b

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Refer to applicable government agency regulations and requirements and make sure that the work described 

in this publication is performed in compliance with manufacturer’s recommendations and/or acceptable industry standards. 

This document is proprietary to Bombardier Inc. and/or its affiliates and may not be reproduced or copied in any form or by any means without the prior written consent of Bombardier Inc. and/or its affiliates. 

© 2009, Bombardier Inc. All rights reserved. Challenger*, Global Express*, Learjet*, are Trademarks of Bombardier Inc.

SB 45-71-7

Page 1 of 37

Basic Issue: Dec 7/09

Contact Information Distribution Date

Business Aircraft

Learjet Inc.

MS 53

P.O. Box 7707

Wichita, Kansas 67277‐7707

Customer Response Center (CRC)

1‐866‐538‐0247 (Toll Free)

(316) 946‐6100 (Tel)

Push 2 for Parts Logistics or push 4 then push

1 for Technical Publications.

December 7, 2009

LEARJET 45

SB 45-71-7

Recommended

If you cannot complete the instructions in this publication because of an STC change to the aircraft, speak to

the STC holder or the regional Federal Aviation Administration (FAA) office for information and disposition.

Service Bulletin

APPROVED WHITE IN 

POWERPLANT - REPLACEMENT OF THE LEFT ENGINE FUEL AND HYDRAULIC TUBING AND

INSTALLATION OF TUBING SUPPORT CHANNEL

1. Planning Information

A. Effectivity

(1) Learjet 45-005 thru 45-405.

NOTE: You must do Learjet Service Bulletin No. 45-71-5, “Modification of the Left and Right

Engine Wire Routing and Clamping” before or at the same time you complete these

instructions. The effectivity of Learjet Service Bulletin 45-71-5 will tell you if it is applicable to your aircraft.

B. Reason

(1) The left engine hydraulic/fuel lines can contact each other and structure. If not corrected, chafing

of these lines could result in loss of hydraulic fluid and fuel. Completing this service bulletin will

provide better support and clamping to maintain the proper clearance of the hydraulic/fuel lines

routed between the engine firewall, engine driven hydraulic pump and the engine driven motive

flow fuel pump.
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LEARJET 45

Service Bulletin

C. Description

(1) This service bulletin provides instructions to replace the left engine hydraulic lines and fuel lines

and install a support channel to provide better clamping and maintain proper clearance between

the hydraulic and fuel lines.

D. Compliance

(1) Recommended - Bombardier Learjet Inc. recommends that you complete these instructions in less

than 300 flight hours or 12 months from the initial distribution date of this publication, whichever

occurs first.

E. Approval

(1) The Federal Aviation Administration (FAA) has approved the technical content in this publication

that has an affect on the airplane type design.

NOTE: This Service Bulletin (Basic Issue) is approved as an alternate method of compliance

with AD 2009-11-13, Paragraphs g, h, i and j, by the Manager, Wichita Aircraft Certification Office, ACE-115W, by letter number L115W-09-1145.

(2) The European Aviation Safety Agency (EASA) has accepted the technical content in this publication that has an affect on the airplane type design.

F. Labor Hours - Estimated Accomplishment Time

NOTE: These labor hours are an estimate and are for planning purposes only. Facility and personnel capabilities may cause the labor hours to change.

When planning to complete these instructions, please contact Bombardier Aerospace,

Learjet Inc. Business Aircraft Customer Service, Parts Logistics for parts availability and

shipping times as necessary. (Refer to the title page of this document for contact information.)

‐801

KIT

‐802

KIT TASK

2.5 N/A Labor hours to gain access.

18.5 0.5 Labor hours to do the aircraft modification.

1.5 N/A Labor hours to do a functional test/operational check.

1.5 N/A Labor hours to return the aircraft to airworthy status.

24.0 0.5 Total Labor Hours
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

G. Expense Coverage

(1) Labor Coverage - Labor coverage applies to all aircraft affected by this publication.

NOTE: For labor coverage to apply, you must complete these instructions at a Bombardier

Business Aviation Service Facility or at a Bombardier Learjet Authorized Service

Facility. You must complete these instructions within 24 months from the Basic Issue

distribution date of this publication, December 7, 2009.

(2) Material Coverage

(a) Aircraft in the new aircraft warranty period, material coverage is provided.

NOTE: For material coverage to apply, you must place an order for these kits from Bombardier Learjet within 12 months from the Basic Issue distribution date of this publication, December 7, 2009.

(b) Aircraft out of the new warranty period, no material coverage is provided.

(3) Smart Parts Plus Coverage

(a) On aircraft in the new aircraft warranty period at the time of service bulletin distribution, Smart

Parts Plus does not pay for the kits necessary to do this service bulletin at any time.

(b) On aircraft out of the new aircraft warranty period at the time of service bulletin distribution,

Smart Parts Plus pays for the kits necessary to do this service bulletin for up to 12 months

from the Basic Issue distribution date of this service bulletin. 

H. Material Required

NOTE: The above price can change. 

Refer to Paragraph 3.A. to know which kit is necessary.

For ordering and shipping information, please call Bombardier Aerospace, Learjet Inc.

Business Aircraft Customer Service, Parts Logistics. (Refer to the title page of this document for contact information.)

(1) Other materials/parts that may be necessary if the fuel supply manifold assembly shows signs of

galling during the replacement of the main fuel supply line.

PART NUMBER QTY NOMENCLATURE PRICING

4571430001‐801 1 Service Bulletin Kit $14,739.95

4571430001‐802 1 Service Bulletin Kit $233.70

PART NUMBER NOMENCLATURE QTY NOTES

4573100000V3‐1

(* See note)

Manifold Assembly 1 Required if existing

manifold is galled.

MS29512‐04

(* See note)

O‐Ring 1 Part of the manifold

installation.
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

NOTE: * Before ordering these parts required to replace the fuel manifold assembly, make

sure the inspection of the manifold assembly threads reveals damage caused by galling.

** These parts are only required on aircraft 45-005 thru 45-076.

For ordering and shipping information, please contact Bombardier Aerospace, Learjet

Inc., Business Aircraft Customer Service, Parts Logistics. (Refer to the title page of

this document for contact information.)

I. Tools and Equipment

(1) Special tools and equipment necessary to complete these instructions.

J. Weight and Balance

(1) Change in basic weight and moment for the 4571430001-801 kit.

MS29513‐118

(* See note)

O‐Ring 1 Part of the manifold

installation.

MS21923J4

(** See note)

Adapter 1

MS8005E146DA127

(** See note)

Hose Assembly,

Case Drain (Pylon)

1

N385‐9028 Liquid ‐ Moly NV

Thread Compound

or Equivalent

1 Obtain Locally

Dapco 2200 Primerless

Firewall Sealant

As Required Obtain Locally

00116 LPS 2 Penetrating Oil

or Equivalent

As Required LPS Laboratories Inc.

Tucker, GA 30025

EC‐1252 Torque Putty As Required 3M CO

Minneapolis, MN

NOMENCLATURE QTY USAGE NOTES

7/32” Wrench

(7 to 8 inches in length)

1 Used to remove and install fasteners

located on the firewall fuel supply

tube assembly flange

Obtain Locally

CHANGE IN BASIC WEIGHT CHANGE IN BASIC MOMENT

Plus (+) 1.02 pounds Plus (+) 506.3 inch‐pounds

PART NUMBER NOMENCLATURE QTY NOTES
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

(2) Change in basic weight and moment for the 4571430001-802 kit.

K. References

(1) Learjet Maintenance Manual, Chapters 6, 12, 20, 24, 28, 29, 71 and 80. 

(2) Airplane Flight Manual.

L. Other Publications Affected

(1) Learjet Illustrated Parts Catalog, Chapter 28 and 29.

2. Accomplishment Instructions

A. Gain Access

(1) Depressurize the main hydraulic system. (Refer to Chapter 12 of the Maintenance Manual.)

(2) Push and release the L Engine Fire switch to close the firewall shutoff valves. 

(3) Disconnect external electrical power and the main and emergency batteries from the aircraft.

(Refer to Chapter 24 of the Maintenance Manual.)

(4) Remove the left lower engine cowling (450CL) from the aircraft. (Refer to Chapter 71 of the Maintenance Manual.)

(5) Remove the left upper engine cowling (450AL) from the aircraft. (Refer to Chapter 71 of the Maintenance Manual.)

(6) Remove the left lower forward pylon panel (340DL). (Refer to Chapter 6 of the Maintenance Manual.)

(7) Remove the left upper forward pylon panel (340AL). (Refer to Chapter 6 of the Maintenance Manual.)

(8) Remove the left alternator (G3) from the aircraft. (Refer to Chapter 24 of the Maintenance Manual.)

(9) Remove the left starter/generator (G1) from the aircraft. (Refer to Chapter 24 of the Maintenance

Manual.)

B. Modification of Aircraft

CAUTION: TO PREVENT DAMAGE TO AIRCRAFT AND INJURY TO PERSONNEL MAKE

SURE TO DEPRESSURIZE THE AIRCRAFT HYDRAULIC SYSTEM, AND COMPLY

WITH ALL THE SAFETY PRECAUTIONS OUTLINED IN CHAPTERS 28 AND 29

OF THE AIRCRAFT MAINTENANCE MANUAL.

(1) Spray the fuel supply manifold assembly fitting with penetrating oil.

NOTE: The penetrating oil is used to help aid in the loosening of the fuel supply tube assembly from the fuel supply manifold assembly.

CHANGE IN BASIC WEIGHT CHANGE IN BASIC MOMENT

Plus (+) 0.37 pounds Plus (+) 184.0 inch‐pounds
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Service Bulletin

(2) Inspect the fuel supply manifold assembly for galling as follows: (See Figure 1, Detail B.)

(a) Disconnect the nacelle fuel supply tube assembly fitting from the fuel supply manifold assembly.

(b) Inspect the fuel supply manifold assembly threads for signs of galling. 

NOTE: If galling is present on the threads of the fuel supply manifold assembly, place an

order for a new manifold assembly as soon as possible. Have the new fuel supply

manifold assembly shipped next day air to avoid additional aircraft down time due

to parts delay. (Refer to Paragraph 1.H.(1).)

(3) Remove all nacelle/firewall flexible fuel and hydraulic hoses and tube assemblies listed in Paragraph 3.B Parts Removed List. (See Figure 1, Details A and C.)

NOTE: Retain large hardware (nuts and washers) that secures the fuel and hydraulic tubes to

the engine firewall. Discard all clamps and associated attaching hardware. New

clamps and attaching hardware are supplied in the service bulletin kit for all new fuel

and hydraulic tubes required to complete these instructions.

When disconnecting the fuel and hydraulic tubes and flexible hoses, make sure to

place a container under the affected tubes and flexible hoses to catch any residual

fluid.

(4) After the removal of the firewall fuel supply tube assembly, clean the old residual firewall sealant

from the pylon firewall.

(5) Replace the existing rivets on the lower engine inlet bulkhead flange. (See Figure 1, View D-D and

Detail N.)

NOTE: The new rivets are installed double flushed with the head of the rivets installed on the

inboard side of the lower engine inlet bulkhead flange. These rivets are required to be

shaved after installation on the engine inlet bulkhead flange.

(6) Apply alodine and epoxy primer to all bare metal at the rivet location. (Refer to Chapter 20 of the

Maintenance Manual.)

(7) Install the forward and aft nacelle bracket assemblies as follows: (See Figure 1, Views E-E and FF.)

(a) Remove the bolt and washer from the engine flange at the location where the aft nacelle

bracket assembly is to be installed. Discard the bolt and washer.

NOTE: The engine flange bolt location is the fourth (4th) bolt from the bottom engine

flange centerline, moving clockwise when looking aft at the engine flange.

(b) Install the aft bracket assembly onto the engine flange using a new bolt and washer.
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LEARJET 45

Service Bulletin

(c) Temporarily install the channel assembly onto the forward and aft nacelle bracket assemblies

to determine the proper location of the forward nacelle bracket assembly.

(d) Temporarily position the forward nacelle bracket assembly onto the lower engine inlet bulkhead assembly. (See Figure 1, View E-E.)

NOTE: It is acceptable to use double back tape to temporarily position the forward nacelle

bracket onto the lower engine inlet bulkhead assembly for location of the forward

nacelle bracket assembly.

CAUTION: WHEN DRILLING THROUGH THE LOWER ENGINE INLET BULKHEAD

ASSEMBLY, MAKE SURE TO USE A DRILL STOP TO PREVENT DAMAGE TO

THE THRUST REVERSER HYDRAULIC LINES LOCATED BEHIND THE

LOWER ENGINE BULKHEAD ASSEMBLY.

(e) When proper location of the forward nacelle bracket assembly is determined, remove the

channel assembly and drill three #40 pilot holes (0.098 in [2.54 mm]) through the lower engine

inlet bulkhead assembly using the forward nacelle bracket as a template.

(f) Enlarge the holes in the forward nacelle bracket assembly and lower engine inlet bulkhead

assembly to #30 (0.129 in [3.27 mm]).

(g) Remove the forward nacelle bracket assembly from the lower engine inlet bulkhead assembly.

(h) Deburr and apply alodine to the holes in the forward nacelle bracket assembly and lower

engine inlet bulkhead assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(i) Identify the lower engine inlet bulkhead assembly using an indelible marker. (Refer to Paragraph 3.C.)

NOTE: The lower engine inlet bulkhead assembly part number may not be visible. Identify

the bulkhead assembly just below the drilled holes location.

(j) Install the forward nacelle bracket assembly onto the lower engine inlet bulkhead assembly. 

(8) Remove the existing support bracket and attaching hardware from the lower engine inlet bulkhead

assembly. (See Figure 1, Detail A.)

(9) Install the new support bracket with attaching hardware onto the lower engine inlet bulkhead

assembly. (See Figure 1, Detail G.)

(10) Install the firewall hydraulic and fuel tubes assemblies as follows: (See Figure 1, View H-H.)

NOTE: Do not torque the clamps or the fuel and hydraulic line fittings until installation is complete, lines should be left loose for clearance adjustment, if needed. 

(a) Loosely install the firewall fuel supply tube assembly in place with securing hardware.

(b) Loosely install all attaching hardware to support the firewall fuel supply tube assembly flange

to firewall.

NOTE: Loosely install hardware such that firewall sealant can be injected between flange

and firewall at a later time.
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

(c) Inspect for a minimum clearance between the firewall fuel supply tube assembly and the

engine firewall cutout of 0.125 in [3.17 mm]. 

NOTE: The clearance measurement is taken by moving the tube assembly up and down

on the engine firewall and checking for clearance between tube assembly and the

engine firewall cutout.

(d) On aircraft that fail the minimum clearance requirements between the firewall fuel supply tube

assembly and engine firewall cutout, do the steps that follow:

1) Trim the engine firewall cutout to meet minimum clearance requirements of 0.125 in [3.17

mm].

2) Deburr and apply alodine and epoxy primer to the engine firewall cutout. (Refer to Chapter

20 of the Maintenance Manual.)

3) Proceed to Paragraph 2.B.(10)(f) to loosely install the firewall motive flow tube assembly

onto the pylon firewall.

(e) On aircraft that pass the minimum clearance requirements between the firewall fuel supply

tube assembly and engine firewall cutout, proceed to Paragraph 2.B(10)(f) to loosely install

the firewall motive flow tube assembly onto the pylon firewall.

NOTE: Do not tighten/torque any fuel tube assemblies until all of the required clearances

have been met.

(f) Loosely install the firewall fuel motive flow tube assembly onto the pylon firewall and secure in

place using retained hardware.

(g) Loosely install the firewall hydraulic case drain tube assembly onto the pylon firewall and

secure in place using retained hardware.

(h) Loosely install the firewall hydraulic pressure tube assembly onto the pylon firewall and secure

in place using retained hardware.

(i) Loosely install the firewall hydraulic suction tube assembly onto the pylon firewall and secure

in place using retained hardware.

(11) Install the channel assembly onto the forward and aft nacelle bracket assemblies. (See Figure 1,

View H-H.)

(12) Loosely install all clamps that secure the firewall tube assemblies to the channel assembly. (See

Figure 1, View H-H.)

(13) Install the nacelle hydraulic flexible hoses and tube assemblies as follows: (See Figure 1, Detail

G.)

NOTE: Do not torque the clamps or the hydraulic line fittings until installation is complete,

lines should be left loose for clearance adjustment, if needed. 

(a) Loosely install the nacelle hydraulic suction tube assembly onto the firewall hydraulic suction

tube assembly.

(b) Loosely install a new clamp and spacer and attaching hardware to secure the nacelle hydraulic suction tube assembly to the lower engine inlet bulkhead assembly.

(c) Loosely install a new clamp and attaching hardware to secure the nacelle hydraulic suction

tube assembly to the support bracket.

(d) Loosely install the flexible hydraulic suction hose assembly onto the nacelle hydraulic suction

tube assembly.

(e) Loosely install the opposite end of the flexible hydraulic suction hose assembly onto the

engine driven hydraulic pump.
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Service Bulletin

(f) Loosely install the nacelle hydraulic case drain tube assembly onto the firewall hydraulic case

drain tube assembly.

NOTE: When installing the nacelle hydraulic case drain tube assembly, make sure to

route the tube assembly between the thrust reverser hydraulic pressure and suction lines.

(g) Loosely install a new clamp and spacer and attaching hardware to secure the nacelle hydraulic case drain tube assembly to the lower inlet bulkhead assembly.

(h) Loosely install the flexible hydraulic case drain hose assembly onto the nacelle hydraulic case

drain tube assembly. 

(i) Loosely install the opposite end of the flexible hydraulic case drain hose assembly onto the

engine driven hydraulic pump.

(j) Loosely install the nacelle hydraulic pressure tube assembly onto the firewall hydraulic pressure tube assembly.

(k) Loosely install new clamps and attaching hardware to secure the nacelle hydraulic pressure

tube assembly and the nacelle hydraulic case drain tube assembly to the support bracket.

(l) Loosely install the flexible hydraulic pressure hose assembly onto the nacelle hydraulic pressure tube assembly.

(m) On aircraft that have not performed Learjet Service Bulletin 45-29-7, “Installation of Hydraulic

Bleeder Fittings, install the 4571430001-802 kit. (See Figure 2, Detail A and View B-B.)

(n) On aircraft that have performed Learjet Service Bulletin 45-29-7, “Installation of Hydraulic

Bleeder Fittings, proceed to Paragraph 2.B.(13)(o) to loosely install the opposite end if the

flexible hydraulic pressure hose assembly onto the engine driven hydraulic pump bleeder fitting tee.

(o) Loosely install the opposite end of the flexible hydraulic pressure hose assembly onto the

engine driven hydraulic pump bleed fitting tee. 

(14) Install the hydraulic case drain support assembly. (See Figure 1, Detail G.)

(15) Inspect the lower nacelle hydraulic tube and hose assemblies for minimum clearances.

NOTE: Minimum clearance unless otherwise noted is 0.125 in [3.17 mm] between all unsupported sections of tubing/hoses and adjacent components/structure, or a minimum

clearance of 0.06 in [1.52 mm] between all supported sections of tubing/hoses and

adjacent components/structure.

An unsupported section of tube/hose is defined as the portion of tube/hose that

extends beyond 4.00 in [9.16 cm] on either side of the support clamp. A supported

section of tube/hose is defined as the portion of tube/hose that extends within 4.00 in

[9.16 cm] on either side of the support clamp.

The flexible hydraulic suction hose assembly has a minimum clearance requirement

of 0.05 in [1.27 mm] between the suction hose assembly and the lower engine inlet

bulkhead assembly.

(a) On aircraft that fail the minimum hydraulic tube and hose clearance requirements, adjust the

tubing, flexible hoses and clamps to achieve the minimum clearance requirements. After minimum clearance requirements have been met, proceed to Paragraph 2.B.(16) to torque all

hydraulic flexible hoses, nacelle hydraulic tube assemblies and associated clamps

(b) On aircraft that pass the minimum hydraulic tube and hose clearance requirements, proceed

to Paragraph 2.B.(16) to torque all hydraulic flexible hoses, nacelle hydraulic tube assemblies

and associated clamps.
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Service Bulletin

(16) Torque all hydraulic flexible hoses, nacelle hydraulic tube assemblies and associated clamps as

follows:

NOTE: Care should be taken to maintain the minimum clearance requirements and not to

preload the nacelle hydraulic tubing while torquing.

(a) Torque the nacelle hydraulic suction tube assembly at the connection point of the firewall

hydraulic suction tube assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(b) Torque the nacelle hydraulic suction tube assembly at the connection point of the flexible

hydraulic suction hose assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(c) Torque the flexible hydraulic suction hose assembly at the connection point of the engine

driven hydraulic pump. (Refer to Chapter 20 of the Maintenance Manual.)

(d) Torque the nacelle hydraulic case drain tube assembly at the connection point of the firewall

hydraulic case drain tube assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(e) Torque the nacelle hydraulic case drain tube assembly at the connection point of the flexible

hydraulic case drain hose assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(f) Torque the flexible hydraulic case drain hose assembly at the connection point of the engine

driven hydraulic pump. (Refer to Chapter 20 of the Maintenance Manual.)

(g) Torque the nacelle hydraulic pressure tube assembly at the connection point of the firewall

hydraulic pressure tube assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(h) Torque the nacelle hydraulic pressure tube assembly at the connection point of the flexible

hydraulic pressure hose assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(i) Torque the flexible hydraulic pressure hose assembly at the connection point of the engine

driven hydraulic pump bleed fitting. (Refer to Chapter 20 of the Maintenance Manual.)

(j) Torque all associated support clamps on the flexible hydraulic hoses and hydraulic tube

assemblies. (Refer to Chapter 20 of the Maintenance Manual.)

NOTE: At this point, all hydraulic flexible hoses and hydraulic nacelle tubes must be properly installed with all fittings and support clamps torqued, and minimum clearances maintained.

(17) On aircraft 45-005 thru 45-356 replace the existing spacer and attachment screw on the thrust

reverser hydraulic return and pressure tube assemblies, as follows: (See Figure 1, Detail N.)

(a) If not already done, remove the starter/generator inlet duct from the engine nacelle.

NOTE: The thrust reverser hydraulic return and pressure tube assemblies are located on

the forward side of the engine inlet bulkhead assembly. The tube assemblies can

be reached through the starter/generator inlet duct opening.

(b) Remove the existing spacer and attachment screw from the clamp location used to secure the

thrust reverser hydraulic return tube assembly to the engine inlet bulkhead assembly.

(c) Install the new spacer and screw into the retained clamp to secure the thrust reverser hydraulic return tube assembly to the engine inlet bulkhead assembly.

(d) Remove the existing spacer and attachment screw from the clamp location used to secure the

thrust reverser hydraulic pressure tube assembly to the engine inlet bulkhead assembly.

(e) Install the new spacer and screw into the retained clamp to secure the thrust reverser hydraulic pressure tube assembly to the engine inlet bulkhead assembly.

(f) Make sure that a minimum clearance of 0.125 in [3.17 mm] exists between the thrust reverser

hydraulic pressure tube assembly and support bracket attachment screw. 
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Service Bulletin

(18) Install the starter/generator (G1) on the aircraft. (Refer to Chapter 24 of the Maintenance Manual.)

(19) Install the alternator (G3) on the aircraft. (Refer to Chapter 24 of the Maintenance Manual.)

(20) Install the nacelle fuel tubes and flexible hose assemblies as follows:

NOTE: Minimum clearance unless otherwise noted is 0.125 in [3.17 mm] between all unsupported sections of tubing/hoses and adjacent components/structure, or a minimum

clearance of 0.06 in [1.52 mm] between all supported sections of tubing/hoses and

adjacent components/structure.

An unsupported section of tube/hose is defined as the portion of tube/hose that

extends beyond 4.00 in [9.16 cm] on either side of the support clamp. A supported

section of tube/hose is defined as the portion of tube/hose that extends within 4.00 in

[9.16 cm] on either side of the support clamp.

(a) On aircraft where the inspection of the fuel supply manifold assembly threads revealed galling

and the pressure switch (S21) is attached to the manifold assembly, do the steps that follow:

(See Figure 1, View J-J.)

1) Disconnect electrical connector and remove the pressure switch (S21) from the manifold

assembly. 

2) Remove the O-ring from pressure switch.

3) Remove and discard the fuel supply manifold assembly from the aircraft. Retain attaching

hardware for the installation of new fuel supply manifold assembly.

4) Install a new O-ring onto the new fuel supply manifold assembly.

5) Install the new fuel supply manifold assembly on the engine driven fuel pump using

retained attaching hardware.

6) Install the pressure switch and a new o-ring into the new fuel supply manifold assembly.

7) Connect electrical connector (S21) to the pressure switch.

8) Proceed to Paragraph 2.B.(20)(d) to position the five (5) MS21919WCH16 clamps on the

nacelle fuel supply tube assembly prior to installation.

(b) On aircraft where the inspection of the fuel supply manifold assembly threads revealed galling

with a damper assembly attached to the fuel manifold assembly, do the steps that follow: (See

Figure 1, View J-J.)

1) Disconnect the damper assembly tubing from the fuel supply manifold assembly.

2) Remove the union from the fuel supply manifold assembly.

3) Remove the O-ring from the union and discard.

4) Remove and discard the fuel supply manifold assembly from the aircraft. Retain attaching

hardware for the installation of new fuel supply manifold assembly

5) Install a new O-ring onto the new fuel supply manifold assembly.

6) Install the new fuel supply manifold assembly on the engine driven fuel pump using

retained attaching hardware.

7) Install the union and a new O-ring into the new fuel supply manifold assembly.

8) Connect the damper assembly tube to the new fuel supply manifold assembly.

9) Proceed to Paragraph 2.B.(20)(d) to position the five (5) MS21919WCH16 clamps on the

nacelle fuel supply tube assembly prior to installation.
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Service Bulletin

(c) On aircraft where the inspection of the fuel supply manifold assembly threads did not reveal

galling, the fuel supply manifold does not require replacement.

NOTE: Before connecting the nacelle fuel supply tube assembly on the aircraft, apply

anti-seize compound (Liquid Moly) to the threads of the fuel supply manifold

assembly and the male threads of the firewall fuel supply tube assembly. 

(d) Position the five (5) MS21919WCH16 clamps on the nacelle fuel supply tube assembly prior to

installation. (See Figure 1, Detail L for clamp position and orientation.)

NOTE: The MS21219WCH16 clamps used to support the nacelle motive flow assembly

must be in position on the nacelle fuel supply tube assembly prior to installation.

(e) Loosely install the nacelle fuel supply tube assembly onto the firewall fuel supply tube assembly and the fuel supply manifold assembly.

NOTE: It is permissible to loosen the attaching hardware on the fuel supply manifold

assembly to ease in the installation of the nacelle fuel supply tube assembly.

(f) Loosely install the nacelle fuel supply tube assembly onto the lower engine inlet bulkhead

assembly using the required clamps, spacers and hardware. (See Figure 1, Detail L.)

(g) Loosely install the nacelle fuel motive flow tube assembly onto the firewall fuel motive flow

tube assembly.

(h) Loosely install the opposite end of the nacelle fuel motive flow tube assembly onto the lower

engine inlet bulkhead assembly using the required clamps and hardware. (See Figure 1, Detail

L.)

(i) Loosely install the flexible fuel motive flow hose assembly onto the nacelle fuel motive flow

tube assembly. (See Figure 1, Detail L.)

(j) Loosely install the opposite end of the flexible fuel motive flow hose assembly onto the motive

flow pump.

(21) Inspect the lower nacelle fuel tubes and flexible hoses for minimum clearances.

NOTE: Minimum clearance unless otherwise noted is 0.125 in [3.17 mm] between all unsupported sections of tubing/hoses and adjacent components/structure, or a minimum

clearance of 0.06 in [1.52 mm] between all supported sections of tubing/hoses and

adjacent components/structure.

An unsupported section of tube/hose is defined as the portion of tube/hose that

extends beyond 4.00 in [9.16 cm] on either side of the support clamp. A supported

section of tube/hose is defined as the portion of tube/hose that extends within 4.00 in

[9.16 cm] on either side of the support clamp.

(a) On aircraft that fail the minimum fuel tube and hose clearance requirements, loosen and adjust

the tubing, flexible hoses and clamps to maintain the minimum clearance requirements. After

minimum clearance requirements have been met, proceed to Paragraph 2.B.(22) to adjust the

inboard area of the nacelle fuel supply tube assembly and the lower engine inlet bulkhead

flange.

(b) On aircraft that pass the minimum fuel tube and hose clearance requirements, proceed to

Paragraph 2.B.(22) to adjust the inboard area of the nacelle fuel supply tube assembly and the

lower engine inlet bulkhead flange.
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Service Bulletin

(22) Adjust the inboard area of the nacelle fuel supply tube assembly and the lower engine inlet bulkhead flange to a minimum clearance of 0.05 in [1.27 mm] between the flange and the tube assembly as follows:

NOTE: The flange of the firewall fuel supply tube assembly is slotted for adjustment to maintain the 0.05 in [1.27 mm] clearance between the nacelle fuel supply tube assembly

and lower engine inlet flange.

(a) Place a 0.05 in [1.27 mm] shim or feeler gauge between the nacelle fuel supply tube assembly, and the lower engine inlet bulkhead flange to maintain the required 0.05 in [1.27 mm]

clearance.

(23) Fay seal the firewall fuel supply tube assembly flange as follows:

(a) Loosely install all screws attaching the flange of the firewall fuel supply tube assembly to the

engine firewall as necessary to inject Dapco 2200 Primerless Firewall Sealant.

(b) Loosen the clamps and attaching hardware on the firewall fuel supply tube fuel assembly as

required to fay seal the flange of the tube assembly to the engine firewall.

(c) Fay seal the flange of the firewall fuel supply tube assembly with Dapco 2200 Primerless Firewall Sealant.

NOTE: The fuel supply tube assembly flange is fay sealed by using a sealer gun to inject

the firewall sealant between the tube flange and firewall assembly.

(24) Torque all fasteners in the firewall fuel supply tube assembly flange. (Refer to Chapter 20 of the

Maintenance Manual.) 

NOTE: While torquing the fasteners on the tube assembly flange, make sure to maintain the

required clearance of 0.05 in [1.27mm] between the nacelle fuel supply tube assembly

and the lower engine inlet flange.

Contact between the firewall fuel supply tube assembly and the fire extinguisher discharge tube assembly lower support clamp is permissible.

(25) Torque the attaching hardware that secures the firewall fuel and hydraulic tube assemblies to the

engine firewall (large attachment nuts). (Refer to Chapter 20 of the Maintenance Manual.)

(26) Torque all fuel flexible hoses and nacelle fuel tube assemblies and associated clamps as follows:

NOTE: Care should be taken to maintain minimum clearance requirements, and not preload

the nacelle fuel tubing while torquing.

(a) Torque the nacelle fuel supply tube assembly at the connection point of the firewall fuel supply

tube assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(b) Torque the nacelle fuel supply tube assembly at the connection point of the fuel supply manifold. (Refer to Chapter 20 of the Maintenance Manual.)

(c) If loosened to aid in the alignment of the nacelle fuel supply tube assembly, torque the attaching hardware on the fuel manifold assembly. (Refer to Chapter 20 of the Maintenance Manual.)

(d) Torque the nacelle motive flow tube assembly at the connection point of the firewall motive

flow fuel tube assembly. (Refer to Chapter 20. of the Maintenance Manual.)

(e) Torque the nacelle motive flow tube assembly at the connection point of the flexible motive

flow hose assembly. (Refer to Chapter 20 of the Maintenance Manual.)
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Service Bulletin

(f) Torque the flexible motive flow hose assembly at the connection point of the engine driven

motive flow fuel pump. (Refer to Chapter 20 of the Maintenance Manual.)

(g) Torque all associated support clamps on the flexible fuel hoses and fuel tube assemblies.

(Refer to Chapter 20 of the Maintenance Manual.)

(27) On aircraft 45-005 thru 45-076 replace the engine pylon hydraulic case drain flexible hose assembly and union, as follows: (See Figure 1, Detail M.)

(a) Remove the existing engine pylon hydraulic case drain flexible hose assembly from the aircraft. 

(b) In the baggage compartment, disconnect the left hydraulic case drain tube assembly from the

hydraulic case drain union.

(c) Remove the existing hydraulic case drain union from the aircraft and retain attachment hardware.

(d) Install the new hydraulic case drain adapter on the aircraft using the retained attachment hardware.

(e) Tighten and torque the adapter attachment hardware. (Refer to Chapter 20 of the Maintenance Manual.)

(f) In the baggage compartment, connect the left hydraulic case drain tube assembly to the

adapter.

(g) Torque the left hydraulic case drain tube assembly. (Refer to Chapter 20 of the Maintenance

Manual.)

(h) Install the new engine pylon hydraulic case drain flexible hose assembly on the aircraft.

(i) Torque the engine pylon hydraulic case drain flexible hose assembly. (Refer to Chapter 20 of

the Maintenance Manual.)

(28) Connect the flexible fuel and hydraulic hose assemblies located in the engine pylon to the engine

firewall. (Refer to Chapter 20 of the Maintenance Manual.)

(29) Torque all fuel and hydraulic tube and hose assembly clamps on the support channel. (Refer to

Chapter 20 of the Maintenance Manual.)

(30) Remove the 0.05 in [1.27 mm] shim or feeler gauge from the aircraft.

(31) Check the electrical bond of the hydraulic tube assemblies. (Refer to Chapter 20 of the Wiring

Manual.)

(32) Check the electrical bond of the fuel tube assemblies. (Refer to Chapter 20 of the Wiring Manual.)

NOTE: The resistance of the fuel tube assemblies should not exceed 1.0 ohm.

(33) Route and clamp the starter/generator wiring harnesses (G1-E, G1-B) and the left alternator wiring

harness (G3P2) on the left engine. (See Figure 1, Detail R.)

NOTE: Minimum clearance requirements between the starter/generator electrical harness,

and hydraulic and fuel tube assemblies that have been installed by this service bulletin, is 0.125 in [1.27 mm] unless otherwise specified.

(34) Clamp the alternator wire harness (G3P1) onto the firewall hydraulic suction tube assembly. (See

Figure 1, Detail S.)

NOTE: Minimum clearance requirements between the alternator electrical harness and

hydraulic and fuel tube assemblies that have been installed by this service bulletin, is

0.125 in [1.27 mm] unless otherwise specified.

(35) Connect the main and emergency batteries to the aircraft. (Refer to Chapter 24 of the Maintenance Manual.)

(36) Push and release the L Engine Fire switch to open the firewall shutoff valves.
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Service Bulletin

(37) If necessary, service the aircraft hydraulic system. (Refer to Chapter 12 of the Maintenance Manual.)

(38) If not already done, install the starter/generator inlet duct on the aircraft.

C. Functional Test/Operational Check

(1) Bleed the aircraft hydraulic system. (Refer to Chapter 29 of the Maintenance Manual.)

(2) Do the Operational Check of the Engine Driven Hydraulic Pump. (Refer to Chapter 29 of the Maintenance Manual.)

(3) Do an Automatic Engine Start (Left Engine Only). (Refer to Chapter 80 of the Maintenance Manual.)

(4) Advance the left engine throttle lever to the Takeoff detent for one (1) minute. (Refer to the Airplane Flight Manual.)

(5) Check all replaced hydraulic flexible hoses and tube assemblies for leakage.

(6) Check all replaced flexible fuel hoses and tube assemblies for leakage.

(7) Shut down the left engine. (Refer to the Airplane Flight Manual.)

D. Return Aircraft to Airworthy Status

(1) Install the left upper forward pylon panel (340AL). (Refer to Chapter 6 of the Maintenance Manual.)

(2) Install the left lower forward pylon panel (340DL). (Refer to Chapter 6 of the Maintenance Manual.)

(3) Install the left upper engine cowling (450AL) on the aircraft. (Refer to Chapter 71 of the Maintenance Manual.)

(4) Install the left lower engine cowling (450CL) on the aircraft. (Refer to Chapter 71 of the Maintenance Manual.)

E. Compliance Response Form

(1) Complete the compliance response form.

(2) Send the compliance response form to Learjet Inc. as soon as possible.

F. Aircraft Maintenance Records

(1) Complete the Aircraft Maintenance Records.

NOTE: Complete the aircraft records in accordance with the regulatory requirements of your

aircraft certification authority.

3. Material Information

A. Parts Required

(1) The 4571430001-801 kit is for aircraft 45-005 thru 45-405 and contains the parts that follow:

PART

NUMBER QTY NOMENCLATURE ALTERNATE PARTNUMBER

7629100003‐001 1 Flex Hose Assembly,

Hydraulic Case Drain

AE720134‐1

7629100002‐001 1 Flex Hose Assembly,

Hydraulic Suction

AE720133‐1

7629100001‐001 1 Flex Hose Assembly,

Hydraulic Pressure

AE720132‐1

7628200001‐001 1 Flex Hose Assembly,

Fuel Motive Flow

AE713701‐2
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Service Bulletin

4571408529‐001 1 Channel Assembly

4571408519‐001 1 Nacelle Bracket Assembly

(Aft)

4571408518‐001 1 Nacelle Bracket Assembly

(Forward)

4529101097‐001 1 Tube Assembly,

Hydraulic Case Drain,

Firewall

4529101096‐001 1 Tube Assembly,

Hydraulic Suction,

Firewall

4529101095‐001 1 Tube Assembly,

Hydraulic Pressure,

Firewall

4529101094‐001 1 Tube Assembly,

Hydraulic Case Drain,

Nacelle

4529101093‐001 1 Tube Assembly,

Hydraulic Pressure,

Nacelle

4529101092‐005 1 Tube Assembly,

Hydraulic Suction,

Nacelle

4529101027‐001 1 Support Assembly,

Case Drain

4529101026‐001 1 Bracket Assembly,

Support

4528200013‐009 1 Tube Assembly,

Fuel Supply, Nacelle

4528200010‐009 1 Tube Assembly,

Motive Flow, Nacelle

4528200009‐001 1 Tube Assembly,

Motive Flow,

Firewall

4528200007‐005 1 Tube Assembly,

Fuel Supply, Firewall

PART

NUMBER QTY NOMENCLATURE ALTERNATE PARTNUMBER
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Service Bulletin

NOTE: Some hardware comes in pre-packaged quantities. When that occurs, the quantity in the

kit will be more than the quantity in the parts list.

NAS1097AD3‐3 2 Rivet

NAS1097AD3‐4 2 Rivet

NAS1802‐3‐8 15 Screw

NAS1802‐3‐10 2 Screw

NAS1802‐3‐12 2 Screw

NAS1802‐3‐14 1 Screw

NAS1802‐3‐24 2 Screw

NAS1802‐08‐7 5 Screw

NAS1149C0316R 20 Washer

NAS1149CN816R 10 Washer

NAS620C10L 4 Washer

NAS43DD3‐32FC 1 Spacer

NAS43DD3‐16FC 4 Spacer

NAS43HT3‐25 1 Spacer

NAS43HT3‐48 1 Spacer

M85052/3‐8 4 Clamp

M85052/3‐6 2 Clamp

M85052/3‐4 4 Clamp

MS21919WCH5 1 Clamp

MS21919WCH15 1 Clamp

MS21919WCH16 6 Clamp

MS21919WCH8 4 Clamp

MS21279‐07 1 Bolt

MS21042‐08 5 Nut

MS21042‐3 9 Nut

MS27039C1‐12 1 Screw

MS27039C1‐18 1 Screw

CR3213‐4‐02 3 Rivet

PART

NUMBER QTY NOMENCLATURE ALTERNATE PARTNUMBER
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Service Bulletin

(2) The 4571430001-802 kit is for aircraft 45-005 thru 45-194 that have not complied with Learjet Service Bulletin 45-29-7 and contains the parts that follow: 

NOTE: Some hardware comes in pre-packaged quantities. When that occurs, the quantity in the

kit will be more than the quantity in the parts list.

B. Parts Removed List

PART NUMBER QTY NOMENCLATURE

274‐220 1 Bleeder Fitting

M83461/2‐906 1 Packing

MS28773‐06 1 Retainer

F6446 1 Bleeder Screw

AS1001J060604 1 Tee

AN6289J6 1 Nut

M83461/2‐904 1 Packing

PART

NUMBER QTY NOMENCLATURE DISPOSITION EFFECTIVITY

4529101088‐001 1 Tube Assembly

Hydraulic Suction,

Nacelle

Destroy All

4529101089‐001 1 Tube Assembly

Hydraulic Pressure,

Nacelle

Destroy All

4529101090‐001 1 Tube Assembly

Hydraulic Case Drain,

Nacelle

Destroy 45‐005 thru 45‐356

4529101090‐005 1 Tube Assembly

Hydraulic Case Drain,

Nacelle

Destroy 45‐357 thru 45‐405

4529101066‐001 1 Bracket‐ Support,

Nacelle

Destroy 45‐005 thru 45‐071

4529101066‐003 1 Bracket‐ Support,

Nacelle

Destroy 45‐072 thru 45‐405

4528200005‐001 1 Tube Assembly

Fuel Supply, Firewall

Destroy All
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LEARJET 45

Service Bulletin

4528200011‐001 1 Tube Assembly

Motive Flow, Firewall

Destroy All

4529101067‐001 1 Tube Assembly

Hydraulic Pressure,

Firewall

Destroy All

4529101071‐001 1 Tube Assembly

Hydraulic Suction,

Firewall

Destroy All

4529101075‐001 1 Tube Assembly

Hydraulic Case Drain,

Firewall

Destroy 45‐005 thru 45‐076

4529101075‐005 1 Tube Assembly

Hydraulic Case Drain,

Firewall

Destroy 45‐077 and 45‐405

4528200044‐001 1 Tube Assembly

Motive Flow, Nacelle

Destroy 45‐005 thru 45‐267

4573100000V13‐001 1 Tube Assembly

Motive Flow, Nacelle

Destroy 45‐268 thru 45‐405

4573100005V1‐005 1 Tube Assembly

Fuel Supply, Nacelle

Destroy 45‐005 thru 45‐040

4573100005‐009 1 Tube Assembly

Fuel Supply, Nacelle

Destroy When Installed

4573100005‐013 1 Tube Assembly

Fuel Supply, Nacelle

Destroy 45‐195 thru 45‐267

4573100000V12‐001 1 Tube Assembly

Fuel Supply, Nacelle

Destroy 45‐268 thru 45‐405

4573100000V5‐001 1 Tube Assembly

Fuel Supply, Nacelle

Destroy When Installed

4573100000V8‐001 1 Tube Assembly

Fuel Supply, Nacelle

Destroy When Installed

A7967‐2 1 Hose Assembly

Hydraulic Pressure

Destroy When Installed

AS623‐06H0073 1 Hose Assembly

Hydraulic Pressure

Destroy When Installed

A7968‐1 1 Hose Assembly

Hydraulic Suction

Destroy When Installed

PART

NUMBER QTY NOMENCLATURE DISPOSITION EFFECTIVITY
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Service Bulletin

C. Identification Table

AE1010563H0081 1 Hose Assembly

Hydraulic Suction

Destroy When Installed

A7969‐1 1 Hose Assembly

Hydraulic Case Drain

Destroy When Installed

AE3663169E0067 1 Hose Assembly

Hydraulic Case Drain

Destroy When Installed

A7970‐1 1 Hose Assembly

Motive Flow

Destroy When Installed

AE713701‐1 1 Hose Assembly

Motive Flow

Destroy When Installed

NAS43HT3‐25 1 Spacer Destroy 45‐005 thru 45‐356

NAS43HT3‐31 1 Spacer Destroy 45‐005 thru 45‐356

MS27039C1‐12 1 Screw Destroy 45‐005 thru 45‐356

MS27039C1‐14 1 Screw Destroy 45‐005 thru 45‐356

MS27039C1‐17 1 Screw Destroy 45‐005 thru 45‐356

PART NUMBER NOMENCLATURE IDENTIFY TO SPARES

REPLACEMENT EFFECTIVITY

4571600052‐005 Lower Engine Inlet

Bulkhead Assembly

4571430001‐803 No Spares Available All

PART

NUMBER QTY NOMENCLATURE DISPOSITION EFFECTIVITY
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Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 1 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 2 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 3 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 4 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 5 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 6 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 7 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Replacement of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 8 of 15)
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Page 29 of 37

Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 9 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 10 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (sheet 11 of 15)
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Basic Issue: Dec 7/09

LEARJET 45

Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 12 of 15)
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Basic Issue: Dec 7/09

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Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 13 of 15)
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Basic Issue: Dec 7/09

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Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 14 of 15)
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Basic Issue: Dec 7/09

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Service Bulletin

Installation of the Left Engine Fuel and Hydraulic Tubing

Figure 1 (Sheet 15 of 15)
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Basic Issue: Dec 7/09

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Service Bulletin

Installation of the Hydraulic Pump Bleeder Assembly

Figure 2 (Sheet 1 of 2)
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Service Bulletin

Installation of the Hydraulic Pump Bleeder Assembly

Figure 2 (Sheet 2 of 2)