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2009-26-12 ENGINE COMPONENTS, INC. (ECI):
Amendment 39-16151. Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD. 
EFFECTIVE DATE

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

AFFECTED ADS

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

APPLICABILITY

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

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

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

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

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

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

                    ILLUSTRATION (Table 1--Engine Models)

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:

       ILLUSTRATION (Table 2--Engines Installed on, but Not Limited To)

UNSAFE CONDITION

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

COMPLIANCE

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

ENGINES OVERHAULED OR CYLINDER ASSEMBLIES REPLACED SINCE NEW

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

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

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

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

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

GROUP "A" CYLINDER ASSEMBLIES; S/N 1138-02 THROUGH S/N 35171-22

(i) For Group "A" cylinder assemblies:

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

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

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

(D) Replace cylinder assemblies  installed in airplane engines  within 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 (i) of this AD, and repetitive compression tests as  specified
    in paragraphs (j)  through (m) of  this AD, within  every 50 operating
    hours TIS.

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

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

GROUP "B" CYLINDER ASSEMBLIES; S/N 35239-01 THROUGH S/N 42179-30

(ii) For Group "B" cylinder assemblies:

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

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

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

VISUAL INSPECTION

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

(i) Replace cracked cylinder assemblies before further flight.

CYLINDER ASSEMBLY COMPRESSION TEST

(j) Perform a standard cylinder differential compression test.

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

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

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

PROHIBITION OF GROUP "B" ECI CYLINDER ASSEMBLIES AFFECTED BY THIS AD

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

ALTERNATIVE METHODS OF COMPLIANCE

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

SPECIAL FLIGHT PERMITS

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

RELATED INFORMATION

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

Issued in Burlington, Massachusetts, on December 22, 2009. Peter A. White,
Assistant   Manager,   Engine   and   Propeller   Directorate,    Aircraft
Certification Service.

FOR  FURTHER INFORMATION  CONTACT: Peter  W. Hakala,  Aerospace  Engineer,
Special Certification  Office, FAA,  Rotorcraft Directorate,  2601 Meacham
Blvd.,  Fort Worth,  TX 76193;  e-mail: peter.w.hakala@faa.gov;  telephone
(817) 222-5145; fax (817) 222-5785.
PREAMBLE 

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

ACTION: Final rule.

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

DATES: This AD becomes effective February 4, 2010.

ADDRESSES: 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: peter.w.hakala@faa.gov; telephone (817) 222-5145; fax (817) 222-5785.

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

Examining the AD Docket

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

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

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

Conclusion

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

Costs of Compliance

We estimate that this AD will affect about 18,000 ECi cylinder assemblies installed in aircraft of U.S. registry. The visual inspection and compression tests will take about 4 work-hours for each engine. An individual cylinder replacement will require $1,100 for parts and 6 work-hours. 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 $10,172,000. Our estimate is exclusive of any possible warranty coverage.

Authority for This Rulemaking

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

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

Regulatory Findings

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

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

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

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

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

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

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

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

PART 39--AIRWORTHINESS DIRECTIVES

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

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

Sec. 39.13 [Amended]

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