 off to torque the nut to 25 to 35 lbfin (2.824 to 3.954 Nm).

         Apply CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER on the threaded studs of the Row 1 liner segments, you can use a small artists brush. Full coverage is necessary, but there is no thickness limit. Refer to Figure for coating application.

         If engine oil was not used on liner segments Row 2 thru 5, apply CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER on the threaded studs using a small artist's brush. Complete coverage is necessary but there is no thickness requirement. Refer to Figure as a reference for coating application.

         NOTE

         If the lip of the bulkhead segment obstructs liner segments in Row 1, do the procedure that follows:

5. SUBTASK 72-42-61-350-069-002 Install Repair Liner Segments (01-631 and 01-641) in Row 1

   
   CAUTION
   DO NOT USE CoMat 10-049 MOLYBDENUM DISULFIDE TO LUBRICATE THE NUT THREADS. MOLYBDENUM DISULFIDE CAN CAUSE CORROSION. ENGINE OIL IS NOT NECESSARY FOR THIS ASSEMBLY PROCESS.
   
   CAUTION
   DO NOT USE ENGINE OIL AND CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER ON THE SAME STUDS.
   
   CAUTION
   IT IS REQUIRED TO USE CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER ON ROW 1 LINER SEGMENTS AFTER FINAL TORQUE THE NUTS. DO NOT USE CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER ON ALL THE STUD THREADS DURING INSTALLATION.
   
   CAUTION
   IF CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER WAS USED IN LINER SEGMENTS, LIGHTLY USE A STAINLESS STEEL WIRE BRUSH TO REMOVE LOOSE DEBRIS BEFORE NEW COATING.

   NOTE

   This SUBTASK is for A1 engines only.

   1. Refer to Figure and Figure.

   2. Manually blend the panel and the rail to remove the coating overspray.

      1. Make sure the end rail width is a minimum of 0.025 in. (0.635 mm).

         NOTE

         You can remove the coating overspray from the panel and rails. This will reduce the risk of chipping the coating from the functional panel surface during installation.

   3. Install a repair liner segment at the marked location with washers and new nuts.

      1. Install oval-shaped washers with dimple facing to the liner shell and seated in slot.

         Do not use engine oil on Row 1 liner segment stud threads.

         Install the nuts with IAE 3P16238 Angle box wrench 1 off.

         Turn the nuts down the stud with less than 50 lbfin (5.649 Nm) of torque until the washer and the segment cannot move.

         Back the nut off one-half turn, then use IAE 3P16239 Ratchet wrench 1 off to torque the nut to 25 to 35 lbfin (2.824 to 3.954 Nm).

         Use IAE 3P16240 Igniter guide segment wrench 1 off to install the liner segments at the igniter locations.

         Torque the segment's center stud first followed by the two adjacent studs then the segment's two outer-most studs. Tighten nuts down on the stud between 40 to 50 lbfin (4.519 o 5.649 Nm) of torque and make sure that the washer is not free to move. Back the nut off one-half turn, then use IAE 3P16239 Ratchet wrench 1 off to torque the nut to 25 to 35 lbfin (2.824 to 3.954 Nm).

         Apply CoMat 07-175 COATING COMPOUND - ALUMINUM, INORGANIC BINDER on the threaded studs of the Row 1 liner segments, you can use a small artist's brush. Full coverage is necessary, but there is no thickness limit. Refer to Figure for coating application.

6. SUBTASK 72-42-61-350-070 Determine the Assembly Part Number

   1. Refer to Figure, Figure and Figure to determine the assembly part number.

Figure: Repair Details and Dimensions

Repair Details and Dimensions



Figure: Repair Details and Dimensions

Sheet 1



Legend

Repair Details and Dimensions

Sheet 1

Close

Figure: Repair Details and Dimensions

Sheet 2



Legend

Repair Details and Dimensions

Sheet 2

Close

Figure: Repair Details and Dimensions

Sheet 3



Legend

Repair Details and Dimensions

Sheet 3

Close

Figure: Repair Details and Dimensions

Repair Details and Dimensions



Figure: Repair Details and Dimensions

Repair Details and Dimensions