GEnx-1B SERVICE BULLETIN - 73-0053 R00 Revised: 11/15/2016 GE .

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GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement GEnx-1B SERVICE BULLETIN - 73-0053 R00 SB 73-0053 R00 ENGINE FUEL AND CONTROL - SIGNAL FUEL MANIFOLDS (73-11-40) - FUEL MANIFOLD REPLACEMENT Revised: 11/15/2016 Issued: 11/15/2016 GE PROPRIETARY INFORMATION The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. This technical data is considered EAR controlled pursuant to 15 CFR Parts 730-774 respectively. Transfer of this data by any means to a Non-US Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited. Copyright (2016) General Electric Company, U.S.A. 1. PLANNING INFORMATION A. Effectivity * * * GEnx-1B64, -1B64/P1, -1B64/P2, -1B67, -1B67/P1, -1B67/P2, -1B70, -1B70/75/P1, -1B70/75/P2, -1B70/P1, -1B70/P2, -1B70C/P1, -1B70C/P2, -1B74/75/P1, -1B74/75/P2, -1B76A/P2 This Service Bulletin is applicable to all GEnx-1B engines. The outer left side (LS) signal fuel manifold (fuel manifold) P/N 2403M46G01 with CAGE code 05813 is affected by this Service Bulletin. NOTE: The fuel manifolds replaced by the GEnx-1B S/B 73-0051 and with the "INS", "KB", or "XB" mark already complied with this Service Bulletin. B. Description This Service Bulletin provides instructions to identify and replace the fuel manifold listed in paragraph 1.A., Effectivity. C. Compliance Category 2 GE recommends that you do this Service Bulletin as soon as possible without effect on revenue service but before 60 days from the issue date of this Service Bulletin. Impact A This recommendation is to address a condition that may affect GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 1 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Flight Safety. NOTE: This Service Bulletin can be accomplished on wing or in shop. This Service Bulletin is offered to improve the reliability or performance of your GE product, or to help prevent the occurrence of the event or condition described in this Service Bulletin. If the operator elects not to participate in the bulletin, that decision will be taken into consideration by GE in evaluating future product performance issues that may arise in the operator's fleet. NOTE: GE recommends that you follow your approved extended-range twin-engine operations (ETOPS) maintenance plan regarding dual engine maintenance. D. Concurrent Requirements None. E. Reason (1) Objective: To remove the fuel manifolds that have a potential non-conformance. (2) Condition: A crack in the fuel manifold was found in service. The crack was found in the weld joint between the tee and the pigtail tube, causing a fuel leakage. (3) Cause: The cause of this cracking has been identified as a possible non-conformance on the fuel manifolds with CAGE code 05813. (4) Improvement: Instructions to remove and replace the fuel manifolds that do not have the "KB", "XB", or "INS" mark following CAGE code 05813. (5) Substantiation: Substantiation is by comparative analysis. F. Approval The data contained in this Service Bulletin has been reviewed by the FAA or authorized entity representing the FAA and the repair(s) and modification(s) herein comply with the applicable Aviation Regulations and are APPROVED for installation in the model(s) listed in this Service Bulletin. G. Manpower After you get access to the fuel manifold, you will need approximately 2 man-hours for each engine or component. H. Weight and Balance Weight and balance are not changed. I. References (Use the latest version of these documents) GEnx-1B, Boeing 787 Aircraft Maintenance Manual (AMM) GEK 9250, Commercial Engine Standard Practices Manual (SPM) GEK 112851, GEnx-1B Engine Manual (EM) GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) GEnx-1B S/B 73-0051, ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Visual Inspection of Fuel Manifold Units GEnx-1B S/B 73-0052, ENGINE FUEL AND CONTROL - Fuel Manifolds (73-11-40) - Fuel Manifold Repair NOTE: The reference documents listed below are for the engine manufacturer's internal use only: CID: 575760 J. Publications Affected None. GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 2 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement K. Interchangeability Not applicable. L. Software Accomplishment Summary Not applicable. 2. MATERIAL INFORMATION A. Material - Price and Availability (1) Parts necessary to do this Service Bulletin: None. (2) Other Spare Parts: Qty/ Unit ( ) Part Number Eng Part Name Price Pkg Qty Lead Time Days 2403M46G01 (1) Manifold, Outer LS Signal Fuel 16,010.00 (1) 5 J222P011 (2) Packing, Preformed 113.50 (5) 5 J222P013 (4) Packing, Preformed 1.40 (50) 5 J222P015 (1) Packing, Preformed 1.15 (50) 5 NOTE: Prices are provided for planning purposes and are subject to change. (3) Consumables: Code Number Description C02-023 Oil, Engine Lubricating (engine oil) C02-033 Petrolatum, Soft (petrolatum) C02-058 Compound, Thread Lubricating (lubricant) C10-071 Safety Wire, 0.020 or 0.032 in. dia. (safety wire) C10-143 Safety Cable Assembly (safety cable) B. Industry Support Information Contact your Customer Support Manager (CSM). C. Configuration Chart None. D. Parts Disposition Refer to the GEnx-1B S/B 73-0052 paragraph 2.D., Parts Disposition for the fuel manifold repair instructions. E. Tooling - Price and Availability None. 3. ACCOMPLISHMENT INSTRUCTIONS A. General (1) If the engine is on wing, prepare the aircraft for the fuel manifold (1, Figure 1) inspection as follows: (a) On the pilot's overhead panel, P5, make sure that the applicable ENGINE START switch is in the NORM position. (b) Put a DO NOT OPERATE tag on the applicable ENGINE START switch. (c) On the control stand, P10, make sure that the applicable FUEL CONTROL switch is in the CUTOFF position. (d) Put a DO NOT OPERATE tag on the applicable FUEL CONTROL switch. (e) Open the left and right thrust reversers on the applicable engine as follows: 1 Retract the leading edge slat. Refer to the GEnx-1B, Boeing 787 AMM, 27-81-00, DMC-B787-A-27-81-00-27B-110A-A. GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 3 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement 2 Deactivate the leading edge slat system. Refer to the GEnx-1B, Boeing 787 AMM, 27-81-00, DMC-B787-A-27-81-00-24A-510B-A. 3 Deactivate the thrust reversers. Refer to the GEnx-1B, Boeing 787 AMM, 78-31-00, DMC-B787-AG78-31-00-15H-510B-A. 4 Open the left and right fan cowls. Refer to the GEnx-1B, Boeing 787 AMM, 71-11-04, DMC-B787-AG71-11-04-00B-540A-A. 5 Open the left and right thrust reversers. Refer to the GEnx-1B, Boeing 787 AMM, 78-31-00, DMC-B787-AG78-31-00-15B-540A-A. 6 Install protective covers on the left and right variable frequency starter generator (VFSG) air/oil heat exchangers and the engine air cooled oil cooler (ACOC). (2) If the engine is in shop, do as follows: (a) Before you start this procedure, read the assembly and disassembly techniques section. Refer to the SPM, 70-10-00, ASSEMBLY AND DISASSEMBLY TECHNIQUES. (b) Do a general visual inspection of the engine parts that are exposed during maintenance and all parts that will be installed again. (c) This procedure does not give instructions for the removal or installation of the engine build-up hardware. Refer to the GEnx-1B, Boeing 787 AMM as necessary. B. Visual Inspection and Replacement of Fuel Manifold (1) Do a visual inspection of the fuel manifold (1, Figure 1) to identify the CAGE code and marks as follows: NOTE: The fuel manifold (1) CAGE code can be identified at the process marking. If Fuel Manifold Has CAGE Code 05813? Has "XB" (Figure 2) and (Figure 5), "KB" (Figure 3), or "INS" (Figure 4) Mark? P/N 2403M46G01 Illegible Not applicable Contact your GE Customer Team. P/N 2403M46G01 No Not applicable No further action necessary. P/N 2403M46G01 Yes Yes No further action necessary. P/N 2403M46G01 Yes No Action Replace the fuel manifold (1, Figure 1). Continue with step 3.B.(2).* *For shipping and repair information of the fuel manifold (1), refer to paragraph 2.D., Parts Disposition. (2) Replace the unserviceable fuel manifold (1, Figure 1) as follows: (a) Drain the inner LS signal fuel manifold (inner LS fuel manifold) (2) and the inner right side (RS) signal fuel manifold (inner RS fuel manifold) (3) as follows: NOTE: The fuel manifolds can have a small amount of fuel pressure remaining. 1 Put a 10 gal (38 l) fuel resistant container STD-200 below the two fuel manifold plugs (drain plugs) (8). 2 Remove the drain plugs (8) and drain the fuel. NOTE: The drain plugs (8) are located approximately at the 6:00 o'clock position. 3 Remove and discard the old preformed packings (9). (b) Remove the fuel manifold (1) as follows: 1 Disconnect the B-nut that attaches the signal fuel tube hose (tube hose) (10) to the fuel manifold (1). 2 If it is necessary, remove two of the five clamps (11) that attach the hose tube (10) to the case brackets. Store the clamps (11) for reinstallation. GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 4 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement 3 Remove and discard the preformed packing (12) from the fuel manifold (1) and install the protective covers to all the exposed openings. 4 Disconnect the fuel manifold (1) from the fuel nozzles at positions No. 17 through No. 20. NOTE: The fuel nozzle positions are determined from the top of the vertical centerline aft looking forward (ALF). 5 Remove the three machine bolts (bolts) (4) from the cushioned loop clamps (clamps) (5) that attach the fuel manifold (1) and the inner LS fuel manifold (2). 6 Remove the bolt (6) that attaches the clamp (7) and the fuel manifold (1) to the fuel manifold bracket (01-030, 73-11-30). 7 Carefully rotate and remove the fuel manifold (1, Figure 1) from the engine to avoid any damage of the adjacent hardware. 8 Remove and discard the preformed packings (13) from the four fuel nozzles. 9 Store the remaining hardware in bags and label them for reinstallation. 10 Ship the removed fuel manifold (1) for repair and certification. Refer to paragraph 2.D., Parts Disposition. (c) Install the new fuel manifold (1) as follows: WARNING: REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT. 1 Lubricate the lead-in chamfers of the fuel manifold (1) with C02-033 petrolatum. 2 Lubricate the preformed packing (12) and four preformed packings (13) with C02-033 petrolatum. 3 Install the preformed packing (12) in the fuel manifold (1). 4 Install a preformed packing (13) on each fuel nozzle. 5 Connect the fuel manifold (1) coupling nuts to the fuel nozzles at locations No. 17 through No. 20. Do not torque the fuel manifold (1) coupling nuts at this time. 6 Connect the tube hose (10) B-nut to the fuel manifold (1). Do not torque the tube hose (10) B-nut at this time. 7 Install the clamps (5) and (7) as follows: a Lubricate the bolt (6) and three bolts (4) with C02-058 lubricant. b Install the clamp (7) and bolt (6) to attach the fuel manifold (1) to the fuel manifold bracket (01-030, 73-11-30). Do not torque the bolt (6, Figure 1) at this time. c Install the clamps (5) and bolts (4) to attach the inner LS fuel manifold (2) to the fuel manifold (1). Do not torque the bolts (4) at this time. 8 If the two clamps (11) were removed, install them again to attach the hose tube (10) to the case brackets. CAUTION: USE TWO WRENCHES TO TIGHTEN THE FUEL MANIFOLD (1) COUPLING NUTS. USE ONE TO HOLD THE NIPPLE AND THE OTHER TO TIGHTEN THE COUPLING NUT. IF YOU DO NOT USE TWO WRENCHES, DAMAGE TO THE EQUIPMENT CAN OCCUR. 9 Torque the fuel manifold (1) coupling nuts as follows: a Start at fuel nozzle location No. 17 and torque the fuel manifold (1) coupling nuts at the fuel nozzles locations No. 17 through No. 20, in sequence, to 460 to 540 lb in. (51.9 to 61.0 Nm). b Go back to the fuel nozzle location No. 17 and loosen the four fuel manifold (1) coupling nuts, until the coupling nut is loose. c Start at fuel nozzle location No. 17 and torque again the fuel manifold (1) coupling nuts at the fuel nozzles locations No. 17 through No. 20, in sequence, to 460 to 540 lb in. (51.9 to 61.0 GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 5 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Nm). Start at fuel nozzle location No. 17 and apply the final torque to the fuel manifold (1) coupling nuts at fuel nozzles locations No. 17 through No. 20, in sequence, of 460 to 540 lb in. (51.9 to 61.0 Nm). e Safety the fuel manifold (1) coupling nuts with C10-071 safety wire or C10-143 safety cable. CAUTION: USE TWO WRENCHES TO TIGHTEN THE TUBE HOSE (10) B-NUT. USE ONE TO HOLD THE NIPPLE AND THE OTHER TO TIGHTEN THE B-NUT. IF YOU DO NOT USE TWO WRENCHES, DAMAGE TO THE EQUIPMENT CAN OCCUR. 10 Torque the tube hose (10) B-nut to the fuel manifold (1) as follows: a Torque the tube hose (10) B-nut to the fuel manifold (1) to 55 to 65 lb ft (74.5 to 88.1 Nm). b Loosen the tube hose (10) B-nut. c Torque again the tube hose (10) B-nut to the fuel manifold (1) to 55 to 65 lb ft (74.5 to 88.1 Nm). d Apply a final torque to the tube hose (10) B-nut of 55 to 65 lb ft (74.5 to 88.1 Nm). e Safety the tube hose (10) B-nut with C10-071 safety wire or C10-143 safety cable. 11 Torque the bolts (4) and (6) to 32 to 38 lb in. (3.6 to 4.2 Nm). 12 Install the fuel manifold drain plugs (8) as follows: WARNING: REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT. a Apply C02-023 engine oil to the preformed packings (9). b Apply C02-023 engine oil to the lead-in chamfers of the inner LS fuel manifold (2) and inner RS fuel manifold (3) and to the threads and friction surfaces of the drain plugs (8). c Install the preformed packings (9) on the drain plugs (8). d Install the drain plugs (8) on the inner LS fuel manifold (2) and the inner RS fuel manifold (3). e Torque the drain plugs (8) to 262 to 308 lb in. (29.6 to 34.7 Nm). f Safety the drain plugs (8) with C10-071 safety wire or C10-143 safety cable. d C. Close-Up and Test Procedures (1) If the engine is on wing, put the aircraft back to its usual condition as follows: (a) Close the left and right thrust reversers and fan cowls on the applicable engine as follows: 1 Remove the protective covers from the left and right VFSG air/oil heat exchangers and the ACOC. 2 Close the left and right thrust reversers. Refer to the GEnx-1B, Boeing 787 AMM, 78-31-00, DMC-B787-AG78-31-00-15B-740A-A. 3 Close the left and right fan cowls. Refer to the GEnx-1B, Boeing 787 AMM, 71-11-04, DMC-B787-AG71-11-04-00B-740A-A. (b) Activate the thrust reversers. Refer to the GEnx-1B, Boeing 787 AMM, 78-31-00, DMC-B787-AG78-31-00-15G-730B-A. (c) Activate the leading edge slat system. Refer to the GEnx-1B, Boeing 787 AMM, 27-81-00, DMC-B787-A-27-81-00-24A-730B-A. (d) Remove the DO NOT OPERATE tag from the applicable ENGINE START switch at the pilot's overhead panel P5. (e) Remove the DO NOT OPERATE tag from the applicable FUEL CONTROL switch at the control stand P10. (2) Do a post-maintenance operational check as follows: (a) Do an idle-leak test (Test No. 3). Refer to the GEnx-1B Boeing, 787 AMM, 71-00-00, DMC-B787-A-G71-00-00-12A-364A-A. GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 6 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold Replacement Figure 1 (Sheet 1) GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 7 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold Replacement Figure 1 (Sheet 2) GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 8 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold Replacement Figure 1 (Sheet 3) GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 9 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold Replacement Figure 1 (Sheet 4) GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 10 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold XB Marking Location Figure 2 GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 11 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold KB Marking Location Figure 3 GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 12 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold INS Marking Location Figure 4 GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 13 of 14

GEnx-1B Service Bulletins (SBs) SB 73-0053 R00 ENGINE FUEL AND CONTROL - Signal Fuel Manifolds (73-11-40) - Fuel Manifold Replacement Fuel Manifold XB Marking Location Figure 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the media. GE PROPRIETARY INFORMATION - Not to be used, disclosed to Date Printed: others or reproduced without the express written consent of GE. Technical data is considered ITAR and/or EAR controlled; 2016/12/12 transfer of this data to a Non-US Person, without USG authorization, is strictly prohibited. Page 14 of 14

"KB", or "XB" mark already complied with this Service Bulletin. B. Description This Service Bulletin provides instructions to identify and replace the fuel manifold listed in paragraph 1.A., Effectivity. C. Compliance Category 2 GE recommends that you do this Service Bulletin as soon as possible without effect on revenue service but before 60 days

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