Airworthiness Directives; Engine Components Inc. (ECi) Reciprocating Engine Cylinder Assemblies

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-22358; Directorate Identifier 2005-NE-20-AD; Amendment 39-14431; AD 2005-26-10]

RIN 2120-AA64

Airworthiness Directives; Engine Components Inc. (ECi) Reciprocating Engine Cylinder Assemblies

AGENCY:

Federal Aviation Administration (FAA), Department of Transportation (DOT).

ACTION:

Final rule.

SUMMARY:

The FAA is adopting a new 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 “Classic Cast”, installed. This AD requires replacing these ECi cylinder assemblies. This AD results from reports of about 30 failures of the subject cylinder assemblies marketed by ECi. We are issuing this AD to prevent loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.

DATES:

This AD becomes effective January 31, 2006.

ADDRESSES:

You may examine the AD docket on the Internet at

http://dms.dot.gov

or in Room PL-401 on the plaza level of the Nassif Building, 400 Seventh Street, SW., Washington, DC.

FOR FURTHER INFORMATION CONTACT:

Peter Hakala, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; telephone (817) 222-5145; fax (817) 222-5785.

SUPPLEMENTARY INFORMATION:

The FAA proposed to amend 14 CFR part 39 with a proposed AD. The proposed AD applies to certain ECi cylinder assemblies, P/N AEL65102 series, with casting P/N AEL65099, installed on Lycoming Engines models 320, 360, and 540 series, parallel valve reciprocating engines. Parallel valve Lycoming reciprocating engines are identified by the intake and exhaust valves in a parallel configuration. We published the proposed AD in the

Federal Register

on September 9, 2005 (70 FR 53586). That action proposed to require replacing these ECi cylinder assemblies.

Examining the AD Docket

You may examine the docket that contains the AD, any comments received, and any final disposition in person at the Docket Management Facility Docket Office between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The Docket Office (telephone (800) 647-5227) is located on the plaza level of the Department of Transportation Nassif Building at the street address stated in

ADDRESSES.

Comments will be available in the AD docket shortly after the DMS receives them.

Comments

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

Request To Extend the Proposed AD Comment Period

One commenter, a law office representing ECi, requests we extend the proposed AD comment period an additional 90 days. We do not agree. We have worked with ECi for the past four years regarding the safety and airworthiness issues with the affected ECi cylinder assemblies. ECi is very familiar with the problems with these cylinder assemblies. ECi published Service Bulletin No. 05-08, dated September 1, 2005, for the identification and warranty of the affected cylinder assemblies. Evidence of ECi's awareness of the problem is confirmed by the extensive correspondence with the FAA regarding the service difficulties with P/N AEL65102 “Classic Cast” cylinder assemblies. For these reasons, and because of the minimal amount of comments received (two) on the proposed AD, we find it unnecessary to extend the proposed AD comment period.

Request To Allow Cylinder Assembly Removal at Normal Operating Time-Between-Overhaul

One commenter, ECi, requests that we allow affected cylinder assemblies to be removed at the normal engine operating time-between-overhaul. We do not agree. We have carefully reviewed ECi's request. Both ECi and the FAA participated in the Alloytek Metallurgical Services, Inc. examination and analysis. The examination and

analysis showed that the failure mode of the ECi cylinder assemblies, P/N AEL65102, is most likely due to metal fatigue. The proposed AD required replacing affected cylinder assemblies at no later than 800 operating hours-in-service. The failure data records show that a longer operating time for the affected cylinder assemblies would jeopardize aircraft safety. We have not changed the AD.

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 as proposed.

Costs of Compliance

There were 9,879 ECi cylinder assemblies produced of the affected design available to the worldwide fleet. ECi reported that about fifteen percent of their cylinder assemblies go to foreign countries. We estimate ten percent of the remaining cylinders were never installed or are already removed from service, leaving 7,557 cylinder assemblies in service in the United States. We estimate that 1,574 Lycoming engines are in the United States with the subject cylinder assemblies installed. We estimate that it will take about two work hours per engine to perform the aircraft inspections of the cylinder assemblies for applicability, and that the average labor rate is $65 per work hour. From the Lycoming Engines “Removal and Installation Labor Allowance Guidebook”, dated May 2000, the complete cylinder replacement for a four cylinder engine takes 12 hours, while the complete cylinder replacement for a six cylinder engine takes 16 hours. Required parts will cost about $1,000 per cylinder assembly. Based on these figures, we estimate that the total cost of the AD to U.S. operators to be $9,152,140. ECi indicated that they might give operators and repair stations credit for returned cylinder assemblies toward the purchase of new ECi cylinder assemblies.

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 regulations for 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.

§ 39.13

[Amended]

2. The FAA amends § 39.13 by adding the following new airworthiness directive:

2005-26-10  Engine Components Incorporated (ECi):

Amendment 39-14431. Docket No. FAA-2005-22358; Directorate Identifier. 2005-NE-20-AD.

Effective Date

(a) This airworthiness directive (AD) becomes effective January 31, 2006.

Affected ADs

(b) None.

Applicability

(c) This AD applies to Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, parallel valve, reciprocating engines specified in Table 1 of this AD, with Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series “Classic Cast”, with casting P/N AEL65099 and serial numbers (SNs) 1 through 9879, installed.

Table 1.—Engine Models

Cylinder head part number:

Installed on engine models

AEL65102-NST04

O-320-A1B, A2B, A2C, A2D, A3A, A3B, B2B, B2C, B3B, B3C, C2B, C2C, C3B, C3C, D1A, D1AD, D1B, D1C, D1D, D1F, D2A, D2B, D2C, D2F, D2G, D2H, D2J, D3G, E1A, E1B, E1C, F1F, E1J, E2A, E2B, E2C, E2D, E2E, E2F, E2G, E2H, E3D, E3H

IO-320-A1A, A2A, B1A, B1B, B1C, B1D, B1E, B2A, C1B, D1A, D1AD, D1B, D1C, E1A, E1B, E2A, E2B

AEIO-320-D1B, D2A, D2B, E1A, E1B, E2B

AIO-320-A1A, A1B, A2A, A2B, B1B, C1B

LIO-320-B1A

AEL65102-NST05

O-320-C1A, C1F, F1A

LIO-320-C1A

AEL65102-NST06

O-320-A1A, A2A, A2B, A2C, A3A, A3B, A3C, E1A, E1B, E2A, E2C

AEL65102-NST07

O-320-A2A, B1A, B1B

AEL65102-NST08

O-320-C1A, C1B, C2A, C2B, C3A, C2B, C3C

AEL65102-NST10

O-360-A1A, A1C, A1D, A2A, A2E, A3A, A3D, A4A, C1A, C1C, C1G, C2A, C2B, C2C, C2D, B1A, B1B, B2A, B2B, D1A, D2A, D2B

IO-360-B1A, B1B, B1C

HO-360-A1A, B1A, B1B

HIO-360-B1A, B1B

AEIO-360-B1B

AEIO-540-A1A, A1A5, A1B5, A1C5, A1D, A1D5, A2B, A3D5, A4A5, A4B5, A4C5, A4D5, B1A5, B1B5, B1C5, B2C5D, B4A5, B4A5D, D1A5, E1A, E4A5, E4B5, E4C5, F1A5, F1B5, G1A5, G2A5

IO-540-C1B5, C1C5, C2C, C4B5, C4B5D, C4C5, D4A5, D4B5, N1A5, N1A5D

AEL65102-NST12

O-360-A1A, A1AD, A1C, A1D, A1F, A1F6, A1F6D, A1G, A1G6, A1G6D, A1H, A1H6, A1J, A1LD, A2A, A2D, A2F, A2G, A2H, A3A, A3AD, A3D, A4A, A4AD, A4D, A4G, A4J, A4JD, A4K, A4M, A4N, A5AD, B1A, C1A, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, D2A, F1A6, G1A6

TIO-360-A1A6D

LTO-360-A1A6D

IO-360-A1G6D, A1H6, B1B, B1BD, B1D, B1E, B1F, B1F6, B2E, B2F, B2F6, B4A, E1A, E4A, F1A

IHO-360-B1A, B1B

AEIO-360-B1B, B1D, B1F, B1F6, B1G6, B2F, B2F6, B4A, H1A

O-540-A4D5, B2B5, B2C5, B2C5D, B4B5, B4B5D, E4A5, E4B5, E4B5D, E4C5, G1A5, G1A5D, G2A5, H1A5, H1A5D, H1B5, H1B5D, H2A5, H2A5D, H2B5D

IO-540-C4A5, C4B5, C4B5D, C4D5D, D4A5, D4B5, D4C5, N1A5, T4A5, T4A5D, T4B5D, T4C5D, V4A5D

AEIO-540-D4A5, D4B5, D4C5

AEL65102-NST26

IO-540-J4A5, R1A5

TIO-540-C1A, E1A, G1A, H1A

AEL65102-NST38

(T)IO-360-F1A

TIO-360-AA1AD, AB1AD, C1A, C1AD, AF1A, K1AD

LTIO-540-K1AD

AEL65102-NST43

O-540-J1A5D, J1B5D, J1C5D, J1D5D, J2A5D, J2B5D, J2C5D, J3A5, J3A5D, J3C5D

IO-540-L3C5D, W1A5D, W3A5D

AEL65102-NST44

O-540-L3C5D

For information, the subject 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

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: Musketeer III (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

O-320-H2AD

Cessna Aircraft: Skyhawk 172

Partenavia: P-66C

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-C1G

Christen: 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-E1A6D

Piper Aircraft: Seminole (PA-44 “180”)

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

Vans Aircraft: RV6, RV7, RV8

Lancair: 360

AIO-360-B1B

Moravan: Zlin (Z-526-L)

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

TO-360-C1A6D

Avions Pierre Robin

Partenavia

Rockwell: 112TC

TO-360-F1A6D

Maule: Star Rocket (M-5-210TC)

TIO-360-C1A6D

Partenavia: P68C-TC

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 “150”)

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: Cherokee (PA-24 “250”)

Doyn Aircraft: Doyn-Piper (PA-24 “250”)

O-540-B1D5

Wassmer: (WA-421)

O-540-B2B5

Piper Aircraft: Pawnee (PA-24 “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-24 “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-AF1B

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

(d) This AD results from reports of about 30 failures of the subject cylinder assemblies marketed by ECi. We are issuing this AD to prevent loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.

Compliance

(e) 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 Not Repaired or Overhauled Since New

(f) If your engine has not been overhauled or had any major repair since new, no further action is required.

Engines Overhauled or Repaired Since New

(g) If your engine was overhauled or repaired since new, do the following:

(1) Determine if ECi cylinder assemblies, P/N AEL65102 series “Classic Cast”, with casting P/N AEL65099 and SNs 1 through 9879 are installed on your engine, as follows:

(i) Inspect the engine log books and maintenance records for reference to the subject ECi cylinder assemblies.

(ii) If the engine log books and maintenance records did not record the P/N and SN of the cylinder assemblies, visually inspect the cylinder assemblies and verify the P/N and SN of the cylinder assemblies.

(2) If the cylinder assemblies are not ECi, P/N AEL65102 series “Classic Cast”, with casting P/N AEL65099, no further action is required.

(3) If any cylinder assembly is an ECi P/N AEL65102 series “Classic Cast”, with casting P/N AEL65099 and a SN 1 through 9879, do the following:

(i) If the cylinder assembly has fewer than 800 operating hours-in-service (HIS) on the effective date of this AD, replace the cylinder assembly at no later than 800 operating HIS. No action is required until the operating HIS reaches 800 hours.

(ii) If the cylinder assembly has 800 operating HIS or more on the effective date of this AD, replace the cylinder assembly within 60 operating HIS after the effective date of this AD.

Definition of a Replacement Cylinder Assembly

(h) For the purpose of this AD, a replacement cylinder assembly is defined as follows:

(1) A serviceable cylinder assembly made by Lycoming Engines.

(2) A serviceable FAA-approved, Parts Manufacturer Approval cylinder assembly from another manufacturer.

(3) A serviceable ECi cylinder assembly, P/N AEL65102 series, “Titan”, with casting P/N AEL85009.

(4) A serviceable ECi cylinder assembly, P/N AEL65102 series, with casting P/N AEL65099, that has a SN 9880 or higher.

Prohibition of Cylinder Assemblies, P/N AEL65102 Series “Classic Cast”, With Casting P/N AEL65099 and SNs 1 Through 9879

(i) After the effective date of this AD, do not install any ECi cylinder assembly, P/N AEL65102, with casting P/N AEL65099 that has a SN 1 through 9879, onto any engine.

Alternative Methods of Compliance

(j) 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.

Related Information

(k) ECi Service Bulletin No. 05-08, dated September 1, 2005, pertains to the subject of this AD.

Issued in Burlington, Massachusetts, on December 19, 2005.

Peter A. White,

Acting Manager, Engine and Propeller Directorate, Aircraft Certification Service.

[FR Doc. 05-24449 Filed 12-23-05; 8:45 am]

BILLING CODE 4910-13-P