[Federal Register Volume 70, Number 174 (Friday, September 9, 2005)]
[Proposed Rules]
[Pages 53586-53594]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-17893]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-22358; Directorate Identifier 2005-NE-20-AD]
RIN 2120-AA64


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

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

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: The FAA proposes to adopt 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 proposed AD would 
require replacing these ECi cylinder assemblies. This proposed AD 
results from reports of about 30 failures of the subject cylinder 
assemblies marketed by ECi. We are proposing 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: We must receive any comments on this proposed AD by November 8, 
2005.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov

[[Page 53587]]

and follow the instructions for sending your comments electronically.
     Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street, SW., Nassif Building, Room PL-401, 
Washington, DC 20590-0003.
     Fax: (202) 493-2251.
     Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    You may examine the comments on this proposed AD in the AD docket 
on the Internet at http://dms.dot.gov.

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:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-22358; 
Directorate Identifier 2005-NE-20-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments received by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of the 
Docket Management System (DMS) Web site, anyone can find and read the 
comments in any of our dockets, including the name of the individual 
who sent the comment (or signed the comment on behalf of an 
association, business, labor union, etc.). You may review the DOT's 
complete Privacy Act Statement in the Federal Register published on 
April 11, 2000 (65 FR 19477-78) or you may visit http://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the proposal, any comments 
received and, any final disposition in person at the DMS 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.

Discussion

    We received reports of about 30 failures of 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 investigated the failures and discovered that 
cylinder head fatigue cracks start in the thin wall located between the 
counter-bore of the exhaust valve seat and adjacent cooling fin root. 
Our investigation concluded that the wall thickness of the affected 
area is too thin, making the wall vulnerable to fatigue cracking. Our 
investigation also concluded that the fatigue origin is not associated 
with surface damage resulting from cylinder head over-temperature 
conditions. Based on these findings, we issued Special Airworthiness 
Information Bulletin (SAIB) No. NE-01-32, dated July 18, 2001, to alert 
owners and operators to visually inspect, and to report and replace ECi 
cylinder heads if found cracked.
    As a result of our investigation and issuing SAIB No. NE-01-32, ECi 
introduced an improved cylinder head design for casting P/N AEL65099, 
starting with serial number (SN) 9880. Their design change increased 
the cylinder head exhaust port wall thickness. Since the issuance of 
the SAIB, we continue to receive reports of cracking of ECi cylinder 
assemblies with casting P/N AEL65099, SNs 1 through 9879. The most 
recent report, from Kenya, described three cylinders showing cracks, 
with two of the cylinders separating from the barrel. This condition, 
if not corrected, could result in loss of engine power due to cracks in 
the cylinder assembly and possible engine failure caused by separation 
of a cylinder head. This proposed AD only applies to ECi ``Classic 
Cast'' cylinder assemblies identified with casting P/N AEL65099 and SNs 
1 through 9879.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design.
    We are proposing this AD, which would require the following:
     Determine if ECi cylinder assemblies, P/N AEL65102 series 
``Classic Cast'', with casting P/N AEL65099 and SN 1 through 9879 are 
installed on your engine; and
     If any cylinder assembly is an ECi P/N AEL65102 series 
``Classic Cast'', with casting P/N AEL65099 and a SN 1 through 9879, 
and has fewer than 800 operating hours-in-service (HIS) on the 
effective date of the proposed AD, replace the cylinder assembly at no 
later than 800 operating HIS. No action is required until the operating 
HIS reaches 800 hours.
     If any cylinder assembly is an ECi P/N AEL65102 series 
``Classic Cast'', with casting P/N AEL65099 and a SN 1 through 9879, 
and has 800 operating HIS or more on the effective date of the proposed 
AD, replace the cylinder assembly within 60 operating HIS after the 
effective date of the proposed AD.
     After the effective date of the proposed 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.

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 would take about two work hours per 
engine to perform the proposed 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 would cost about $1,000 per cylinder assembly. Based on 
these figures, we estimate the total cost of the proposed 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.

[[Page 53588]]

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 proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 the proposed 
regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979); and
    3. Would 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 regulatory evaluation of the estimated costs to 
comply with this proposed AD. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Under the authority delegated to me by the Administrator, the 
Federal Aviation Administration proposes to amend 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 adding the following new 
airworthiness directive:

Engine Components Incorporated (ECi): Docket No. FAA-2005-22358; 
Directorate Identifier 2005-NE-20-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by November 8, 
2005.

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.

[[Page 53589]]

 
AEL65102-NST38....................  (T)IO-360--F1A.
                                    TIO-360--AA1AD, AB1AD, C1A, C1AD,
                                     AF1A, K1AD.
                                    LTIO-540--K1AD.
AEL65102-NST38....................  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).

[[Page 53590]]

 
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 (B-209-B).
O-320-E2D.........................  Cessna Aircraft: Cardinal (172-I,
                                     177).
O-320-E2F.........................  M.B.B.: Monsun (BO-209-B).
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).

[[Page 53591]]

 
                                    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.

[[Page 53592]]

 
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).

[[Page 53593]]

 
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 approximately 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.

[[Page 53594]]

    (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.

    Issued in Burlington, Massachusetts, on September 2, 2005.
Ann C. Mollica,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-17893 Filed 9-8-05; 8:45 am]
BILLING CODE 4910-13-P