## Alert Service Bulletin B787-81205-SB540004-00 PYLON - General - Pylon Structures - Fuel Leak Path Seal Installation Issue 002, 03 Dec 2015 B787-81205-SB540004-00 Publication:

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 Boeing. Unpublished Work. All rights reserved. Treatment of this data module and its content is governed by contract with Boeing. Rights to use this data module are licensedon a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. EXPORT CONTROLLED Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controllerof this data has the individual responsibility to abide by all export laws. ECCN: 9E991 The applicability information below is referenced at the lower left of each page to indicate the page applicability. These references are valid for this print copy only. PM Applicability (Publication Module applicability) 787-8 Airplanes. Refer to Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1., Effectivity for the list of affected airplanes.

B787-81205-SB540004-00 TITLE PAGE Issue 002, 03 Dec 2015 Page 1 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. 3.0 B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Table of Contents Page Revision Transmittal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 9. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 10. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Installation Requirement Modules Used in the Preparation of this Service Bulletin: . . . 23 11. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 12. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24 13. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . 40 C. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 D. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 5. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . 41 ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 2. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Task 1 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Task 2 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

B787-81205-SB540004-00 TABLE OF CONTENTS Issue 002, 03 Dec 2015 Page 2 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTask 3 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Task 4 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Task 5 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]. . . 109 Task 6 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]. . 125 Task 7 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]. . . 141 Task 8 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]. . 156 Task 9 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Task 10 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Task 11 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]. . 197 Task 12 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]. . 210 Appendix A – INPUT SURVEY [Group 1-6:]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

B787-81205-SB540004-00 TABLE OF CONTENTS Issue 002, 03 Dec 2015 Page 3 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 List of Illustrations
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. 

## Description Group 1-6: Table 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00 Used In ICN B787-A-54-00-0004-00A-931C-D Issue 003 ICN-B787-A-000061-A-81205-07439-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07440-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07441-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07442-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07443-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07444-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07445-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07446-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07447-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07448-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07449-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07450-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003 B787-A-54-00-0004-02A-933B-D Issue 003 B787-A-54-00-0004-03A-933B-D Issue 003 B787-A-54-00-0004-04A-933B-D Issue 003 B787-A-54-00-0004-05A-933B-D Issue 003 B787-A-54-00-0004-06A-933B-D Issue 003 B787-A-54-00-0004-07A-933B-D Issue 003 B787-A-54-00-0004-08A-933B-D Issue 003 B787-A-54-00-0004-09A-933B-D Issue 003 B787-A-54-00-0004-10A-933B-D Issue 003 B787-A-54-00-0004-11A-933B-D Issue 003 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07451-A-01-1

B787-A-54-00-0004-00A-00AA-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 4 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00 Used In ICN B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07452-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07453-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07454-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07455-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07456-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07457-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07458-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07459-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07460-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07461-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07462-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07463-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07464-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07465-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07466-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07467-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07468-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07469-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07470-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07471-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07472-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07473-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07474-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07475-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07476-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07477-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07478-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07479-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07480-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07481-A-01-1

B787-A-54-00-0004-00A-00AA-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 5 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00 Used In ICN B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07482-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07483-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07484-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07485-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07486-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07487-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07488-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07489-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07490-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07491-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07492-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07493-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07494-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07495-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07496-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07497-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07498-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07499-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07500-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07501-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07502-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07503-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07504-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07505-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07506-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07507-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07508-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07509-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07510-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07511-A-01-1

B787-A-54-00-0004-00A-00AA-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 6 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00 Used In ICN B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07512-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07513-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07514-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07515-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07516-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07517-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07518-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07519-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07520-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07521-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07522-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07523-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07524-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07525-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07526-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07527-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07528-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07529-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07530-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07531-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07532-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07533-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07534-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07535-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07536-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07537-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07538-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07539-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07540-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07541-A-01-1

B787-A-54-00-0004-00A-00AA-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 7 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00 Used In ICN B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07542-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07543-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07544-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07545-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07546-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07547-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07548-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07549-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07550-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07551-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07552-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07553-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07554-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07555-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07556-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07557-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07558-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07559-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07560-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07561-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07562-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-11000-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003 ICN-B787-A-000061-A-81205-07564-A-01-1 B787-A-54-00-0004-0AA-931D-D Issue 003 ICN-B787-A-000061-A-81205-07008-A-01-1

B787-A-54-00-0004-00A-00AA-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 8 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 List of Effective Data Modules
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. 

## Description Group 1-6: Table 1 List of Effective Data Modules - Alert Service Bulletin B787-81205-SB540004-00 Issue Date Issue Status Issue Data Module – Information Name 2015-12-03 Changed 003 B787-A-54-00-0004-00A-00AA-D – List of Illustrations 2015-12-03 Changed 003 B787-A-54-00-0004-00A-00SA-D – List of Effective Data Modules 2015-12-03 New 001 B787-A-54-00-0004-00A-931B-D – Revision Transmittal Information 2015-12-03 Changed 003 B787-A-54-00-0004-00A-931C-D – Summary 2015-12-03 Changed 003 B787-A-54-00-0004-00A-932A-D – PLANNING INFORMATION 2015-12-03 Changed 003 B787-A-54-00-0004-00A-934A-D – MATERIAL INFORMATION 2015-12-03 Changed 003 B787-A-54-00-0004-00A-933A-D – ACCOMPLISHMENT INSTRUCTIONS 2015-12-03 Changed 003 B787-A-54-00-0004-01A-933B-D – Task 1 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ] 2015-12-03 Changed 003 B787-A-54-00-0004-02A-933B-D – Task 2 – RIGHT ROLLS ROYCE EN- GINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ] 2015-12-03 Changed 003 B787-A-54-00-0004-03A-933B-D – Task 3 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ] 2015-12-03 Changed 003 B787-A-54-00-0004-04A-933B-D – Task 4 – RIGHT ROLLS ROYCE EN- GINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ] 2015-12-03 Changed 003 B787-A-54-00-0004-05A-933B-D – Task 5 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ] 2015-12-03 Changed 003 B787-A-54-00-0004-06A-933B-D – Task 6 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ] 2015-12-03 Changed 003 B787-A-54-00-0004-07A-933B-D – Task 7 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]

B787-A-54-00-0004-00A-00SA-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 9 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 List of Effective Data Modules - Alert Service Bulletin B787-81205-SB540004-00 Issue Date Issue Status Issue Data Module – Information Name 2015-12-03 Changed 003 B787-A-54-00-0004-08A-933B-D – Task 8 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ] 2015-12-03 Changed 003 B787-A-54-00-0004-09A-933B-D – Task 9 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ] 2015-12-03 Changed 003 B787-A-54-00-0004-10A-933B-D – Task 10 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ] 2015-12-03 Changed 003 B787-A-54-00-0004-11A-933B-D – Task 11 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ] 2015-12-03 Changed 003 B787-A-54-00-0004-12A-933B-D – Task 12 – RIGHT GE ENGINE IN- BOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ] 2015-12-03 Changed 003 B787-A-54-00-0004-0AA-931D-D – Appendix A – INPUT SURVEY [Group 1-6:]

B787-A-54-00-0004-00A-00SA-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 10 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Revision Transmittal Information
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference Airplanes SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 1.A. Compliance SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 5. Material - Price and Availability SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 1. Kits/Parts SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 3.A. Parts and Materials Supplied by the Operator SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 3.B. Alert Service Bulletin B787-81205-SB540004-00 – Task 1 – LEFT ROLLS SB B787-A-54-00-0004-01A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 2 – RIGHT ROLLS SB B787-A-54-00-0004-02A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 12 – RIGHT GE SB B787-A-54-00-0004-12A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ] 

## Description Group 1-6: This revision includes all pages of the service bulletin.

B787-A-54-00-0004-00A-931B-D Applicable To: Issue 001, 03 Dec 2015 Model 787 See Applicability of this data module Page 11 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD is related to this service bulletin. Effects of this revision on Airplanes on which Issue 001 was previously done: None 2. REASON FOR REVISION This issue is sent to remove airplanes ZD001-ZD009 and ZA151 from the list of airplanes affected by this service bulletin. These airplanes, which are affected by the Issue 001 of this service bulletin, will receive the intent of the change contained in this service bulletin in production. In addition, this issue clarifies instructions as a result of feedback reported by operators after incorporation of the Issue 001 of this service bulletin on their fleet. These sections were changed: 1. Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1.A., Airplanes - Removed airplanes ZD001-ZD009 and ZA151 from the list of airplanes affected by this service bulletin. 2. Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 5., Compliance - Added reference ofFederal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD to the compliance section of this service bulletin.3. Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 1., Material - Price and Availability - Updated the Price and Availability data for the Top Kits. 4. Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 3.A., Kits/Parts - Added Washer NAS1149V0363M to the list of parts required for this change and clarified the name of all Sub Kits. 5. Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 3.B., Parts and Materials Supplied by the Operator - Added new footnote for BMS 1-68 Silicone Foam Rubber Sealant to direct operators to the task table for more information on its usage. 6. Data Module Task 1, SB B787-A-54-00-0004-01A-933B-D - Re-Sequenced the numbers of the footnotes to match correct steps in Task table. 7. Data Module Task 2, SB B787-A-54-00-0004-02A-933B-D - Re-Sequenced the numbers of the footnotes and the reference in the More Data Column to match correct steps in Task table. 8. Data Module Task 12, SB B787-A-54-00-0004-12A-933B-D - Corrected an error with a circle note in figure 8 of Task 12. Circle Note 18 called out in the SB is an error and should be Circle Note 17 Change marks are added, except in Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1.A., Airplanes and format changes, to show the location of all content changes. 3. REVISION HISTORY Table 1 October 24, 2014 Issue 1: December 03, 2015 Issue 2:

B787-A-54-00-0004-00A-931B-D Applicable To: Issue 001, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 12 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Summary

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference Spares Affected SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 1.B. Compliance SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 5. Weight and Balance Changes SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 8. Electrical Load Data SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 9. Publications Affected SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 11. Kits/Parts SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 3.A. Parts and Materials Supplied by the Operator SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 3.B. Special Tooling Necessary to do this Service Bulletin SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 6. Effectivity SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 1. Industry Support Information SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 2. Manpower SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 7. Material - Price and Availability SB B787-A-54-00-0004-00A-934A-D Issue 003, Paragraph 1.

B787-A-54-00-0004-00A-931C-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 13 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Description Group 1-6: 1. CONCURRENT REQUIREMENTS None. 2. BACKGROUND This Service Bulletin gives instructions to install a Seal Dam at the inboard and outboard corners of the aft pylon compartment. An earlier failure on a flexible coupling installed in the leading edge led to a leakage of fuel into this cavity. If the change given in this service bulletin is not accomplished, an un-intended drain path would exist which could result in fuel leaking onto the hot exhaust portion of an engine and a consequent fire. During operations, one operator discovered fuel leaking onto the hot exhaust portion of the engine. The fuelleakage was as a result of a failure of a flexible coupling installation in the wing leading edge. During an investigation, it was determined that the pylon to wing interface design did not address drain paths for potential low flow leakage rates. This caused the un-intended leak path from the leading edge through the pylons and onto the hot exhaust part of the engines. Boeing Service Related Problem (SRP) 787-SRP-54-0144 is related to this service bulletin. As a part of a service bulletin validation program, this change was completed on airplane ZA117 by Service Bulletin 787-54A0004 VC 1 before Issue 001 of this service bulletin. The change completed on airplane ZA117 by Service Bulletin 787-54A0004 VC 1 is equivalent to Issue 001 of this service bulletin. Airplane ZA117 has the configuration of a Group 2 airplane.This table is provided to operators for planning purposes only. Refer to the applicable sections for more information. Table 1 Data Module Reference Affected Planning Data Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 1.B., Spares Affected No Spares Affected
Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 5., Compliance Yes AD Related
Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 8., Weight and Balance Changes Yes Weight and Balance Changed
Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 9., Electrical Load Data No Electrical Load Changed
Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 11., Publications Affected Yes Publications Affected
Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 11., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Data Module SB B787-A-54-00-0004-00A-934AD, Paragraph 3.A., Kits/Parts Yes Kits/Parts Required

B787-A-54-00-0004-00A-931C-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 14 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 Data Module Reference Affected Planning Data Data Module SB B787-A-54-00-0004-00A-934AD, Paragraph 3.B., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material

Data Module SB B787-A-54-00-0004-00A-934AD, Paragraph 6., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

3. ACTION (CN-AA39164L) Remove the left and right inboard and outboard pylon underwing panels and install new Seal Dams in the inboard and outboard corners of the Aft Pylon frame. Install the left and right inboard and outboard underwing panels. 4. EFFECTIVITY 787-8 Airplanes. Refer to Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1., Effectivity for the list of affected airplanes. 5. COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD is related to this service bulletin. Boeing recommends that the change given in this service bulletin be done within 60 months after the Issue 001 date of this service bulletin. 6. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of December 20, 2012. Please refer to Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 2., Industry Support Information. The warranty remedies will expire eight years from the original release date of this service bulletin. 7. MANPOWER Refer to Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 7., Manpower. 8. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 1., Material - Price and Availability. Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

B787-A-54-00-0004-00A-931C-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 15 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07439-A-01-1 Figure 1

B787-A-54-00-0004-00A-931C-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 16 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 PLANNING INFORMATION

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED Alert: OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
GENERAL CLEANING PROCEDURES SOPM 20-30-03 BOLT AND NUT INSTALLATION SOPM 20-50-01 APPLICATION OF ADHESIVES SOPM 20-50-12 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
GENERAL SEALING SOPM 20-50-19 Standard Wiring Practices Manual SWPM 20-10-11 Standard Wiring Practices Manual SWPM 20-10-12 Standard Wiring Practices Manual SWPM 20-10-19 

## Description Group 1-6:

1. Effectivity A. Airplanes This service bulletin is applicable to 787-8 Airplanes, line numbers 6-125, 127-132, 134-138,140-145,147-168, 170-180, 182-196. in 6 Group(s). The Variable Numbers and Group information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to CN-AA39164 for data about this change.

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 17 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 DESCRIPTION CONFIGURATION GROUP 787 Airplanes with Rolls Royce Engine that have a non trimmed one piece Bulb Seal Retainer configuration. - 1 787 Airplanes with Rolls Royce Engine that have a non trimmed two piece Bulb Seal Retainer configuration. - 2 787 Airplanes with GE Engine that have a non trimmed one piece Bulb Seal Retainer configuration. - 3 787 Airplanes with GE Engine that have a non trimmed two piece Bulb Seal Retainer configuration. - 4 787 Airplanes with Rolls Royce Engine that have a trimmed Bulb Seal Retainer configuration. - 5 787 Airplanes with GE Engine that have a trimmed Bulb Seal Retainer configuration. - 6
Airplane Models: 787-8 Table 2 Group Variable Number 3 ZA006 1 ZA100-ZA103 2 ZA104-ZA105 2 ZA116-ZA123 5 ZA124 2 ZA135 5 ZA136 3 ZA175-ZA177 4 ZA178-ZA187 6 ZA188-ZA189 4 ZA215-ZA217 6 ZA218-ZA220 4 ZA230-ZA243 6 ZA244-ZA245 4 ZA260-ZA264 6 ZA265-ZA268 2 ZA270-ZA274

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 18 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 Group Variable Number 5 ZA275 4 ZA285-ZA294 6 ZA295 4 ZA317-ZA320 6 ZA321 4 ZA327 6 ZA334 4 ZA380-ZA387 6 ZA388-ZA389 4 ZA430-ZA435 6 ZA436-ZA437 2 ZA445-ZA446 5 ZA447-ZA448 2 ZA450-ZA453 5 ZA454-ZA456 4 ZA460-ZA471 6 ZA472-ZA474 2 ZA506-ZA515 5 ZA516 2 ZA536-ZA540 5 ZA541-ZA542 4 ZA560-ZA563 6 ZA564-ZA565 2 ZA576-ZA577 5 ZA578-ZA580 4 ZA586 5 ZA588 6 ZA610-ZA612 2 ZA650 5 ZA651

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 19 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 Group Variable Number 6 ZA655-ZA657 6 ZA695 5 ZA778-ZA779 1 ZD002 B. Spares Affected None. 2. Concurrent Requirements None. 3. Reason This Service Bulletin gives instructions to install a Seal Dam at the inboard and outboard corners of the aft pylon compartment. An earlier failure on a flexible coupling installed in the leading edge led to a leakage of fuel into this cavity. If the change given in this service bulletin is not accomplished, an un-intended drain path would exist which could result in fuel leaking onto the hot exhaust portion of an engine and a consequent fire. During operations, one operator discovered fuel leaking onto the hot exhaust portion of the engine. The fuel leakage was as a result of a failure of a flexible coupling installation in the wing leading edge. During an investigation, it was determined that the pylon to wing interface design did not address drain paths for potential low flow leakage rates. This caused the un-intended leak path from the leading edge through the pylons and onto the hot exhaust part of the engines. Boeing Service Related Problem (SRP) 787-SRP-54-0144 is related to this service bulletin. As a part of a service bulletin validation program, this change was completed on airplane ZA117 by Service Bulletin 787-54A0004 VC 1 before Issue 001 of this service bulletin. The change completed on airplane ZA117 by Service Bulletin 787-54A0004 VC 1 is equivalent to Issue 001 of this service bulletin. Airplane ZA117 has the configuration of a Group 2 airplane. Issue 002 is sent to remove airplanes ZD001-ZD009 and ZA151 from the list of airplanes affected by this service bulletin. These airplanes will receive the intent of the change contained in this service bulletin in production. In addition, this issue clarifies instructions as a result of feedback reported by operators after incorporation of the Issue 001 of this service bulletin on their fleet. 4. Description Remove the left and right inboard and outboard pylon underwing panels and install new Seal Dams in the inboard and outboard corners of the Aft Pylon frame. Install the left and right inboard and outboard underwing panels. Effects of this revision on Airplanes on which Issue 001 was previously done: None

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 20 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINThe work in this service bulletin is done in the maintenance zone(s) given below. Table 3 Affected Maintenance Zones Zone Model 434, 444 787-8 5. Compliance Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD, is related to this service bulletin. Boeing recommends that the change given in this service bulletin be done within 60 months after the Issue 001 date of this service bulletin. 6. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as EuropeanAviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. 7. Manpower The table below shows an estimate of the task hours necessary to do this change for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: – Time to adjust to the workplace – Time to schedule the work – Time to inspect the work – Time to cure the materials – Time to make the parts – Time to find the tools Group 1: Table 4 Elapsed Hours Task Hours Number of Per- sons Task
5.50 11.00 2 Work Package A 5.50 11.00 2 Work Package B 11.00 22.00 TOTAL FOR EACH AIRPLANE

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 21 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINGroup 2: Table 5 Elapsed Hours Task Hours Number of Per- sons Task
4.50 9.00 2 Work Package C 4.50 9.00 2 Work Package D 9.00 18.00 TOTAL FOR EACH AIRPLANE Group 5: Table 6 Elapsed Hours Task Hours Number of Per- sons Task
3.25 6.50 2 Work Package E 3.25 6.50 2 Work Package F 6.50 13.00 TOTAL FOR EACH AIRPLANE Group 3: Table 7 Elapsed Hours Task Hours Number of Per- sons Task
5.50 11.00 2 Work Package G 5.50 11.00 2 Work Package H 11.00 22.00 TOTAL FOR EACH AIRPLANE Group 4: Table 8 Elapsed Hours Task Hours Number of Per- sons Task
4.50 9.00 2 Work Package I 4.50 9.00 2 Work Package J 9.00 18.00 TOTAL FOR EACH AIRPLANE Group 6: Table 9 Elapsed Hours Task Hours Number of Per- sons Task
3.25 6.50 2 Work Package K 3.25 6.50 2 Work Package L 6.50 13.00 TOTAL FOR EACH AIRPLANE

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 22 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINGroup 1-6: 8. Weight and Balance Changes Table 10 Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane
+ 1,313.0 + 1.5 All Airplanes
9. Electrical Load Data Not changed. 10. References A. Existing Data: 1. Change Notice CN-AA39164C and CN-AA39164L 2. Standard Overhaul Practices Manual (SOPM) SOPM 20-11-03, SOPM 20-30-03, SOPM 20-50- 01, SOPM 20-50-12, SOPM 20-50-18, SOPM 20-50-19 3. Standard Wiring Practices Manual (SWPM) SWPM 20-10-11, SWPM 20-10-12, SWPM 20-10-19 4. Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD is related to this service bulletin. B. Data Supplied with this Service Bulletin: None. C. Installation Requirement Modules Used in the Preparation of this Service Bulletin: Table 11 Title Requirement Mod- ule UNDERWING FAIRING INSTALLATION REWORK 715Z3201-17 UNDERWING FAIRING INSTALLATION REWORK 715Z3201-18 UNDERWING FAIRING INSTALLATION REWORK 715Z3201-21 UNDERWING FAIRING INSTALLATION REWORK 715Z3201-22 UNDERWING FAIRINGS - RECONCILIATION IRM 715Z3201-23 UNDERWING FAIRINGS - RECONCILIATION IRM 715Z3201-24 UNDERWING FAIRING INSTALLATION 715Z3201-25 UNDERWING FAIRING INSTALLATION 715Z3201-26 UNDERWING FAIRINGS - RECONCILIATION IRM 715Z3201-29 UNDERWING FAIRINGS - RECONCILIATION IRM 715Z3201-30 UNDERWING FAIRING INSTALLATION 715Z3201-55

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 23 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 11 Title Requirement Mod- ule UNDERWING FAIRING INSTALLATION 715Z3201-56 UNDERWING FAIRING INSTALLATION 715Z3201-57 UNDERWING FAIRING INSTALLATION 715Z3201-58 The Requirements Modules above were used to prepare this service bulletin. The Requirements Modules are not necessary to make the specified changes, and are not supplied with this service bulletin. The Requirements Modules may not be applicable to all airplane configurations or operators. 11. Publications Affected Table 12Chapter-Section Publication 54-64 787 Maintenance Manual 54-62, ZA4-31, ZA4-41 787 Illustrated Parts Data Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary. 12. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. 13. Software Accomplishment Summary Not Affected.

B787-A-54-00-0004-00A-932A-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 24 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 MATERIAL INFORMATION

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference Work Instructions SB B787-A-54-00-0004-00A-933A-D Issue 003, Step 2. References SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 10. 

## Description Group 1-6: 1. Material - Price and AvailabilityBoeing can supply the kits shown in Paragraph 3., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION. Group 1: Table 1 Unit Price as of the Issue 001 date ofthis Service Bulletin (US Dollars)ROLT as of the Issue 001 date of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

14,490.00 286 13 October 14, 2014 PYLON FUEL LEAKAGE SEAL INSTALLATION 036Z0136-5

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 25 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINGroup 2: Table 2 Unit Price as of the Issue 001 date ofthis Service Bulletin (US Dollars)ROLT as of the Issue 001 date of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

8,586.00 216 40 October 14, 2014 PYLON FUEL LEAKAGE SEAL INSTALLATION 036Z0136-6

Group 3: Table 3 Unit Price as of the Issue 001 date ofthis Service Bulletin (US Dollars)ROLT as of the Issue 001 date of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

14,490.00 286 6 October 14, 2014 PYLON FUEL LEAKAGE SEAL INSTALLATION 036Z0136-7

Group 4: Table 4 Unit Price as of the Issue 001 date ofthis Service Bulletin (US Dollars)ROLT as of the Issue 001 date of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

8,586.00 216 78 December 18, 2014 PYLON FUEL LEAKAGE SEAL INSTALLATION 036Z0136-8

Group 5: Table 5 Unit Price as of the Issue 001 date ofthis Service Bulletin (US Dollars)ROLT as of the Issue 001 date of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

5,272.00 204 18 September 19, 2014 PYLON FUEL LEAKAGE SEAL INSTALLATION 036Z0136-9

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 26 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINGroup 6: Table 6 Unit Price as of the Issue 001 date ofthis Service Bulletin (US Dollars)ROLT as of the Issue 001 date of this Service Bulletin (Calendar Days) QTY Date Name Kit Number

5,272.00 204 30 September 19, 2014 PYLON FUEL LEAKAGE SEAL INSTALLATION 036Z0136-10

Group 1-6: Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. 2. Industry Support Information Boeing warranty remedies are available for 787 airplanes in warranty as of December 20, 2012. For task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Fleet Support Contracts - Warranty. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Material Management. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight years from the original release date of this service bulletin. 3. Parts Necessary for Each Airplane A. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 1., Material - Price and Availability. NOTE: One top kit and the items shown in Paragraph 3.B., Parts and Materials Supplied by the Operator, are necessary for each airplane. Table 7 Kit 036Z0136 Notes Existing Part Number Name QTY New Part Number -10 -9 -8 -7 -6 -5 SERVICE BULLETIN TOP KIT - PYLON FUEL LEAKAGE SEAL INSTALLATION . . . . . - 036Z0136-5

SERVICE BULLETIN TOP KIT - PYLON FUEL LEAKAGE SEAL INSTALLATION . . . . - . 036Z0136-6

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 27 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 7 Kit 036Z0136 Notes Existing Part Number Name QTY New Part Number -10 -9 -8 -7 -6 -5 SERVICE BULLETIN TOP KIT - PYLON FUEL LEAKAGE SEAL INSTALLATION . . . - . . 036Z0136-7

SERVICE BULLETIN TOP KIT - PYLON FUEL LEAKAGE SEAL INSTALLATION . . - . . . 036Z0136-8

SERVICE BULLETIN TOP KIT - PYLON FUEL LEAKAGE SEAL INSTALLATION . - . . . . 036Z0136-9

SERVICE BULLETIN TOP KIT - PYLON FUEL LEAKAGE SEAL INSTALLATION - . . . . . 036Z0136-10

This Kit is used on the InboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . 1

. . 711Z1002-1

This Kit is used on the InboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . 1

. . 711Z1002-2

This Kit is used on the InboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . 1

. . . 711Z1002-3

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 28 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 7 Kit 036Z0136 Notes Existing Part Number Name QTY New Part Number -10 -9 -8 -7 -6 -5 This Kit is used on the InboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . 1

. . . 711Z1002-4

This Kit is used on theOutboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . 1

. . 711Z1002-5

This Kit is used on theOutboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . 1

. . 711Z1002-6

This Kit is used on theOutboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . 1

. . . 711Z1002-7

This Kit is used on theOutboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . 1

. . . 711Z1002-8

This Kit is used on the InboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD 1

. . . . . 711Z1002-9

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 29 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 7 Kit 036Z0136 Notes Existing Part Number Name QTY New Part Number -10 -9 -8 -7 -6 -5 This Kit is used on the InboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD 1

. . . . . 711Z1002-10

This Kit is used on theOutboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD 1

. . . . . 711Z1002-11

This Kit is used on theOutboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD 1

. . . . . 711Z1002-12

This Kit is used on the InboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . . 1 715Z1002-1

This Kit is used on the InboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . . 1 715Z1002-2

This Kit is used on the InboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . 1

. 715Z1002-3

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 30 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 7 Kit 036Z0136 Notes Existing Part Number Name QTY New Part Number -10 -9 -8 -7 -6 -5 This Kit is used on the InboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . 1

. 715Z1002-4

This Kit is used on theOutboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . . 1 715Z1002-5

This Kit is used on theOutboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . . 1 715Z1002-6

This Kit is used on theOutboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . 1

. 715Z1002-7

This Kit is used on theOutboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . 1

. 715Z1002-8

This Kit is used on the InboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . 1

. . . . 715Z1002-9

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 31 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 7 Kit 036Z0136 Notes Existing Part Number Name QTY New Part Number -10 -9 -8 -7 -6 -5 This Kit is used on the InboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, INBOARD . 1

. . . . 715Z1002-10

This Kit is used on theOutboardLH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . 1

. . . . 715Z1002-11

This Kit is used on theOutboardRH Pylon. RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . 1

. . . . 715Z1002-12

Table 8 Kit 711Z1002 Notes Existing Part Number Name QTY New Part Number -6 -5 -4 -3 -2 -1 RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . . - 711Z1002-1

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . - . 711Z1002-2

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . - . . 711Z1002-3

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . - . . . 711Z1002-4

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 32 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 8 Kit 711Z1002 Notes Existing Part Number Name QTY New Part Number -6 -5 -4 -3 -2 -1 RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . - . . . . 711Z1002-5

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD - . . . . . 711Z1002-6

SEAL

. . . 1

. 1 710Z3443-1 SEAL

. . 1

. 1

. 710Z3443-2 SEAL

. 1

. . . . 711Z3443-1 SEAL 1

. . . . . 711Z3443-2 *[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . 1

. . . . 715Z3213-3

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD 1

. . . . . 715Z3213-4

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . 1

. . . . 715Z3213-7

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD 1

. . . . . 715Z3213-8

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . . . . 1 715Z3233-3

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . . . 1

. 715Z3233-4

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 33 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 8 Kit 711Z1002 Notes Existing Part Number Name QTY New Part Number -6 -5 -4 -3 -2 -1 *[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . . 1

. 1 715Z3233-7

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . 1

. 1

. 715Z3233-8

*[1] *[2] Seal, MID-SPRT

. 1 1

. 1

. 715Z3443-9 *[1] *[2] Seal-MID-SPRT 1

. . 1

. 1 715Z3443-9 *[1] *[2] *[3] BOLT, 100 DEG TENSION HEAD, HEX DRIVE, 160 KSI MIN TENSILE, 6AL-4V TITANIUM (NOM 20 20 11 10 20 20 BACB30NY5HK6

*[1] *[2] NUT, SELF- LOCKING, HEXAGON,COUNTERBORED, ALUMINUM ALLOY 20 20 11 10 20 20 BACN10XJ08

*[1] *[2] WASHER, FLAT

. . 1 1 1 1 NAS1149V0363M *[1] Discard the existing part. *[2] You cannot use the existing part to replace the new or changed part. *[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits.

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 34 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 9 Kit 711Z1002 Notes Existing Part Number Name QTY New Part Number -12 -11 -10 -9 -8 -7 RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . . - 711Z1002-7

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . - . 711Z1002-8

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . - . . 711Z1002-9

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . - . . . 711Z1002-10

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . - . . . . 711Z1002-11

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD - . . . . . 711Z1002-12

SEAL

. . . 1

. . 710Z3443-1 SEAL

. . 1

. . . 710Z3443-2 SEAL

. 1

. . . 1 711Z3443-1 SEAL 1

. . . 1

. 711Z3443-2 *[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . . . . . 1 715Z3213-7

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . . . . 1

. 715Z3213-8

*[1] *[2] Seal, MID-SPRT

. 1 1

. . 1 715Z3443-9 *[1] *[2] Seal-MID-SPRT 1

. . 1 1

. 715Z3443-9

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 35 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 9 Kit 711Z1002 Notes Existing Part Number Name QTY New Part Number -12 -11 -10 -9 -8 -7 *[1] *[2] *[3] BOLT, 100 DEG TENSION HEAD, HEX DRIVE, 160 KSI MIN TENSILE, 6AL-4V TITANIUM (NOM . . . . 20 11 BACB30NY5HK6

*[1] *[2] NUT, SELF- LOCKING, HEXAGON,COUNTERBORED, ALUMINUM ALLOY . . . . 20 11 BACN10XJ08

*[1] Discard the existing part. *[2] You cannot use the existing part to replace the new or changed part. *[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Table 10 Kit 715Z1002 Notes Existing Part Number Name QTY New Part Number -6 -5 -4 -3 -2 -1 RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . . - 715Z1002-1

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . . - . 715Z1002-2

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . - . . 715Z1002-3

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . - . . . 715Z1002-4

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . - . . . . 715Z1002-5

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 36 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 10 Kit 715Z1002 Notes Existing Part Number Name QTY New Part Number -6 -5 -4 -3 -2 -1 RETROFIT KIT - PYLON SEAL DAM, OUTBOARD - . . . . . 715Z1002-6

SEAL

. . . 1

. 1 710Z3443-1 SEAL

. . 1

. 1

. 710Z3443-2 *[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . 1

. . . . 715Z3213-3

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD 1

. . . . . 715Z3213-4

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . 1

. . . . 715Z3213-7

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD 1

. . . . . 715Z3213-8

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . . . . 1 715Z3233-3

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . . . 1

. 715Z3233-4

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . . 1

. 1 715Z3233-7

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, INBOARD . . 1

. 1

. 715Z3233-8

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 37 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 10 Kit 715Z1002 Notes Existing Part Number Name QTY New Part Number -6 -5 -4 -3 -2 -1 *[1] *[2] Seal, MID-SPRT

. 1 1

. 1

. 715Z3443-9 SEAL

. 1

. . . . 715Z3443-11 SEAL 1

. . . . . 715Z3443-12 *[1] *[2] Seal-MID-SPRT 1

. . 1

. 1 715Z3443-9 *[1] *[2] *[3] BOLT, 100 DEG TENSION HEAD, HEX DRIVE, 160 KSI MIN TENSILE, 6AL-4V TITANIUM (NOM 20 20 11 11 20 20 BACB30NY5HK6

*[1] *[2] NUT, SELF- LOCKING, HEXAGON,COUNTERBORED, ALUMINUM ALLOY 20 20 11 11 20 20 BACN10XJ08

*[1] *[2] WASHER, FLAT

. . 1 1 1 1 NAS1149V0363M *[1] Discard the existing part. *[2] You cannot use the existing part to replace the new or changed part. *[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Table 11 Kit 715Z1002 Notes Existing Part Number Name QTY New Part Number -12 -11 -10 -9 -8 -7 RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . . - 715Z1002-7

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . . . . - . 715Z1002-8

RETROFIT KIT - PYLON SEAL DAM, INBOARD . . . - . . 715Z1002-9

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 38 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 11 Kit 715Z1002 Notes Existing Part Number Name QTY New Part Number -12 -11 -10 -9 -8 -7 RETROFIT KIT - PYLON SEAL DAM, INBOARD . . - . . . 715Z1002-10

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD . - . . . . 715Z1002-11

RETROFIT KIT - PYLON SEAL DAM, OUTBOARD - . . . . . 715Z1002-12

SEAL

. . . 1

. . 710Z3443-1 SEAL

. . 1

. . . 710Z3443-2 *[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . . . . . 1 715Z3213-7

*[1] *[2] RETAINER -SEAL, UNDERWING FAIRING, OUTBOARD . . . . 1

. 715Z3213-8

*[1] *[2] Seal, MID-SPRT

. 1 1

. . 1 715Z3443-9 *[1] *[2] SEAL

. 1

. . . 1 715Z3443-11 *[1] *[2] SEAL 1

. . . 1

. 715Z3443-12 *[1] *[2] Seal-MID-SPRT 1

. . 1 1

. 715Z3443-9 *[1] *[2] *[3] BOLT, 100 DEG TENSION HEAD, HEX DRIVE, 160 KSI MIN TENSILE, 6AL-4V TITANIUM (NOM . . . . 20 20 BACB30NY5HK6

*[1] *[2] NUT, SELF- LOCKING, HEXAGON,COUNTERBORED, ALUMINUM ALLOY . . . . 20 20 BACN10XJ08

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 39 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 11 Kit 715Z1002 Notes Existing Part Number Name QTY New Part Number -12 -11 -10 -9 -8 -7 *[1] Discard the existing part. *[2] You cannot use the existing part to replace the new or changed part. *[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. B. Parts and Materials Supplied by the Operator: Table 12 Notes Name QTY Part Number / Specification *[1] ADHESIVE As Re- quired Type 68
*[1] ADHESIVE As Re- quired Type 60
*[1] SEALANT As Re- quired BMS 5-63 TYPE II *[1] SEALANT As Re- quired BMS 5-45 Class B-1/2 *[1] CORROSION INHIBITING COM- POUNDAs Required BMS 3-38
*[1] *[2] SILICONE FOAM RUBBER SEALANTAs Required BMS 1-68 Grade A, Form III *[1] See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. *[2] Requirement and Dimensions for Sealant tape can be found in the Task Tables in Data Module SB B787-A-54-00- 0004-00A-933A-D, Step 2., Work Instructions. C. Parts Modified and Reidentified: None D. Parts Removed and Not Replaced: None 4. Parts Necessary to Change Spares None. 5. Special Tooling - Price and Availability None.

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 40 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN6. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 10., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

B787-A-54-00-0004-00A-934A-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 41 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 ACCOMPLISHMENT INSTRUCTIONS

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference References SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 10. Manpower SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 7. Compliance SB B787-A-54-00-0004-00A-932A-D Issue 003, Paragraph 5. Alert Service Bulletin B787-81205-SB540004-00 – Task 1 – LEFT ROLLS SB B787-A-54-00-0004-01A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 2 – RIGHT ROLLS SB B787-A-54-00-0004-02A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 3 – LEFT ROLLS SB B787-A-54-00-0004-03A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 4 – RIGHT ROLLS SB B787-A-54-00-0004-04A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 9 – LEFT ROLLS SB B787-A-54-00-0004-09A-933B-D Issue 003 ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 10 – RIGHT SB B787-A-54-00-0004-10A-933B-D Issue 003

B787-A-54-00-0004-00A-933A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 42 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTitle Reference ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 5 – LEFT GE SB B787-A-54-00-0004-05A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 6 – RIGHT GE SB B787-A-54-00-0004-06A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 7 – LEFT GE SB B787-A-54-00-0004-07A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 8 – RIGHT GE SB B787-A-54-00-0004-08A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 11 – LEFT GE SB B787-A-54-00-0004-11A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ] Alert Service Bulletin B787-81205-SB540004-00 – Task 12 – RIGHT GE SB B787-A-54-00-0004-12A-933B-D Issue 003 ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ] BOLT AND NUT INSTALLATION SOPM 20-50-01 

## Procedure Group 1-6: 1. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Data Module SB B787-A-54-00-0004-00A932A-D, Paragraph 10., References, for definition of the acronyms.

B787-A-54-00-0004-00A-933A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 43 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN2. Obey all of the warnings and cautions given in the specified manual sections. 3. The work instructions are divided into work packages. Task Hours and Elapsed Hours for each package are given in Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 7., Manpower. You can do each work package independently. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in SRM Chapter 51 – Torque Values: – Values for structural fasteners are given in 787 Structural Repair Manual, Chapter 51.– Values for airframe maintenance tasks are included in Chapter 20 of 787 Aircraft Maintenance Manual (AMM). – Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).– Values for engine maintenance tasks are included in Chapter 70 of 787 Aircraft Maintenance Manual (AMM).– Non-standard torque values for maintenance tasks are included in the applicable installation step. 5. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 6. If the length of any fastener specified in this service bulletin does not meet the installationstandards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 7. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is madeunder normal available lighting conditions such as daylight, hangar lighting, flashlight or droplight and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 9. The instructions in Step 2., Work Instructions and the Tasks can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools

B787-A-54-00-0004-00A-933A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 44 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINor test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 10. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 11. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 12. The compliance times for the actions in Step 2., Work Instructions are in Data Module SB B787- A-54-00-0004-00A-932A-D, Paragraph 5., Compliance.
2. WORK INSTRUCTIONS Group 1: A. WORK PACKAGE A - Rolls Royce Airplanes Group 1 Left EngineGet access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 1, SB B787-A-54-00-0004-01A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 1: B. WORK PACKAGE B - Rolls Royce Airplanes Group 1 Right EngineGet access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 2, SB B787-A-54-00-0004-02A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 2: C. WORK PACKAGE C - Rolls Royce Airplanes Group 2 Left EngineGet access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 3, SB B787-A-54-00-0004-03A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 2: D. WORK PACKAGE D - Rolls Royce Airplanes Group 2 Right EngineGet access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 4, SB B787-A-54-00-0004-04A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 5: E. WORK PACKAGE E - Rolls Royce Airplanes Group 5 Left EngineGet access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 9, SB B787-A-54-00-0004-09A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 5: F. WORK PACKAGE F - Rolls Royce Airplanes Group 5 Right EngineGet access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 10, SB B787-A-54-00-0004-10A-933B-D. (1)

B787-A-54-00-0004-00A-933A-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 45 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN(2) Put the airplane back to a serviceable condition. Group 3: G. WORK PACKAGE G - GE Airplanes Group 3 Left EngineGet access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 5, SB B787-A-54-00-0004-05A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 3: H. WORK PACKAGE H - GE Airplanes Group 3 Right EngineGet access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 6, SB B787-A-54-00-0004-06A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 4: I. WORK PACKAGE I - GE Airplanes Group 4 Left EngineGet access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 7, SB B787-A-54-00-0004-07A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 4: J. WORK PACKAGE J - GE Airplanes Group 4 Right EngineGet access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 8, SB B787-A-54-00-0004-08A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 6: K. WORK PACKAGE K - GE Airplanes Group 6 Left EngineGet access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 11, SB B787-A-54-00-0004-11A-933B-D. (1) (2) Put the airplane back to a serviceable condition. Group 6: L. WORK PACKAGE L - GE Airplanes Group 6 Right Engine(1) Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 12, SB B787-A-54-00-0004-12A-933B-D. (2) Put the airplane back to a serviceable condition.

B787-A-54-00-0004-00A-933A-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 46 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 1 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL CLEANING PROCEDURES SOPM 20-30-03 GENERAL SEALING SOPM 20-50-19 REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 47 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 1:

ICN-B787-A-000061-A-81205-07440-A-01-1 Figure 1

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 48 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07441-A-01-1 Figure 2

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 49 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07442-A-01-1 Figure 3

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 50 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07443-A-01-1 Figure 4

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 51 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07444-A-01-1 Figure 5

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 52 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07445-A-01-1 Figure 6

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 53 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07446-A-01-1 Figure 7

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 54 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07447-A-01-1 Figure 8

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 55 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07448-A-01-1 Figure 9

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 56 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07449-A-01-1 Figure 10

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 57 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07450-A-01-1 Figure 11

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 58 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 40
- FASTENERS Remove / Keep 1

- 1 715Z3230-7 INBOARD UNDER- WING PANEL Remove / Keep 2

- 20
- FASTENERS Remove 3

- 1 715Z3233-1 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3233-7 BULB SEAL RETAIN- ER Install (New) 5

- 1 715Z3233-3 BULB SEAL RETAIN- ER Install (New) 6
See Fastener Code Table. 20
- FASTENERS Install (New) 7
*[1] 1 715Z3443-9 BLADE SEAL Remove 8 *[2] Trim the new Blade Seal provided in the kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 9

*[3] 1 715Z3443-9 BLADE SEAL Install (New) 10 *[4] 1 710Z3443-1 INBOARD SEAL DAM Install (New) 11 *[5] 1
- FILLET SEAL Apply 12

- 34
- FASTENERS Remove / Keep 13

- 1 715Z3210-11 OUTBOARD UNDER- WING PANEL Remove / Keep 14

- 20
- FASTENERS Remove 15

- 1 715Z3213-1 BULB SEAL RETAIN- ER Remove 16

- 1 715Z3213-3 BULB SEAL RETAIN- ER Install (New) 17

- 1 715Z3213-7 BULB SEAL RETAIN- ER Install (New) 18

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 59 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step See Fastener Code Table. 20
- FASTENERS Install (New) 19
*[6] *[2] 1 715Z3443-9 BLADE SEAL Inspect 20 *[4] 1 715Z3443-11 OUTBOARD SEAL DAM Install (New) 21
*[5] 1
- FILLET SEAL Apply 22 *[7] 1
- SEALANT Apply 23 *[8] 1 715Z3210-11 OUTBOARD UNDER- WING PANEL Install (Kept) 24
See Fastener Code Table. 34
- FASTENERS Install (Kept) 25
*[9] 1 715Z3230-7 INBOARD UNDER- WING PANEL Install (Kept) 26
See Fastener Code Table. 40
- FASTENERS Install (Kept) 27
*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 60 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the washer.*[1] *[2] *[3] - 2 BACB31V4-5W BOLT, 100 DEG HEAD A

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[4] *[5] - 72 BACB31U3K5W BOLT B

Bolt must be installed flush to the washer.*[1] *[2] *[3] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[6] *[7] - 1 BACB30NY5HK6 BOLT D

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT Bolt must be installed flush to the panel.*[6] *[7] - 39 BACB30NY5HK6 BOLT E

- - 39 BACN10XJ08 NUT *[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth.
B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 61 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-01A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 62 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 2 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL SEALING SOPM 20-50-19 GENERAL CLEANING PROCEDURES SOPM 20-30-03 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 63 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 1:

ICN-B787-A-000061-A-81205-07452-A-01-1 Figure 1

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 64 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07453-A-01-1 Figure 2

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 65 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07454-A-01-1 Figure 3

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 66 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07455-A-01-1 Figure 4

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 67 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07456-A-01-1 Figure 5

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 68 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07457-A-01-1 Figure 6

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 69 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07458-A-01-1 Figure 7

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 70 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07459-A-01-1 Figure 8

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 71 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07460-A-01-1 Figure 9

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 72 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07461-A-01-1 Figure 10

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 73 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07462-A-01-1 Figure 11

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 74 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 48
- FASTENERS Remove / Keep 1

- 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Remove / Keep 2

- 20
- FASTENERS Remove 3

- 1 715Z3213-2 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3213-8 BULB SEAL RETAIN- ER Install (New) 5

- 1 715Z3213-4 BULB SEAL RETAIN- ER Install (New) 6
See Fastener Code Table. 20
- FASTENERS Install (New) 7
*[1] 1 715Z3443-9 BLADE SEAL Inspect 8 *[2] 1 715Z3443-12 OUTBOARD SEAL DAM Install (New) 9
*[3] 1
- FILLET SEAL Apply 10

- 26
- FASTENERS Remove / Keep 11

- 1 715Z3230-8 INBOARD UNDER- WING PANEL Remove / Keep 12

- 20
- FASTENERS Remove 13

- 1 715Z3233-2 BULB SEAL RETAIN- ER Remove 14

- 1 715Z3233-4 BULB SEAL RETAIN- ER Install (New) 15

- 1 715Z3233-8 BULB SEAL RETAIN- ER Install (New) 16
See Fastener Code Table. 20
- FASTENERS Install (New) 17
*[4] 1 715Z3443-9 BLADE SEAL Remove 18

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 75 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[5] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 19

*[6] 1 715Z3443-9 BLADE SEAL Install (New) 20 *[2] 1 710Z3443-2 INBOARD SEAL DAM Install (New) 21 *[3] 1
- FILLET SEAL Apply 22

- 1 715Z3230-8 INBOARD UNDER- WING PANEL Install (Kept) 23
See Fastener Code Table. 26
- FASTENERS Install (Kept) 24
*[7] 1
- SEALANT Apply 25 *[8] *[9] 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Install (Kept) 26
See Fastener Code Table. 48
- FASTENERS Install (Kept) 27
*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[2] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[3] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[4] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[5] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 76 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the panel. *[1] *[2] - 72 BACB31U3K5W BOLT, 100 DEG HEAD A

Bolt must be installed flush to the washer.*[3] *[4] *[5] - 2 BACB31V4-5W BOLT B

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the washer.*[3] *[4] *[5] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[6] *[7] - 39 BACB30NY5HK6 BOLT D

- - 39 BACN10XJ08 NUT Bolt must be installed flush to the panel.*[6] *[7] - 1 BACB30NY5HK6 BOLT E

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT *[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.
B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 77 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-02A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 78 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 3 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL CLEANING PROCEDURES SOPM 20-30-03 GENERAL SEALING SOPM 20-50-19 REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 79 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 2:

ICN-B787-A-000061-A-81205-07463-A-01-1 Figure 1

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 80 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07464-A-01-1 Figure 2

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 81 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07465-A-01-1 Figure 3

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 82 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07466-A-01-1 Figure 4

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 83 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07467-A-01-1 Figure 5

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 84 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07468-A-01-1 Figure 6

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 85 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07469-A-01-1 Figure 7

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 86 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07470-A-01-1 Figure 8

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 87 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07471-A-01-1 Figure 9

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 88 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07472-A-01-1 Figure 10

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 89 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07473-A-01-1 Figure 11

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 90 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 40
- FASTENERS Remove / Keep 1

- 1 715Z3230-9 INBOARD UNDER- WING PANEL Remove / Keep 2

- 11
- FASTENERS Remove 3

- 1 715Z3233-5 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3233-7 BULB SEAL RETAIN- ER Install (New) 5
See Fastener Code Table. 11
- FASTENERS Install (New) 6
*[1] 1 715Z3443-9 BLADE SEAL Remove 7 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 8

*[3] 1 715Z3443-9 BLADE SEAL Install (New) 9 *[4] 1 710Z3443-1 INBOARD SEAL DAM Install (New) 10 *[5] 1
- FILLET SEAL Apply 11

- 34
- FASTENERS Remove / Keep 12

- 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Remove / Keep 13

- 11
- FASTENERS Remove 14

- 1 715Z3213-5 BULB SEAL RETAIN- ER Remove 15

- 1 715Z3213-7 BULB SEAL RETAIN- ER Install (New) 16

- 11
- FASTENERS Install (New) 17 *[6] *[2] 1 715Z3443-9 BLADE SEAL Inspect 18 *[4] 1 715Z3443-11 OUTBOARD SEAL DAM Install (New) 19

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 91 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[5] 1
- FILLET SEAL Apply 20 *[7] 1
- SEALANT Apply 21 *[8] 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Install (Kept) 22
See Fastener Code Table. 34
- FASTENERS Install (Kept) 23
*[9] 1 715Z3230-9 INBOARD UNDER- WING PANEL Install (Kept) 24
See Fastener Code Table. 40
- FASTENERS Install (Kept) 25
*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 92 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the washer.*[1] *[2] *[3] - 2 BACB31V4-5W BOLT, 100 DEG HEAD A

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[4] *[5] - 72 BACB31U3K5W BOLT B

Bolt must be installed flush to the washer.*[1] *[2] *[3] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[6] *[7] - 1 BACB30NY5HK6 BOLT D

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT Bolt must be installed flush to the panel.*[6] *[7] - 39 BACB30NY5HK6 BOLT E

- - 39 BACN10XJ08 NUT *[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-03A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 93 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 4 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL SEALING SOPM 20-50-19 GENERAL CLEANING PROCEDURES SOPM 20-30-03 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 94 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 2:

ICN-B787-A-000061-A-81205-07474-A-01-1 Figure 1

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 95 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07475-A-01-1 Figure 2

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 96 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07476-A-01-1 Figure 3

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 97 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07477-A-01-1 Figure 4

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 98 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07478-A-01-1 Figure 5

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 99 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07479-A-01-1 Figure 6

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 100 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07480-A-01-1 Figure 7

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 101 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07481-A-01-1 Figure 8

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 102 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07482-A-01-1 Figure 9

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 103 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07483-A-01-1 Figure 10

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 104 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07484-A-01-1 Figure 11

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 105 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 48
- FASTENERS Remove / Keep 1

- 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Remove / Keep 2

- 11
- FASTENERS Remove 3

- 1 715Z3213-6 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3213-8 BULB SEAL RETAIN- ER Install (New) 5
See Fastener Code Table. 11
- FASTENERS Install (New) 6
*[1] *[2] 1 715Z3443-9 BLADE SEAL Inspect 7 *[3] 1 715Z3443-12 OUTBOARD SEAL DAM Install (New) 8
*[4] 1
- FILLET SEAL Apply 9

- 26
- FASTENERS Remove / Keep 10

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Remove / Keep 11

- 11
- FASTENERS Remove 12

- 1 715Z3233-6 BULB SEAL RETAIN- ER Remove 13

- 1 715Z3233-8 BULB SEAL RETAIN- ER Install (New) 14
See Fastener Code Table. 11
- FASTENERS Install (New) 15
*[5] 1 715Z3443-9 BLADE SEAL Remove 16 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 17

*[6] 1 715Z3443-9 BLADE SEAL Install (New) 18 *[3] 1 710Z3443-2 INBOARD SEAL DAM Install (New) 19

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 106 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[4] 1
- FILLET SEAL Apply 20

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Install (Kept) 21
See Fastener Code Table. 26
- FASTENERS Install (Kept) 22
*[7] 1
- SEALANT Apply 23 *[8] *[9] 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Install (Kept) 24
See Fastener Code Table. 48
- FASTENERS Install (Kept) 25
*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 107 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the panel. *[1] *[2] - 72 BACB31U3K5W BOLT, 100 DEG HEAD A

Bolt must be installed flush to the washer.*[3] *[4] *[5] - 2 BACB31V4-5W BOLT B

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the washer.*[3] *[4] *[5] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel. *[6] *[7] - 39 BACB30NY5HK6 BOLT D

- - 39 BACN10XJ08 NUT Bolt must be installed flush to the panel. *[6] *[7] - 1 BACB30NY5HK6 BOLT E

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT *[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-04A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 108 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 5 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL CLEANING PROCEDURES SOPM 20-30-03 GENERAL SEALING SOPM 20-50-19 REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 109 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 3:

ICN-B787-A-000061-A-81205-07485-A-01-1 Figure 1

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 110 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07486-A-01-1 Figure 2

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 111 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07487-A-01-1 Figure 3

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 112 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07488-A-01-1 Figure 4

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 113 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07489-A-01-1 Figure 5

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 114 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07490-A-01-1 Figure 6

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 115 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07491-A-01-1 Figure 7

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 116 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07492-A-01-1 Figure 8

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 117 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07493-A-01-1 Figure 9

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 118 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07494-A-01-1 Figure 10

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 119 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07495-A-01-1 Figure 11

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 120 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 40
- FASTENERS Remove / Keep 1

- 1 715Z3230-7 INBOARD UNDER- WING PANEL Remove / Keep 2

- 20
- FASTENERS Remove 3

- 1 715Z3233-1 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3233-3 BULB SEAL RETAIN- ER Install (New) 5

- 1 715Z3233-7 BULB SEAL RETAIN- ER Install (New) 6
See Fastener Code Table. 20
- FASTENERS Install (New) 7
*[1] 1 715Z3443-9 BLADE SEAL Remove 8 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 9

*[3] 1 715Z3443-9 BLADE SEAL Install (New) 10 *[4] 1 710Z3443-1 INBOARD SEAL DAM Install (New) 11 *[5] 1
- FILLET SEAL Apply 12

- 34
- FASTENERS Remove / Keep 13

- 1 715Z3210-11 OUTBOARD UNDER- WING PANEL Remove / Keep 14

- 20
- FASTENERS Remove 15

- 1 715Z3213-1 BULB SEAL RETAIN- ER Remove 16

- 1 715Z3213-3 BULB SEAL RETAIN- ER Install (New) 17

- 1 715Z3213-7 BULB SEAL RETAIN- ER Install (New) 18

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 121 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step See Fastener Code Table. 20
- FASTENERS Install (New) 19
*[6] *[2] 1 715Z3443-9 BLADE SEAL Inspect 20 *[4] 1 711Z3443-1 OUTBOARD SEAL DAM Install (New) 21
*[5] 1
- FILLET SEAL Apply 22 *[7] 1
- SEALANT Apply 23 *[8] 1 715Z3210-11 OUTBOARD UNDER- WING PANEL Install (Kept) 24
See Fastener Code Table. 34
- FASTENERS Install (Kept) 25
*[9] 1 715Z3230-7 INBOARD UNDER- WING PANEL Install (Kept) 26
See Fastener Code Table. 40
- FASTENERS Install (Kept) 27
*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 122 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the washer.*[1] *[2] *[3] - 2 BACB31V4-5W BOLT, 100 DEG HEAD A

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[4] *[5] - 72 BACB31U3K5W BOLT B

Bolt must be installed flush to the washer.*[1] *[2] *[3] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[6] *[7] - 1 BACB30NY5HK6 BOLT D

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT Bolt must be installed flush to the panel.*[6] *[7] - 39 BACB30NY5HK6 BOLT E

- - 39 BACN10XJ08 NUT *[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth.
B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 123 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-05A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 124 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 6 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL SEALING SOPM 20-50-19 GENERAL CLEANING PROCEDURES SOPM 20-30-03 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 125 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 3:

ICN-B787-A-000061-A-81205-07496-A-01-1 Figure 1

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 126 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07497-A-01-1 Figure 2

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 127 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07498-A-01-1 Figure 3

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 128 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07499-A-01-1 Figure 4

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 129 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07500-A-01-1 Figure 5

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 130 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07501-A-01-1 Figure 6

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 131 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07502-A-01-1 Figure 7

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 132 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07503-A-01-1 Figure 8

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 133 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07504-A-01-1 Figure 9

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 134 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07505-A-01-1 Figure 10

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 135 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07506-A-01-1 Figure 11

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 136 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 48
- FASTENERS Remove / Keep 1

- 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Remove / Keep 2

- 20
- FASTENERS Remove 3

- 1 715Z3213-2 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3213-4 BULB SEAL RETAIN- ER Install (New) 5

- 1 715Z3213-8 BULB SEAL RETAIN- ER Install (New) 6

- 20
- FASTENERS Install (New) 7 *[1] *[2] 1 715Z3443-9 BLADE SEAL Inspect 8 *[3] 1 711Z3443-2 OUTBOARD SEAL DAM Install (New) 9
*[4] 1
- FILLET SEAL Apply 10

- 26
- FASTENERS Remove / Keep 11

- 1 715Z3230-8 INBOARD UNDER- WING PANEL Remove / Keep 12

- 20
- FASTENERS Remove 13

- 1 715Z3233-2 BULB SEAL RETAIN- ER Remove 14

- 1 715Z3233-4 BULB SEAL RETAIN- ER Install (New) 15

- 1 715Z3233-8 BULB SEAL RETAIN- ER Install (New) 16
See Fastener Code Table. 20
- FASTENERS Install (New) 17
*[5] 1 715Z3443-9 BLADE SEAL Remove 18 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 19

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 137 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[6] 1 715Z3443-9 BLADE SEAL Install (New) 20 *[3] 1 710Z3443-2 INBOARD SEAL DAM Install (New) 21 *[4] 1
- FILLET SEAL Apply 22

- 1 715Z3230-8 INBOARD UNDER- WING PANEL Install (Kept) 23
See Fastener Code Table. 26
- FASTENERS Install (Kept) 24
*[7] 1
- SEALANT Apply 25 *[8] *[9] 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Install (Kept) 26
See Fastener Code Table. 48
- FASTENERS Install (Kept) 27
*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 138 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the panel. *[1] *[2] - 72 BACB31U3K5W BOLT, 100 DEG HEAD A

Bolt must be installed flush to the washer.*[3] *[4] *[5] - 2 BACB31V4-5W BOLT B

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the washer.*[3] *[4] *[5] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[6] *[7] - 39 BACB30NY5HK6 BOLT D

- - 39 BACN10XJ08 NUT Bolt must be installed flush to the panel.*[6] *[7] - 1 BACB30NY5HK6 BOLT E

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT *[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.
B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 139 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-06A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 140 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 7 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL CLEANING PROCEDURES SOPM 20-30-03 GENERAL SEALING SOPM 20-50-19 REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 141 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 4:

ICN-B787-A-000061-A-81205-07507-A-01-1 Figure 1

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 142 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07508-A-01-1 Figure 2

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 143 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07509-A-01-1 Figure 3

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 144 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07510-A-01-1 Figure 4

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 145 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07511-A-01-1 Figure 5

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 146 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07512-A-01-1 Figure 6

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 147 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07513-A-01-1 Figure 7

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 148 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07514-A-01-1 Figure 8

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 149 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07515-A-01-1 Figure 9

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 150 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07516-A-01-1 Figure 10

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 151 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07517-A-01-1 Figure 11

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 152 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 40
- FASTENERS Remove / Keep 1

- 1 715Z3230-9 INBOARD UNDER- WING PANEL Remove / Keep 2

- 11
- FASTENERS Remove 3

- 1 715Z3233-5 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3233-7 BULB SEAL RETAIN- ER Install (New) 5
See Fastener Code Table. 11
- FASTENERS Install (New) 6
*[1] 1 715Z3443-9 BLADE SEAL Remove 7 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 8

*[3] 1 715Z3443-9 BLADE SEAL Install (New) 9 *[4] 1 710Z3443-1 INBOARD SEAL DAM Install (New) 10 *[5] 1
- FILLET SEAL Apply 11

- 34
- FASTENERS Remove / Keep 12

- 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Remove / Keep 13

- 11
- FASTENERS Remove 14

- 1 715Z3213-5 BULB SEAL RETAIN- ER Remove 15

- 1 715Z3213-7 BULB SEAL RETAIN- ER Install (New) 16
See Fastener Code Table. 11
- FASTENERS Install (New) 17
*[6] *[2] 1 715Z3443-9 BLADE SEAL Inspect 18 *[4] 1 711Z3443-1 OUTBOARD SEAL DAM Install (New) 19

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 153 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[5] 1
- FILLET SEAL Apply 20 *[7] 1
- SEALANT Apply 21 *[8] 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Install (Kept) 22
See Fastener Code Table. 34
- FASTENERS Install (Kept) 23
*[9] 1 715Z3230-9 INBOARD UNDER- WING PANEL Install (Kept) 24
See Fastener Code Table. 40
- FASTENERS Install (Kept) 25
*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 154 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the washer.*[1] *[2] *[3] - 2 BACB31V4-5W BOLT, 100 DEG HEAD A

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[4] *[5] - 72 BACB31U3K5W BOLT B

Bolt must be installed flush to the washer.*[1] *[2] *[3] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel.*[6] *[7] - 1 BACB30NY5HK6 BOLT D

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT Bolt must be installed flush to the panel.*[6] *[7] - 39 BACB30NY5HK6 BOLT E

- - 39 BACN10XJ08 NUT *[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-07A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 155 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 8 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL SEALING SOPM 20-50-19 GENERAL CLEANING PROCEDURES SOPM 20-30-03 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 156 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 4:

ICN-B787-A-000061-A-81205-07518-A-01-1 Figure 1

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 157 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07519-A-01-1 Figure 2

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 158 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07520-A-01-1 Figure 3

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 159 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07521-A-01-1 Figure 4

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 160 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07522-A-01-1 Figure 5

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 161 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07523-A-01-1 Figure 6

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 162 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07524-A-01-1 Figure 7

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 163 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07525-A-01-1 Figure 8

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 164 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07526-A-01-1 Figure 9

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 165 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07527-A-01-1 Figure 10

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 166 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07528-A-01-1 Figure 11

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 167 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 48
- FASTENERS Remove / Keep 1

- 1 715Z3210-14 OUTBOARD UNDER- WING PANEL Remove / Keep 2

- 11
- FASTENERS Remove 3

- 1 715Z3213-6 BULB SEAL RETAIN- ER Remove 4

- 1 715Z3213-8 BULB SEAL RETAIN- ER Install (New) 5
See Fastener Code Table. 11
- FASTENERS Install (New) 6
*[1] *[2] 1 715Z3443-9 BLADE SEAL Inspect 7 *[3] 1 711Z3443-2 OUTBOARD SEAL DAM Install (New) 8
*[4] 1
- FILLET SEAL Apply 9

- 26
- FASTENERS Remove / Keep 10

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Remove / Keep 11

- 11
- FASTENERS Remove 12

- 1 715Z3233-6 BULB SEAL RETAIN- ER Remove 13

- 1 715Z3233-8 BULB SEAL RETAIN- ER Install (New) 14
See Fastener Code Table. 11
- FASTENERS Install (New) 15
*[5] 1 715Z3443-9 BLADE SEAL Remove 16 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 17

*[6] 1 715Z3443-9 BLADE SEAL Install (New) 18 *[3] 1 710Z3443-2 INBOARD SEAL DAM Install (New) 19

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 168 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[4] 1
- FILLET SEAL Apply 20

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Install (Kept) 21
See Fastener Code Table. 26
- FASTENERS Install (Kept) 22
*[7] 1
- SEALANT Apply 23 *[8] *[9] 1 715Z3210-14 OUTBOARD UNDER- WING PANEL Install (Kept) 24
See Fastener Code Table. 48
- FASTENERS Install (Kept) 25
*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 12

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 169 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the panel. *[1] *[2] - 72 BACB31U3K5W BOLT, 100 DEG HEAD A

Bolt must be installed flush to the washer.*[3] *[4] *[5] - 2 BACB31V4-5W BOLT B

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the washer.*[3] *[4] *[5] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER Bolt must be installed flush to the panel. *[6] *[7] - 39 BACB30NY5HK6 BOLT D

- - 39 BACN10XJ08 NUT Bolt must be installed flush to the panel. *[6] *[7] - 1 BACB30NY5HK6 BOLT E

- - 1 NAS1149V0363M WASHER

- - 1 BACN10XJ08 NUT *[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure. *[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-08A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 170 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 9 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL CLEANING PROCEDURES SOPM 20-30-03 GENERAL SEALING SOPM 20-50-19 REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 171 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 5:

ICN-B787-A-000061-A-81205-07529-A-01-1 Figure 1

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 172 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07530-A-01-1 Figure 2

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 173 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07531-A-01-1 Figure 3

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 174 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07532-A-01-1 Figure 4

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 175 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07533-A-01-1 Figure 5

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 176 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07534-A-01-1 Figure 6

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 177 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07535-A-01-1 Figure 7

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 178 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07536-A-01-1 Figure 8

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 179 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07537-A-01-1 Figure 9

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 180 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 40
- FASTENERS Remove / Keep 1

- 1 715Z3230-9 INBOARD UNDER- WING PANEL Remove / Keep 2
*[1] 1 715Z3443-9 BLADE SEAL Remove 3 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 4

*[3] 1 715Z3443-9 BLADE SEAL Install (New) 5 *[4] 1 710Z3443-1 INBOARD SEAL DAM Install (New) 6 *[5] 1
- FILLET SEAL Apply 7

- 34
- FASTENERS Remove / Keep 8

- 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Remove / Keep 9
*[6] *[2] 1 715Z3443-9 BLADE SEAL Inspect 10 *[4] 1 715Z3443-11 OUTBOARD SEAL DAM Install (New) 11
*[5] 1
- FILLET SEAL Apply 12 *[7] 1
- SEALANT Apply 13 *[8] 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Install (Kept) 14
See Fastener Code Table. 34
- FASTENERS Install (Kept) 15
*[9] 1 715Z3230-9 INBOARD UNDER- WING PANEL Install (Kept) 16
See Fastener Code Table. 40
- FASTENERS Install (Kept) 17
*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.
B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 181 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 10 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the washer. *[1] *[2] *[3] - 2 BACB31V4-5W BOLT, 100 DEG HEAD A

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the panel. *[4] *[5] - 72 BACB31U3K5W BOLT B

Bolt must be installed flush to the washer.*[1] *[2] *[3] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER *[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 182 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-09A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 183 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 10 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL SEALING SOPM 20-50-19 GENERAL CLEANING PROCEDURES SOPM 20-30-03 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 184 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 5:

ICN-B787-A-000061-A-81205-07538-A-01-1 Figure 1

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 185 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07539-A-01-1 Figure 2

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 186 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07540-A-01-1 Figure 3

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 187 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07541-A-01-1 Figure 4

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 188 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07542-A-01-1 Figure 5

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 189 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07543-A-01-1 Figure 6

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 190 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07544-A-01-1 Figure 7

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 191 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07545-A-01-1 Figure 8

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 192 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07546-A-01-1 Figure 9

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 193 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 48
- FASTENERS Remove / Keep 1

- 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Remove / Keep 2
*[1] *[2] 1 715Z3443-9 BLADE SEAL Inspect 3 *[3] 1 715Z3443-12 OUTBOARD SEAL DAM Install (New) 4
*[4] 1
- FILLET SEAL Apply 5

- 26
- FASTENERS Remove / Keep 6

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Remove / Keep 7
*[5] 1 715Z3443-9 BLADE SEAL Remove 8 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 9

*[6] 1 715Z3443-9 BLADE SEAL Install (New) 10 *[3] 1 710Z3443-2 INBOARD SEAL DAM Install (New) 11 *[4] 1
- FILLET SEAL Apply 12

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Install (Kept) 13
See Fastener Code Table. 26
- FASTENERS Install (Kept) 14
*[7] 1
- SEALANT Apply 15 *[8] *[9] 1 715Z3210-12 OUTBOARD UNDER- WING PANEL Install (Kept) 16
See Fastener Code Table. 48
- FASTENERS Install (Kept) 17
*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal.
B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 194 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 10 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the panel. *[1] *[2] - 72 BACB31U3K5W BOLT, 100 DEG HEAD A

Bolt must be installed flush to the washer.*[3] *[4] *[5] - 2 BACB31V4-5W BOLT B

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the washer.*[3] *[4] *[5] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER *[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.
B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 195 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth.

B787-A-54-00-0004-10A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 196 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 11 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL CLEANING PROCEDURES SOPM 20-30-03 GENERAL SEALING SOPM 20-50-19 REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03
FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 197 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 6:

ICN-B787-A-000061-A-81205-07547-A-01-1 Figure 1

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 198 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07548-A-01-1 Figure 2

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 199 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07549-A-01-1 Figure 3

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 200 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07550-A-01-1 Figure 4

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 201 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07551-A-01-1 Figure 5

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 202 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07552-A-01-1 Figure 6

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 203 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07553-A-01-1 Figure 7

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 204 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07554-A-01-1 Figure 8

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 205 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07555-A-01-1 Figure 9

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 206 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 40
- FASTENERS Remove / Keep 1

- 1 715Z3230-9 INBOARD UNDER- WING PANEL Remove / Keep 2
*[1] 1 715Z3443-9 BLADE SEAL Remove 3 *[2] Trim the new Blade Seal provided in the Kit as shown before installation. 1 715Z3443-9 BLADE SEAL Cut 4

*[3] 1 715Z3443-9 BLADE SEAL Install (New) 5 *[4] 1 710Z3443-1 INBOARD SEAL DAM Install (New) 6 *[5] 1
- FILLET SEAL Apply 7

- 34
- FASTENERS Remove / Keep 8

- 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Remove / Keep 9
*[6] *[2] 1 715Z3443-9 BLADE SEAL Inspect 10 *[4] 1 711Z3443-1 OUTBOARD SEAL DAM Install (New) 11
*[5] 1
- FILLET SEAL Apply 12 *[7] 1
- SEALANT Apply 13 *[8] 1 715Z3210-13 OUTBOARD UNDER- WING PANEL Install (Kept) 14
See Fastener Code Table. 34
- FASTENERS Install (Kept) 15
*[9] 1 715Z3230-9 INBOARD UNDER- WING PANEL Install (Kept) 16
See Fastener Code Table. 40
- FASTENERS Install (Kept) 17
*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal. *[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.
B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 207 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 10 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the washer. *[1] *[2] *[3] - 2 BACB31V4-5W BOLT, 100 DEG HEAD A

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the panel. *[4] *[5] - 72 BACB31U3K5W BOLT B

Bolt must be installed flush to the washer.*[1] *[2] *[3] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER *[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 208 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth. *[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation. *[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

B787-A-54-00-0004-11A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 209 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Task 12 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.


## References Title Reference APPLICATION OF ADHESIVES SOPM 20-50-12 GENERAL SEALING SOPM 20-50-19 GENERAL CLEANING PROCEDURES SOPM 20-30-03 FASTENER INSTALLATION IN COMPOSITE STRUCTURES SOPM 20-50-18
REPAIR OF ELECTRICAL TERMINATIONS AND ELECTRICAL BONDING AREAS SOPM 20-11-03 

## Preliminary Requirements Required Conditions Data Module/Technical Publication Action/Condition B787-A-54-00-0004-00A-933A-D Issue 003 Alert Service Bulletin B787-81205-SB540004-00 - ACCOMPLISHMENT INSTRUCTIONS

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 210 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure This Task applies to Group 6:

ICN-B787-A-000061-A-81205-07556-A-01-1 Figure 1

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 211 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07557-A-01-1 Figure 2

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 212 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07558-A-01-1 Figure 3

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 213 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07559-A-01-1 Figure 4

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 214 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07560-A-01-1 Figure 5

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 215 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07561-A-01-1 Figure 6

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 216 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07562-A-01-1 Figure 7

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 217 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-11000-A-01-1 Figure 8

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 218 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINICN-B787-A-000061-A-81205-07564-A-01-1 Figure 9

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 219 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY numbers shown below are the number of parts necessary for this task. Table 1 More Data Qty Identification Name Action Step

- 48
- FASTENERS Remove / Keep 1

- 1 715Z3210-14 OUTBOARD UNDER- WING PANEL Remove / Keep 2
*[1] *[2] 1 715Z3443-9 BLADE SEAL Inspect 3 *[3] 1 711Z3443-2 OUTBOARD SEAL DAM Install (New) 4
*[4] 1
- FILLET SEAL Apply 5

- 26
- FASTENERS Remove / Keep 6

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Remove / Keep 7
*[5] 1 715Z3443-9 BLADE SEAL Remove 8 *[2] Trim the new Blade Seal provided in the Kit as shown before Installation. 1 715Z3443-9 BLADE SEAL Cut 9

*[6] 1 715Z3443-9 BLADE SEAL Install (New) 10 *[3] 1 710Z3443-2 INBOARD SEAL DAM Install (New) 11 *[4] 1
- FILLET SEAL Apply 12

- 1 715Z3230-10 INBOARD UNDER- WING PANEL Install (Kept) 13
See Fastener Code Table. 26
- FASTENERS Install (Kept) 14
*[7] 1
- SEALANT Apply 15 *[8] *[9] 1 715Z3210-14 OUTBOARD UNDER- WING PANEL Install (Kept) 16
See Fastener Code Table. 48
- FASTENERS Install (Kept) 17
*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary. *[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim to the same size as the removed Blade Seal.
B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 220 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 1 More Data Qty Identification Name Action Step *[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure. *[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for matingsurface between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM 20-50-19 as an accepted procedure. *[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12and SOPM 20-30-03 as an accepted procedure. *[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. *[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboardside of the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure. *[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboardfairing panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure. *[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboardfairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1 Figure 10 2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this Task. Table 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE Bolt must be installed flush to the panel. *[1] *[2] - 72 BACB31U3K5W BOLT, 100 DEG HEAD A

Bolt must be installed flush to the washer.*[3] *[4] *[5] - 2 BACB31V4-5W BOLT B

- - 2 BACW10U-C419P WASHER Bolt must be installed flush to the washer.*[3] *[4] *[5] - 3 BACB31V4-9W BOLT C

- - 3 BACW10U-C419P WASHER *[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.
B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 221 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETINTable 2 MORE DATA HOLE DIA QTY IDENTIFICATION NAME CODE *[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure. *[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18as an accepted procedure. *[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the OutboardUnderwing Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure. *[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess compound with a dry cloth.

B787-A-54-00-0004-12A-933B-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 222 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Alert Service Bulletin B787-81205-SB540004-00 Appendix A – INPUT SURVEY [Group 1-6:]
THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1., Alert: EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

B787-A-54-00-0004-0AA-931D-D Applicable To: Issue 003, 03 Dec 2015 Model 787 See Applicability of this data module Page 223 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN

## Procedure Group 1-6: 1.

ICN-B787-A-000061-A-81205-07008-A-01-1 Figure 1

B787-A-54-00-0004-0AA-931D-D Applicable To: Issue 003, 03 Dec 2015 End of data module Model 787 See Applicability of this data module Page 224 of 224 EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. B787-81205-SB540004-00 Issue 002, 03 Dec 2015 AIRCRAFT SERVICE BULLETIN