AD 2009-26-12

The FAA is superseding an existing airworthiness directive (AD) for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, "Parallel Valve" reciprocating engines, with certain Engine Components, Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series "Titan," installed. That AD currently requires initial and repetitive visual inspections and compression tests to detect cracks at the head-to-barrel interface, replacement of cylinder assemblies found cracked, and replacement of certain cylinder assemblies at new, reduced times-in-service. This AD requires the same actions, but for an expanded population of cylinder assemblies. This AD results from reports of 10 additional cylinder head separations since issuing AD 2008-19-05, on cylinder serial numbers not listed in that AD. We are issuing this AD to prevent loss of engine power due to cracks at the head-to-barrel interface and possible engine failure caused by separation of a cylinder head, which could result in loss of control of the aircraft.

Final rule.

2009-26-12 Engine Components, Inc. (ECi): Amendment 39-16151. Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD.

Effective Date

(a) This airworthiness directive (AD) becomes effective February 4, 2010.

Affected ADs

(b) This AD supersedes AD 2008-19-05, Amendment 39-15672.

Applicability

(c) If your engine has not been overhauled, or not had any cylinder assemblies replaced since new, no further action is required.

(d) This AD applies to the Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, "Parallel Valve," reciprocating engines listed in Table 1 of this AD, with ECi cylinder assembly, part number (P/N) AEL65102 series "Titan," and with cylinder head, P/N AEL85099, installed.

(1) The applicable cylinder assembly serial numbers (S/Ns) are S/N 1138-02 through S/N 35171-22 (referred to in this AD as Group "A" cylinder assemblies); and

(2) S/N 35239-01 through S/N 42179-30 (referred to in this AD as Group "B" cylinder assemblies).

(3) The cylinder assembly P/N is at the crankcase end of the cylinder assembly, and might be difficult to see. As a guide in determining if your cylinder assemblies are affected, all affected cylinder assemblies have cylinder head P/N AEL85099. The cylinder head P/N is at the top of the cylinder head, near the intake and exhaust valve springs, and is easier to locate than the cylinder assembly P/N.

(4) The set of numbers appearing on the cylinder, above and to the left of the S/N, in the form of "123456" is not used for determining this AD's applicability.

Table 1--Engine Models

Cylinder Assembly Part Number:
Installed on Engine Models:
AEL65102-NST04
O-320-A1B, A2B, A2C, A2D, A3A, A3B, B2B, B2C, B2D, B2E, B3B, B3C, C2B, C2C, C3B, C3C, D1A, D1AD, D1B, D1C, D1D, D1F, D2A, D2B, D2C, D2F, D2G, D2H, D2J, D3G, E1A, E1B, E1C, E1F, E1J, E2A, E2B, E2C, E2D, E2E, E2F, E2G, E2H, E3D, E3H
IO-320-A1A, A2A, B1A, B1B, B1C, B1D, B1E, B2A, D1A, D1AD,D1B, D1C, E1A, E1B, E2A, E2B
AEIO-320-D1B, D2B, E1A, E1B, E2A, E2B
AIO-320-A1A, A1B, A2A, A2B, B1B, C1B
LIO-320-B1A
AEL65102-NST05
IO-320-C1A, C1B, C1F, F1A
LIO-320-C1A
AEL65102-NST06
O-320-A1A, A2A, A2B, A2C, A3A, A3B, A3C, E1A, E1B, E2A, E2C, (also, an O-320 model with no suffix)
IO-320-A1A, A2A
AEL65102-NST07
IO-320- B1A, B1B
LIO-320- B1A
AEL65102-NST08
O-320-B1A, B1B, B2A, B2B, B3A, B3B, B3C, C1A, C1B, C2A, C2B, C3A, C3B, C3C, D1A, D1B, D2A, D2B, D2C
AEL65102-NST10
O-360-A1A, A1C, A1D, A2A, A2E, A3A, A3D, A4A, B1A, B1B, B2A, B2B, C1A, C1C, C1G, C2A, C2B, C2C, C2D, D1A, D2A, D2B
IO-360-B1A, B1B, B1C
HO-360-A1A, B1A, B1B
HIO-360-B1A, B1B
AEIO-360-B1B
O-540-A1A, A1A5, A1B5, A1C5, A1D, A1D5, A2B, A3D5, A4A5, A4B5, A4C5, A4D5, B1A5, B1B5, B1D5, B2A5, B2B5, B2C5, B4A5, B4B5, D1A5, E1A, E4A5, E4B5, E4C5, F1A5, F1B5, G1A5, G2A5
IO-540-C1B5, C1C5, C2C, C4B5, C4B5D, C4C5, D4A5, D4B5, N1A5
AEL65102-NST12
O-360- A1A, A1AD, A1D, A1F, A1F6, A1F6D, A1G, A1G6, A1G6D, A1H,A1H6, A1J, A1LD, A1P, A2A, A2D, A2F, A2G, A2H, A3A, A3AD, A3D, A4A, A4AD, A4D, A4G, A4J, A4JD, A4K, A4M, A4N, A4P, A5AD, B1A, B2C, C1A, C1C, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, C4F, C4P, D2A, F1A6, G1A6
HO-360 C1A
LO-360-A1G6D, A1H6
HIO-360-B1A, B1B, G1A
LTO-360-A1A6D
TO-360-A1A6D
IO-360-B1B, B1BD, B1D, B1E, B1F, B1F6, B1G6, B2E, B2F, B2F6, B4A, E1A, L2A, M1A, M1B
AEIO-360-B1B, B1D, B1E, B1F, B1F6, B1G6, B1H, B2F, B2F6, B4A, H1A, H1B
O-540-A4D5, B2B5, B2C5, B2C5D, B4B5, B4B5D, E4A5, E4B5, E4C5, G1A5, G2A5, H1A5, H1A5D, H1B5, H1B5D, H2A5, H2A5D, H2B5D
IO-540-C4B5, C4B5D, C4D5, C4D5D, D4A5, D4B5, D4C5, N1A5, N1A5D, T4A5D, T4B5, T4B5D, T4C5D, V4A5, V4A5D
AEIO-540-D4A5, D4B5, D4C5, D4D5
AEL65102-NST26
IO-540-J4A5, R1A5
TIO-540-C1A, E1A, G1A, H1A
AEL65102-NST38
IO-360-F1A
TIO-540-AA1AD, AB1AD, AB1BD, AF1A, AG1A, AK1A, C1A, C1AD, K1AD
LTIO-540-K1AD
AEL65102-NST43
O-360-J2A
O-540-F1B5, J1A5D, J1B5D, J1C5D, J1D5D, J2A5D, J2B5D, J2C5D, J2D5D, J3A5, J3A5D, J3C5D
IO-540-AB1A5, W1A5, W1A5D, W3A5D
AEL65102-NST44
O-540-L3C5D

The Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, "Parallel Valve", reciprocating engines are installed on, but not limited to, the aircraft listed in the following Table 2:

Table 2--Engines Installed on, but Not Limited To

Engine Models:
Installed on , But Not Limited To:
O-320-A1A
Piper Aircraft: Tri-Pacer (PA-22 150 , PA-22S 150 ), Apache (PA-23), Pawnee (PA-25)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Mooney Aircraft: Mark (20A)
Dinfia: Ranquel (1A-46)
Simmering-Graz Pauker: Flamingo (SGP-M-222)
Aviamilano: Scricciolo (P-19)
Vos Helicopter Co.: Spring Bok
O-320-A1B
Piper Aircraft: Tri-Pacer (PA-22 150 , PA-22S 150 ), Apache (PA-23)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
S.O.C.A.T.A.: Horizon (Gardan)
O-320-A2A
Piper Aircraft: Tri-Pacer (PA-22 150 , PA-22S 150 ), Agriculture (PA-18A 150 ), Super Cub (PA -18 150 ), Caribbean (PA-22 150 ), Pawnee(PA-25)
Intermountain Mfg. Co.: Call Air Texas (A-5, A-5T)
Lake Aircraft: Colonial (C-1)
Rawdon Bros.: Rawdon (T-1, T-15, T-15D)
Shinn Engineering: Shinn (2150-A)
Dinfia: Ranquel (1A)46)
Neiva: (1PD-5802)
Sud: Gardan-Horizon (GY-80)
LaVerda: Falco (F8L Series II, America)
Malmo: Vipan (MF1-10)
Kingsford Smith: Autocrat (SCRM-153)
Aero Commander: 100
O-320-A2B
Piper Aircraft: Tri-Pacer (PA-22 150 , PA-22S 150 ), Cherokee (PA-28 150 ), Super Cub (PA -18 150 )
Champion Aircraft: Challenger (7GCA, 7GCB, 7KC), Citabria (7GCAA, 7GCRC), Agriculture (7GCBA)
Beagle: Pup (150)
Artic: Interstate S1B2
Robinson: R-22
Varga: Kachina 2150A
O-320-A2C
Robinson: R-22
Cicare: Cicare AG
Bellanca Aircraft: Citabria 150 (7GCAA), Citabria 150S (7GCBC)
O-320-A2D
Piper Aircraft: Apache (PA-23)
O-320-A3A
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Corben-Fettes: Globe Special (Globe GC-1B)
O-320-A3B
Piper Aircraft: Apache (PA-23)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Teal II: TSC (1A2)
O-320-B1A
Piper Aircraft: Apache (PA-23 160 )
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Malmo: Vipan (MF1-10)
O-320-B1B
Piper Aircraft: Apache (PA-23 160 )
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
O-320-B2A
Piper Aircraft: Tri-Pacer (PA-22 160 , PA-22S 160 )
O-320-B2B
Piper Aircraft: Tri-Pacer (PA-22 160 , PA-22S 160 )
Beagle: Airedale (D5-160)
Fuji-Heavy Industries: Fuji (F-200)
Uirapuru: Aerotec 122
O-320-B2C
Robinson: R-22
O-320-B2D
Maule: MX-7-160
O-320-B2E
Lycon
O-320-B3A
Piper Aircraft: Apache (PA-23 160 )
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
O-320-B3B
Piper Aircraft: Apache (PA-23 160 )
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Sud: Gardan (GY80-160)
O-320-C1A
Piper Aircraft: Apache (PA-23 160 )
Riley Aircraft: Rayjay (Apache)
O-320-C1B
Piper Aircraft: Apache (PA-23 160 )
O-320-C3A
Piper Aircraft: Apache (PA-23 160 )
O-320-C3B
Piper Aircraft: Apache (PA-23 160 )
O-320-D1A
Sud: Gardan (GY-80)
Gyroflug: Speed Cancard
Grob: G115
O-320-D1F
Slingsby: T67 Firefly
O-320-D2A
Piper Aircraft: Cherokee (PA-28S 160 )
Robin: Major (DR400-140B), Chevalier (DR-360), (R-3140)
S.O.C.A.T.A.: Tampico TB9
Slingsby: T67C Firefly
Daetwyler: MD-3-160
Nash Aircraft Ltd.: Petrel
Aviolight: P66D Delta
General Avia: Pinguino
O-320-D2B
Beech Aircraft: Musketeer (M-23)
Piper Aircraft: Cherokee (PA-28 160 )
O-320-D2J
Cessna Aircraft: Skyhawk 172
O-320-D3G
Piper Aircraft: Warrior II, Cadet (PA-28-161)
O-320-E1A
Grob: G115
O-320-E1C
M.B.B. (Messerschmitt-Boelkow-Blohm): Monsun (BO-209-B)
O-320-E1F
M.B.B.: Monsun (BO-209-B)
O-320-E2A
Piper Aircraft: Cherokee (PA-28 140 , PA-28 150 )
Robin: Major (DR-340), Sitar, Bagheera (GY-100-135)
S.O.C.A.T.A.: Super Rallye (MS-886), Rallye Commodore (MS-892)
Siai-Marchetti: (S-202)
F.F.A.: Bravo (AS-202/15)
Partenavia: Oscar (P66B), Bucker (131 APM)
Aeromot: Paulistina P-56
Pezetel: Koliber 150
O-320-E2C
Beech Aircraft: MusketeerIII (M -23III)
M.B.B.: Monsun (BO-209-B)
O-320-E2D
Cessna Aircraft: Cardinal (172-I, 177)
O-320-E2F
M.B.B.: Monsun (BO-209-B), Wassmer Pacific (WA-51)
O-320-E2G
American Aviation Corp.: Traveler
O-320-E3D
Piper Aircraft: Cherokee (140)
Beech Aircraft: Sport
IO-320-B2A
Piper Aircraft: Twin Comanche (PA-30)
IO-320-B1C
Hi. Shear: Wing
IO-320-B1D
Ted Smith Aircraft: Aerostar
IO-320-C1A
Piper Aircraft: Twin Comanche (PA-30 Turbo)
IO-320-D1A
M.B.B.: Monsun (BO-209-C)
IO-320-D1B
M.B.B.: Monsun (BO-209-C)
IO-320-E1A
M.B.B.: Monsun (BO-209-C)
IO-320-E1B
Bellanca Aircraft
IO-320-E2A
Champion Aircraft: Citabria
IO-320-E2B
Bellanca Aircraft
IO-320-F1A
CAAR Engineering: Carr Midget
LIO-320-B1A
Piper Aircraft: Twin Comanche (PA-39)
LIO-320-C1A
Piper Aircraft: Twin Comanche (PA-39)
AIO-320-B1B
M.B.B.: Monsun (BO-209-C)
AEIO-320-D1B
Slingsby: T67M Firefly
AEIO-320-D2B
Hundustan Aeronautics Ltd.: HT-2
AEIO-320-E1A
Bellanca Aircraft
Champion Aircraft
AEIO-320-E1B
Bellanca Aircraft
Champion Aircraft: Decathalon (8KCAB-CS)
AEIO-320-E2B
Bellanca Aircraft
Champion Aircraft: Decathalon (8KCAB)
O-320-A1A
Riley Aircraft: Riley Twin
O-360-A1A
Beech Aircraft: Travel Air (95, B-95)
Piper Aircraft: Comanche (PA-24)
Intermountain Mfg. Co.: Call Air (A-6)
Lake Aircraft: Colonial (C-2, LA -4, 4A or 4P)
Doyn Aircraft: Doyn-Cessna (170B, 172, 172A, 172B)
Mooney Aircraft: Mark 20B (M-20B)
Earl Horton: Pawnee (Piper PA-25)
Dinfia: Ranquel (1A-51)
Neiva: (1PD-5901)
Regente: (N-591)
Wassmer: Super 4 (WA-50A), Sancy (WA-40), Baladou (WA-40), Pariou (WA-40)
Sud: Gardan (GY-180)
Bolkow: (207)
Partenavia: Oscar (P-66)
Siai-Marchetti: (S-205)
Procaer: Picchio (F-15-A)
S.A.A.B.: Safir (91-D)
Malmo: Vipan (MF-10B)
Aero Boero: AB-180
Beagle: Airedale (A-109)
DeHavilland: Drover (DHA-3MK3)
Kingsford-Smith: Bushmaster (J5-6)
Aero Engine Service Ltd.: Victa (R-2)
O-360-A1AD
S.O.C.A.T.A.: Tabago TB-10
O-360-A1D
Piper Aircraft: Comanche (PA-24)
Lake Aircraft: Colonial (LA -4, 4A or 4P)
Doyn Aircraft: Doyn-Beech (Beech 95)
Mooney Aircraft: Master 21 (M-20E), Mark 20B , 20D , (M20B, M20C), Mooney Statesman (M-20G)
Dinfia: Querandi (1A-45)
Wassmer: (WA-50)
Malmo: Vipan (MF1-10)
Cessna Aircraft: Skyhawk
Doyn Aircraft: Doyn-Piper (PA-23 160 )
O-360-A1F6
Cessna Aircraft: Cardinal
O-360-A1F6D
Cessna Aircraft: Cardinal 177
Teal III: TSC (1A3)
O-360-A1G6
Aero Commander
O-360-A1G6D
Beech Aircraft: Duchess 76
O-360-A1H6
Piper Aircraft: Seminole (PA-44)
O-360-A1LD
Wassmer: Europa WA-52
O-360-A1P
Aviat: Husky
O-360-A2A
Center Est Aeronautique: Regente (DR-253)
S.O.C.A.T.A.: Rallye Commodore (MS-893)
Societe Aeronautique Normande: Mousquetaire (D-140)
Bolkow: Klemm (K1-107C)
Partenavia: Oscar (P-66)
Beagle: Husky (D5-180) (J1-U)
O-360-A2D
Piper Aircraft: Comanche (PA-24), Cherokee C (PA-28 180 )
Mooney Aircraft: Master 21 (M-20D), Mark 21 (M-20E)
O-360-A2E
Std. Helicopter
O-360-A2F
Aero Commander: Lark (100)
Cessna Aircraft: Cardinal
O-360-A2G
Beech Aircraft: Sport
O-360-A3A
C.A.A.R.P.S.A.N.: (M-23III)
Societe Aeronautique Normande: Jodel (D-140C)
Robin: Regent (DR400/180), Remorqueur (DR400/180R), R-3170
S.O.C.A.T.A.: Rallye 180GT, Sportavia Sportsman (RS-180)
Norman Aeroplace Co.: NAC-1 Freelance
Nash Aircraft Ltd.: Petrel
O-360-A3AD
S.O.C.A.T.A.: TB-10
Robin: Aiglon (R-1180T)
O-360-A4A
Piper Aircraft: Cherokee D (PA-28 180 )
O-360-A4D
Varga: Kachina
O-360-A4G
Beech Aircraft: Musketeer Custom III
O-360-A4K
Grumman American: Tiger
Beech Aircraft: Sundowner 180
O-360-A4M
Piper Aircraft: Archer II (PA-28 18 )
Valmet: PIK-23
O-360-A4N
Cessna Aircraft: 172 (Optional)
O-360-A4P
Penn Yan: Super Cub Conversion
O-360-A5AD
C. Itoh and Co.: Fuji FA-200
O-360-B2C
Seabird Aviation: SB7L
O-360-C1A
Intermountain Mfg. Co.: Call Air (A-6)
O-360-C1E
Bellanca Aircraft: Scout (8GCBC-CS)
O-360-C1F
Maule: Star Rocket MX-7-180
O-360-C1GChristen: Husky (A-1)
O-360-C2B
Hughes Tool Co.: (269A)
O-360-C2D
Hughes Tool Co.: (269A)
O-360-C2E
Hughes Tool Co.: (YHO-2HU) Military
Bellanca Aircraft: Scout (8GCBC FP)
O-360-C4F
Maule: MX-7-180A
O-360-C4P
Penn Yan: Super Cub Conversion
O-360-F1A6
Cessna Aircraft: Cutlass RG
O-360-J2A
Robinson: R22
IO-360-B1A
Beech Aircraft: Travel-Air (B-95A)
Doyn Aircraft: Doyn-Piper (PA-23 200 )
IO-360-B1B
Beech Aircraft: Travel-Air (B-95B)
Doyn Aircraft: Doyn-Piper (PA-23 200 )
Fuji: (FA-200)
IO-360-B1D
United Consultants: See-Bee
IO-360-B1E
Piper Aircraft: Arrow (PA-28 180R )
IO-360-B1F
Utva: 75
IO-360-B2E
C.A.A.R.P. C.A.P. (10)
IO-360-B1F6
Great Lakes: Trainer
IO-360-B1G6
American Blimp: Spector 42
IO-360-B2F6
Great Lakes: Trainer
LO-360-A1G6D
Beech Aircraft: Duchess
LO-360-A1H6
Piper Aircraft: Seminole (PA-44)
IO-360-E1A
T.R. Smith Aircraft: Aerostar
IO-360-L2A
Cessna Aircraft: Skyhawk C-172
IO-360-M1A
Diamond Aircraft: DA-40
IO-360-M1B
VansAircraft: RV6, RV7, RV8
Lancair: 360
AEIO-360-B1F
F.F.A.: Bravo (200)
Grob: G115/Sport-Acro
AEIO-360-B1G6
Great Lakes
AEIO-360-B2F
Mundry: CAP-10
AEIO-360-B4A
Pitts: S-1S
AEIO-360-H1A
Bellanca Aircraft: Super Decathalon (8KCAB-180)
AEIO-360-H1B
American Champion: Super Decathalon
VO-360-A1A
Brantly Hynes Helicopter: (B-2)
VO-360-A1B
Brantly Hynes Helicopter: (B-2, B2-A). Military (YHO-3BR)
VO-360-B1A
Brantly Hynes Helicopter: (B-2, B2-A)
IVO-360-A1A
Brantly Hynes Helicopter: (B2-B)
HO-360-B1A
Hughes Tool Co.: (269A)
HO-360-B1B
Hughes Tool Co.: (269A)
HO-360-C1A
Schweizer: (300C)
HIO-360-B1A
Hughes Tool Co.: Military (269-A-1), (TH-55A)
HIO-360-B1B
Hughes Tool Co.: (269A)
HIO-360-G1A
Schweizer: (CB)
O-540-A1A
Rhein-Flugzeugbau: (RF-1)
O-540-A1A5
Piper Aircraft: Comanche (PA-24 180 )
Helio: Military (H-250)
Yoeman Aviation: (YA-1)
O-540-A1B5
Piper Aircraft: Aztec (PA-23 250 ), Comanche (PA-24 250 )
O-540-A1C5
Piper Aircraft: Comanche (PA-24 250 )
O-540-A1D
Found Bros.: (FBA-2C)
Dornier: (DO-28-B1)
O-540-A1D5
Piper Aircraft: Aztec (PA-23 250 ), Comanche (PA-24 250 ), Military Aztec (U-11A)
Dornier: (DO-28)
O-540-A2B
Aero Commander: (500)
Mid-States Mfg. Co.: Twin Courier (H-500), (U-5)
O-540-A3D5
Piper Aircraft: Navy Aztec (PA-23 250 )
O-540-B1A5
Piper Aircraft: Apache (PA-23 235 )
O-540-B1B5
Piper Aircraft: Comanche (PA-24 250 )
Doyn Aircraft: Doyn-Piper (PA-24 250 )
O-540-B1D5
Wassmer: (WA-421)
O-540-B2B5
Piper Aircraft: Pawnee (PA-25 235 ), Cherokee (PA-28 235 ), Aztec (PA-23 235 )
Intermountain Mfg. Co.: Call Air (A-9)
Rawdon Bros.: Rawdon (T-1)
S.O.C.A.T.A.: Rallye 235CA
O-540-B2C5
Piper Aircraft: Pawnee (PA-25 235 )
O-540-B4B5
Piper Aircraft: Cherokee (PA-28 235 )
Embraer: Corioca (EMB-710)
S.O.C.A.T.A.: Rallye 235GT, Rallye 235C
Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235)
O-540-E4A5
Piper Aircraft: Comanche (PA-24 260 )
Aviamilano:Flamingo (F-250)
Siai-Marchetti: (SF-260), (SF-208)
O-540-E4B5
Britten-Norman: (BN-2)
Piper Aircraft: Cherokee Six (PA-32 260 )
O-540-E4C5
Pilatus Britten-Norman: Islander (BN-2A-26), Islander (BN-2A-27), Islander II (BN-2B-26), Islander (BN-2A-21), Trislander (BN-2A-Mark III-2)
O-540-F1B5
Omega Aircraft: (BS-12D1)
Robinson: (R-44)
O-540-G1A5
Piper Aircraft: Pawnee (PA-25 260 )
O-540-H1B5D
Aero Boero: 260
O-540-H2A5
Embraer: Impanema AG
Gippsland: GA-200
O-540-H2B5D
Aero Boero: 260
O-540-J1A5D
Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235)
O-540-J3A5
Robin: R-3000/235
O-540-J3A5D
Piper Aircraft: Dakota (PA-28-236)
O-540-J3C5D
Cessna Aircraft: Skylane RG
O-540-L3C5D
Cessna Aircraft: TR-182, Turbo Skylane RG
IO-540-C1B5
Piper Aircraft: Aztec B (PA-23 250 ), Comanche (PA-24 250 )
IO-540-C1C5
Riley Aircraft: Turbo-Rocket
IO-540-C4B5
Piper Aircraft: Aztec C (PA-23 250 ), Aztec F
Wassmer: (WA4-21)
Avions Pierre Robin: (HR100/250)
Bellanca Aircraft: Aries T-250
Aerofab: Renegade 250
IO-540-C4D5
S.O.C.A.T.A.: TB-20
IO-540-C4D5D
S.O.C.A.T.A.: Trinidad TB-20
IO-540-D4A5
Piper Aircraft: Comanche (PA-24 260 )
Siai-Marchetti: (SF-260)
IO-540-D4B5
Cerva: (CE-43 Guepard)
IO-540-J4A5
Piper Aircraft: Aztec (PA-23 250 )
IO-540-R1A5
Piper Aircraft: Comanche (PA-24)
IO-540-T4A5D
General Aviation: Model 114
IO-540-T4B5
Commander: 114B
IO-540-T4B5D
Rockwell: 114
IO-540-T4C5D
Lake Aircraft: Seawolf
IO-540-V4A5
Maule: MT-7-260, M -7-260
Aircraft Manufacturing Factory
IO-540-V4A5D
Brooklands: Scoutmaster
IO-540-W1A5
Maule: MX-7-235, MT-7-235, M7-235
IO-540-W1A5D
Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235)
IO-540-W3A5D
Schweizer: Power Glider
AEIO-540-D4A5
Christen: Pitts (S-2S), S-2B)
Siai-Marchetti: SF-260
H.A.L.: HPT-32
Slingsby: Firefly T3A
AEIO-540-D4B5
Moravan: Zlin-50L
H.A.L.: HPT-32
AEIO-540-D4D5
Burkhart Grob: Grob G, 115T Aero
TIO-540-C1A
Piper Aircraft: Turbo Aztec (PA-23-250)
TIO-540-K1AD
Piper Aircraft
TIO-540-AA1AD
Aerofab Inc.: Turbo Renegade (270)
TIO-540-AB1AD
S.O.C.A.T.A.: Trinidad TC TB-21
TIO-540-AB1BD
Schweizer
TIO-540-AF1A
Mooney Aircraft: TLS M20M
TIO-540-AG1A
Commander Aircraft: 114TC
TIO-540-AK1A
Cessna Aircraft: Turbo Skylane T182T
LTIO-540-K1AD
Piper Aircraft

Unsafe Condition

(e) This AD results from reports of 10 additional cylinder head separations since issuing AD 2008-19-05, on cylinder S/Ns not listed in that AD. We are issuing this AD to prevent loss of engine power due to cracks at the head-to-barrel interface in the cylinder assemblies and possible engine failure caused by separation of a cylinder head, which could result in loss of control of the aircraft.

Compliance

(f) You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done.

Engines Overhauled or Cylinder Assemblies Replaced Since New

(g) If your engine was overhauled or had a cylinder assembly replaced since new, do the following:

(1) Before further flight, inspect the maintenance records and engine logbook to determine if the overhaul or repair facility installed ECi cylinder assemblies, P/N AEL65102, with cylinder head, PN AEL85099, S/N 1138-02 through S/N 35171-22, or S/N 35239-01 through S/N 42179-30, in your engine.

(2) If your cylinder assemblies are not ECi, P/N AEL65102, no further action is required.

(3) If your cylinder assemblies are ECi, P/N AEL65102, but the S/N is not listed in this AD, no further action is required.

(4) If the cylinder assemblies are ECi, P/N AEL65102, and if the S/N is listed in this AD, do the following:

Group "A" Cylinder Assemblies; S/N 1138-02 Through S/N 35171-22

(i) For Group "A" cylinder assemblies:

(A) Perform an initial visual inspection as specified in paragraphs (h) through (i) of thisAD, and an initial compression test as specified in paragraphs (j) through (m) of this AD, within the next 10 operating hours time-in-service (TIS), if the cylinder assembly has 350 or more operating hours TIS on the effective date of this AD, but fewer than 2,000 operating hours TIS.

(B) Perform an initial visual inspection as specified in paragraphs (h) through (i) of this AD, and an initial compression test as specified in paragraphs (j) through (m) of this AD, within the next 10 operating hours TIS, or before exceeding 350 operating hours TIS, whichever occurs later, if the cylinder assembly has fewer than 350 operating hours TIS on the effective date of this AD.

(C) Replace cylinder assemblies installed in helicopter engines within the next 25 operating hours TIS after the effective date of this AD if the cylinder assembly has 1,500 operating hours TIS or more on the effective date of this AD.

(D) Replace cylinder assemblies installed in airplane engines within thenext 25 operating hours TIS after the effective date of this AD if the cylinder assembly has 2,000 operating hours TIS or more on the effective date of this AD.

(E) Perform repetitive visual inspections as specified in paragraphs (h) through (i) of this AD, and repetitive compression tests as specified in paragraphs (j) through (m) of this AD, within every 50 operating hours TIS.

(F) Replace cylinder assemblies installed in helicopter engines that pass the visual inspections and compression tests, no later than 1,500 operating hours TIS after the effective date of this AD.

(G) Replace cylinder assemblies installed in airplane engines that pass the visual inspections and compression tests, no later than 2,000 operating hours TIS after the effective date of this AD.

Group "B" Cylinder Assemblies; S/N 35239-01 through S/N 42179-30

(ii) For Group "B" cylinder assemblies:

(A) Perform an initial visual inspection as specified in paragraphs (h) through (i) of this AD, and initial compression test as specified in paragraphs (j) through (l) of this AD, within the next 10 operating hours TIS.

(B) Replace the cylinder assembly within the next 25 operating hours TIS after the effective date of this AD if the cylinder assembly has 350 or more operating hours TIS on the effective date of this AD.

(C) Replace cylinder assemblies that pass the initial visual inspections and compression tests, before exceeding 350 operating hours TIS after the effective date of this AD.

Visual Inspection

(h) Visually inspect each cylinder head around the exhaust valve side for cracks or any signs of black or white residue of combustion leakage from cracks.

(i) Replace cracked cylinder assemblies before further flight.

Cylinder Assembly Compression Test

(j) Perform a standard cylinder differential compression test.

(k) During the compression test, if the cylinder pressure gauge reads below 70 pounds-per-square-inch, apply a water andsoap solution to the side of the leaking cylinder, near the head-to- barrel interface.

(l) Replace the cylinder assembly before further flight if air leakage and bubbles are observed on the side of the cylinder assembly, near the head-to-barrel interface.

(m) For Group "A" cylinder assemblies only, repair or replace the engine cylinder assembly before further flight if the cause of the low gauge reading in paragraph (k) of this AD is from leaking intake or exhaust valves, or from leaking piston rings.

Prohibition of Group "B" ECi Cylinder Assemblies Affected by This AD

(n) After the effective date of this AD, do not install any Group "B" ECi cylinder assembly, P/N AEL65102, onto any engine and do not attempt to repair or reuse Group "B" cylinder assemblies.

Alternative Methods of Compliance

(o) The Manager, Special Certification Office, has the authority to approve alternative methods of compliance for this AD if requested using the procedures found in 14 CFR 39.19.

Special Flight Permits

(p) Under 14 CFR 39.23, we will not approve special flight permits for this AD for engines that have failed the visual inspection or the cylinder assembly compression test required by this AD.

Related Information

(q) Contact Peter W. Hakala, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; e-mail: peter.w.hakala@faa.gov; telephone (817) 222-5145; fax (817) 222-5785, for more information about this AD.

The FAA proposed to amend 14 CFR part 39 by superseding AD 2008-19-05, Amendment 39-15672 (73 FR 53105, September 15, 2008), with a proposed AD. The proposed AD applies to Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, "Parallel Valve" reciprocating engines, with certain Engine Components, Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series "Titan," installed. We published the proposed AD in the Federal Register on July 30, 2009 (74 FR 37955). That action proposed to require initial and repetitive visual inspections and compression tests to detect cracks at the head-to-barrel interface, replacement of cylinder assemblies found cracked, and replacement of certain cylinder assemblies at new, reduced times-in-service, and for an expanded population of cylinder assemblies.

Examining the AD Docket

You may examine the AD docket on the Internet at http:// www.regulations.gov; or in person at the Docket Operationsoffice between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD docket contains this AD, the regulatory evaluation, any comments received, and other information. The street address for the Docket Operations office (telephone (800) 647-5527) is provided in the ADDRESSES section. Comments will be available in the AD docket shortly after receipt.

Comments

We provided the public the opportunity to participate in the development of this AD. We have considered the comments received.

Two commenters state that proposed AD paragraphs (m) and (n) are confusing and contradictory. Paragraph (m) allows repair or replacement of cylinders with leakage provided that the cylinder is not cracked, but paragraph (n) prohibits removed cylinders from being re-installed.

We agree. We changed paragraph (m) to state "For Group `A' cylinder assemblies only, repair or replace the engine cylinder assembly before further flight if the cause of the low gauge reading in paragraph (k) of this AD is from leaking intake or exhaust valves, or from leaking piston rings." We also changed paragraph (n) to state, "After the effective date of this AD, do not install any Group `B' ECi cylinder assembly, P/N AEL65102, onto any engine and do not attempt to repair or reuse Group `B' cylinder assemblies."

Conclusion

We have carefully reviewed the available data, including the comments received, and determined that air safety and the public interest require adopting the AD with the changes described previously. We have determined that these changes will neither increase the economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

We estimate that this AD will affect about 18,000 ECi cylinder assemblies installed in aircraft of U.S. registry. The visual inspection and compression tests will take about 4 work-hours for each engine. An individual cylinder replacement will require $1,100 for parts and 6 work-hours. Lycomingengines with a set of 4 ECi cylinders will require 12 work-hours for the cylinder replacement. Lycoming engines with a set of 6 ECi cylinders will require 16 work-hours for the cylinder replacement. We estimate 18 percent of the affected population of cylinders will be replaced. We estimate the total cost of the AD to U.S. operators to be $10,172,000. Our estimate is exclusive of any possible warranty coverage.

Authority for This Rulemaking

Title 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I, Section 106, describes the authority of the FAA Administrator. Subtitle VII, Aviation Programs, describes in more detail the scope of the Agency's authority.

We are issuing this rulemaking under the authority described in Subtitle VII, Part A, Subpart III, Section 44701, "General requirements." Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulationsfor practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action.

Regulatory Findings

We have determined that this AD will not have federalism implications under Executive Order 13132. This AD will not have a substantial direct effect on the States, on the relationship between the national government and the States, or on the distribution of power and responsibilities among the various levels of government.

For the reasons discussed above, I certify that this AD:

(1) Is not a "significant regulatory action" under Executive Order 12866;

(2) Is not a "significant rule" under DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and

(3) Will not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act.

We prepared a summary of the costs to comply with this AD and placed it in the AD Docket. You may get a copy of this summary at the address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

Accordingly, under the authority delegated to me by the Administrator, the Federal Aviation Administration amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. 106(g), 40113, 44701.

Sec. 39.13 [Amended]

2. The FAA amends Sec. 39.13 by removing Amendment 39-39-15672 (73 FR 53105, September 15, 2008), and by adding a new airworthiness directive, Amendment 39-16151, to read as follows: