[Federal Register Volume 73, Number 179 (Monday, September 15, 2008)]
[Rules and Regulations]
[Pages 53105-53113]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E8-21125]



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  Federal Register / Vol. 73, No. 179 / Monday, September 15, 2008 / 
Rules and Regulations  

[[Page 53105]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD; 
Amendment 39-15672; AD 2008-19-05]
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 ``Titan'', installed. This AD 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 results from reports of 45 failures with head 
separations of ECi cylinder assemblies. 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.

DATES: This AD becomes effective October 20, 2008.

ADDRESSES: You can get the service information identified in this AD 
from Engine Components, Inc., 9503 Middlex, San Antonio, TX 78217; 
Phone (800) 324-2359; fax (210) 820-8102; http://www.eci2fly.com.
    The Docket Operations office is located at Docket Management 
Facility, U.S. Department of Transportation, 1200 New Jersey Avenue, 
SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-
0001.

FOR FURTHER INFORMATION CONTACT: Peter W. Hakala, Aerospace Engineer, 
Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76193; e-mail: [email protected]; 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 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 May 
19, 2008 (73 FR 28756). 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.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Operations office 
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.

Request To Reduce the Economic Impact

    One commenter, the Aircraft Owners and Pilots Association, states 
that the 50-hour inspection interval should be increased to 100 hours, 
to reduce the economic impact of the cylinder assembly inspections. 
Another commenter, a private citizen, states that the cost of the 50-
hour inspections was not considered in the NPRM economic estimate.
    We do not agree. We selected the 50-hour inspection interval so 
that aluminum cylinder cracks could be detected before a head 
separation occurred. By removing leaking cylinder heads discovered 
during the periodic 50-hour inspections, the probability of having an 
in flight head separation is greatly reduced. Also, the 50-hour 
inspection interval coincides with the scheduled maintenance for normal 
engine oil and filter changes. Also, the costs of compliance in the 
NPRM did include costs for the additional cylinder assembly 
inspections. We did not change the AD.

Retiring Cylinder Assemblies at Time-Between-Overhaul Is Too Expensive

    One commenter, a private citizen, states that it is too expensive 
to retire all the subject cylinder assemblies at the normal overhaul 
time. Another commenter, a private citizen, states that it is 
unreasonable for general aviation airplane owners, in Part 91 use, to 
be required to retire cylinder assemblies at the time-between-overhaul 
or at normal engine overhaul time.
    We do not agree. The subject cylinder assemblies can be safely run 
to the normal TBO with the required 50-hour inspections, with 
compression tests. Because of metallurgical analysis results of the 
fatigue cracks in the aluminum alloy cylinder heads, and also the 
history of the head separation hours-in-service, the probability of a 
head separation is greater with the subject cylinder assemblies running 
past the time-between-overhaul time. Therefore, we do not consider the 
cylinder assemblies to be airworthy past the normal engine overhaul 
time. We did not change the AD.

[[Page 53106]]

Cylinder Assembly Serial Number Range Is Different in the ECi Mandatory 
Service Bulletin

    One commenter, ECi., states that the cylinder assembly serial 
number range in the proposed AD for the Group ``B'' cylinders is 
slightly different from the serial numbers listed in the ECi Mandatory 
service Bulletin No. 08-1. The commenter states that several additional 
cylinder serial numbers should be included in Group ``B''.
    We do not agree. We researched the cylinder assembly serial numbers 
in the proposed AD and they are correct. The Group ``A'' cylinder 
assemblies go up to serial number 35171-22. The Group ``B'' cylinder 
assemblies start at serial number 35239-01. We discussed the serial 
number comment with ECi. They agree that the serial number range in the 
proposed AD is correct. ECi states that they have revised the serial 
numbers in ECi. Mandatory Service Bulletin (MSB) No. 08-1 to match the 
serial numbers in the AD, and issued MSB No. 08-1, Revision 3, dated 
August 19, 2008. We now reference this MSB Revision 3 in 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. 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 13,000 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. Lycoming engines 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 $7,952,000. 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 
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

0
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

0
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]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2008-19-05 Engine Components, Inc. (ECi): Amendment 39-15672. Docket 
No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective October 
20, 2008.

Affected ADs

    (b) None.

Applicability

    (c) 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 (SNs) are SN 
1138-02 through SN 35171-22, (referred to in this AD as Group ``A'' 
cylinder assemblies); and
    (2) SN 35239-01 through SN 37016-28 (referred to in this AD as 
Group ``B'' cylinder assemblies).
    (3) Note that 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) Note that the set of numbers appearing on the cylinder, 
above and to the left of the SN, in the form of ``123456'' is not 
used for determining applicability.

                         Table 1--Engine Models
------------------------------------------------------------------------
 Cylinder assembly part No.:          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

[[Page 53107]]

 
                               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, B2C5D,
                                B4A5, B4B5, B4B5D, 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, 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, E4B5D, E4C5, G1A5,
                                G1A5D, 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
------------------------------------------------------------------------

    For information, 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).

[[Page 53108]]

 
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).

[[Page 53109]]

 
                               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.
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).

[[Page 53110]]

 
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.:HIO-360-B1A (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...................  Vans Aircraft: 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.

[[Page 53111]]

 
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.

[[Page 53112]]

 
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-K1A.................  Piper Aircraft.
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from reports of 45 failures with head 
separations of ECi cylinder assemblies. 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

    (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 Overhauled or Cylinder Assemblies Not Replaced Since New

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

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 used 
ECi cylinder assemblies, P/N AEL65102, with cylinder head, PN 
AEL85099, with a SN 1138-02 through SN 35171-22, or a SN 35239-01 
through SN 37016-28, installed.
    (2) If the cylinder assemblies are not ECi, P/N AEL65102, no 
further action is required.
    (3) If the cylinder assemblies are ECi, P/N AEL65102, and if the 
serial number is not listed in this AD, no further action is 
required.
    (4) If the cylinder assemblies are ECi, P/N AEL65102, and if the 
serial number is listed in this AD, do the following:

Group ``A'' Cylinder Assemblies

    (i) For Group ``A'' cylinder assemblies:
    (A) Perform an initial visual inspection as specified in 
paragraphs (h) through (j) of this AD, and an initial compression 
test as specified in paragraphs (k) through (o) 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 (j) of this AD, and an initial compression 
test as specified in paragraphs (k) through (o) of this AD, before 
exceeding 350 operating hours TIS, 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 the next 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 (j) of this AD, and repetitive compression 
tests as specified in paragraphs (k) through (o) 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

    (ii) For Group ``B'' cylinder assemblies:
    (A) Perform an initial visual inspection as specified in 
paragraphs (h) through (j) of this AD, and initial compression test 
as specified in paragraphs (k) through (o) of this AD, within an 
additional 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 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.
    (j) Information on cylinder assembly visual inspection can be 
found in ECi Mandatory Service Bulletin (MSB) No. 08-1, Revision 3, 
dated August 19, 2008.

Cylinder Assembly Compression Test

    (k) Compression test the cylinder assembly.
    (l) Information on cylinder assembly compression testing can be 
found in ECi MSB No. 08-1, Revision 3, dated August 19, 2008.
    (m) During the compression test, if the cylinder pressure gauge 
reads below 70 pounds-per-square-inch, apply a water and

[[Page 53113]]

soap solution to the side of the leaking cylinder, near the head-to-
barrel interface.
    (n) 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.
    (o) Repair or replace the engine cylinder assembly before 
further flight if the cause of the low gauge reading in paragraph 
(m) of this AD is from leaking intake or exhaust valves, or from 
leaking piston rings.

Prohibition of ECi Cylinder Assemblies Affected by This AD

    (p) After the effective date of this AD, do not install any ECi 
cylinder assembly, P/N AEL65102, with cylinder head, P/N AEL85099, 
and with SN 1138-02 through SN 35171-22, or SN 35239-01 through SN 
37016-28, onto any engine, and do not attempt to repair or reuse 
these ECi cylinder assemblies.

Alternative Methods of Compliance

    (q) 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

    (r) 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

    (s) ECi Mandatory Service Bulletin No. 08-1, Revision 3, dated 
August 19, 2008, pertains to the subject of this AD.
    (t) Contact Peter W. Hakala, Aerospace Engineer, Special 
Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76193; e-mail: [email protected]; 
telephone (817) 222-5145; fax (817) 222-5785, for more information 
about this AD.

    Issued in Burlington, Massachusetts, on September 5, 2008.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E8-21125 Filed 9-12-08; 8:45 am]
BILLING CODE 4910-13-P