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

Document Details

Information about this document as published in the Federal Register.

Published Document

This document has been published in the Federal Register. Use the PDF linked in the document sidebar for the official electronic format.

Start Preamble


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


Final rule.


The FAA is adopting a new airworthiness directive (AD) for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, “Parallel Valve” reciprocating engines, with certain Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series “Classic Cast”, installed. This AD requires replacing these ECi cylinder assemblies. This AD results from reports of about 30 failures of the subject cylinder assemblies marketed by ECi. We are issuing this AD to prevent loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.


This AD becomes effective January 31, 2006.


You may examine the AD docket on the Internet at or in Room PL-401 on the plaza level of the Nassif Building, 400 Seventh Street, SW., Washington, DC.

Start Further Info


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.

End Further Info End Preamble Start Supplemental Information


The FAA proposed to amend 14 CFR part 39 with a proposed AD. The proposed AD applies to certain ECi cylinder assemblies, P/N AEL65102 series, with casting P/N AEL65099, installed on Lycoming Engines models 320, 360, and 540 series, parallel valve reciprocating engines. Parallel valve Lycoming reciprocating engines are identified by the intake and exhaust valves in a parallel configuration. We published the proposed AD in the Federal Register on September 9, 2005 (70 FR 53586). That action proposed to require replacing these ECi cylinder assemblies.

Examining the AD Docket

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


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

Request To Extend the Proposed AD Comment Period

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

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

One commenter, ECi, requests that we allow affected cylinder assemblies to be removed at the normal engine operating time-between-overhaul. We do not agree. We have carefully reviewed ECi's request. Both ECi and the FAA participated in the Alloytek Metallurgical Services, Inc. examination and analysis. The examination and Start Printed Page 76386analysis showed that the failure mode of the ECi cylinder assemblies, P/N AEL65102, is most likely due to metal fatigue. The proposed AD required replacing affected cylinder assemblies at no later than 800 operating hours-in-service. The failure data records show that a longer operating time for the affected cylinder assemblies would jeopardize aircraft safety. We have not changed the AD.


We have carefully reviewed the available data, including the comments received, and determined that air safety and the public interest require adopting the AD as proposed.

Costs of Compliance

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

Authority for This Rulemaking

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

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

Regulatory Findings

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

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

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

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

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

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

Start List of Subjects

List of Subjects in 14 CFR Part 39

  • Air transportation
  • Aircraft
  • Aviation safety
  • Safety
End List of Subjects

Adoption of the Amendment

Start Amendment Part

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

End Amendment Part Start Part


End Part Start Amendment Part

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

End Amendment Part Start Authority

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

End Authority
Start Amendment Part

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

End Amendment Part

2005-26-10  Engine Components Incorporated (ECi): Amendment 39-14431. Docket No. FAA-2005-22358; Directorate Identifier. 2005-NE-20-AD.

Effective Date

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

Affected ADs

(b) None.


(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-NST04O-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
AEL65102-NST05O-320-C1A, C1F, F1A
AEL65102-NST06O-320-A1A, A2A, A2B, A2C, A3A, A3B, A3C, E1A, E1B, E2A, E2C
AEL65102-NST07O-320-A2A, B1A, B1B
AEL65102-NST08O-320-C1A, C1B, C2A, C2B, C3A, C2B, C3C
AEL65102-NST10O-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
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HO-360-A1A, B1A, B1B
HIO-360-B1A, 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-NST12O-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
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-NST26IO-540-J4A5, R1A5
TIO-540-C1A, E1A, G1A, H1A
AEL65102-NST43O-540-J1A5D, J1B5D, J1C5D, J1D5D, J2A5D, J2B5D, J2C5D, J3A5, J3A5D, J3C5D
IO-540-L3C5D, W1A5D, W3A5D

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-A1APiper 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-A1BPiper 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-A2APiper 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-A2BPiper 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-A2CRobinson: R-22
Cicare: Cicare AG
Bellanca Aircraft: Citabria 150 (7GCAA), Citabria 150S (7GCBC)
O-320-A2DPiper Aircraft: Apache (PA-23)
O-320-A3ADoyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Corben-Fettes: Globe Special (Globe GC-1B)
O-320-A3BPiper Aircraft: Apache (PA-23)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
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Teal II: TSC (1A2)
O-320-B1APiper Aircraft: Apache (PA-23 “160”)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Malmo: Vipan (MF1-10)
O-320-B1BPiper Aircraft: Apache (PA-23 “160”)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
O-320-B2APiper Aircraft: Tri-Pacer (PA-22 “160”, PA-22S “160”)
O-320-B2BPiper Aircraft: Tri-Pacer (PA-22 “160”, PA-22S “160”)
Beagle: Airedale (D5-160)
Fuji-Heavy Industries: Fuji (F-200)
Uirapuru: Aerotec 122
O-320-B2CRobinson: R-22
O-320-B2DMaule: MX-7-160
O-320-B3APiper Aircraft: Apache (PA-23 “160”)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
O-320-B3BPiper Aircraft: Apache (PA-23 “160”)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Sud: Gardan (GY80-160)
O-320-C1APiper Aircraft: Apache (PA-23 “160”)
Riley Aircraft: Rayjay (Apache)
O-320-C1BPiper Aircraft: Apache (PA-23 “160”)
O-320-C3APiper Aircraft: Apache (PA-23 “160”)
O-320-C3BPiper Aircraft: Apache (PA-23 “160”)
O-320-D1ASud: Gardan (GY-80)
Gyroflug: Speed Cancard
Grob: G115
O-320-D1FSlingsby: T67 Firefly
O-320-D2APiper 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-D2BBeech Aircraft: Musketeer (M-23)
Piper Aircraft: Cherokee (PA-28 “160”)
O-320-D2JCessna Aircraft: Skyhawk 172
O-320-D3GPiper Aircraft: Warrior II, Cadet (PA-28-161)
O-320-E1AGrob: G115
O-320-E1CM.B.B. (Messerschmitt-Boelkow-Blohm): Monsun (BO-209-B)
O-320-E1FM.B.B.: Monsun (BO-209-B)
O-320-E2APiper 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-E2CBeech Aircraft: Musketeer III (M-23III)
M.B.B.: Monsun (BO-209-B)
O-320-E2DCessna Aircraft: Cardinal (172-I, 177)
O-320-E2FM.B.B.: Monsun (BO-209-B), Wassmer Pacific (WA-51)
O-320-E2GAmerican Aviation Corp.: Traveler
O-320-E3DPiper Aircraft: Cherokee (140)
Beech Aircraft: Sport
O-320-H2ADCessna Aircraft: Skyhawk 172
Partenavia: P-66C
IO-320-B2APiper Aircraft: Twin Comanche (PA-30)
IO-320-B1CHi. Shear: Wing
IO-320-B1DTed Smith Aircraft: Aerostar
IO-320-C1APiper Aircraft: Twin Comanche (PA-30 Turbo)
IO-320-D1AM.B.B.: Monsun (BO-209-C)
IO-320-D1BM.B.B.: Monsun (BO-209-C)
IO-320-E1AM.B.B.: Monsun (BO-209-C)
IO-320-E1BBellanca Aircraft
IO-320-E2AChampion Aircraft: Citabria
IO-320-E2BBellanca Aircraft
IO-320-F1ACAAR Engineering: Carr Midget
LIO-320-B1APiper Aircraft: Twin Comanche (PA-39)
LIO-320-C1APiper Aircraft: Twin Comanche (PA-39)
AIO-320-B1BM.B.B.: Monsun (BO-209-C)
Start Printed Page 76389
AEIO-320-D1BSlingsby: T67M Firefly
AEIO-320-D2BHundustan Aeronautics Ltd.: HT-2
AEIO-320-E1ABellanca Aircraft
Champion Aircraft
AEIO-320-E1BBellanca Aircraft
Champion Aircraft: Decathalon (8KCAB-CS)
AEIO-320-E2BBellanca Aircraft
Champion Aircraft: Decathalon (8KCAB)
O-320-A1ARiley Aircraft: Riley Twin
O-360-A1ABeech 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-A1ADS.O.C.A.T.A.: Tabago TB-10
O-360-A1DPiper 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-A1F6Cessna Aircraft: Cardinal
O-360-A1F6DCessna Aircraft: Cardinal 177
Teal III: TSC (1A3)
O-360-A1G6Aero Commander
O-360-A1G6DBeech Aircraft: Duchess 76
O-360-A1H6Piper Aircraft: Seminole (PA-44)
O-360-A1LDWassmer: Europa WA-52
O-360-A1PAviat: Husky
O-360-A2ACenter 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-A2DPiper Aircraft: Comanche (PA-24), Cherokee “C” (PA-28 “180”)
Mooney Aircraft: Master “21” (M-20D), Mark “21” (M-20E)
O-360-A2EStd. Helicopter
O-360-A2FAero Commander: Lark (100)
Cessna Aircraft: Cardinal
O-360-A2GBeech Aircraft: Sport
O-360-A3AC.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-A3ADS.O.C.A.T.A.: TB-10
Robin: Aiglon (R-1180T)
O-360-A4APiper Aircraft: Cherokee “D” (PA-28 “180”)
O-360-A4DVarga: Kachina
O-360-A4GBeech Aircraft: Musketeer Custom III
O-360-A4KGrumman American: Tiger
Start Printed Page 76390
Beech Aircraft: Sundowner 180
O-360-A4MPiper Aircraft: Archer II (PA-28 “18”)
Valmet: PIK-23
O-360-A4NCessna Aircraft: 172 (Optional)
O-360-A4PPenn Yan: Super Cub Conversion
O-360-A5ADC. Itoh and Co.: Fuji FA-200
O-360-B2CSeabird Aviation: SB7L
O-360-C1AIntermountain Mfg. Co.: Call Air (A-6)
O-360-C1EBellanca Aircraft: Scout (8GCBC-CS)
O-360-C1FMaule: Star Rocket MX-7-180
O-360-C1GChristen: Husky (A-1)
O-360-C2BHughes Tool Co.: (269A)
O-360-C2DHughes Tool Co.: (269A)
O-360-C2EHughes Tool Co.: (YHO-2HU) Military
Bellanca Aircraft: Scout (8GCBC FP)
O-360-C4FMaule: MX-7-180A
O-360-C4PPenn Yan: Super Cub Conversion
O-360-E1A6DPiper Aircraft: Seminole (PA-44 “180”)
O-360-F1A6Cessna Aircraft: Cutlass RG
O-360-J2ARobinson: R22
IO-360-B1ABeech Aircraft: Travel-Air (B-95A)
Doyn Aircraft: Doyn-Piper (PA-23 “200”)
IO-360-B1BBeech Aircraft: Travel-Air (B-95B)
Doyn Aircraft: Doyn-Piper (PA-23 “200”)
Fuji: (FA-200)
IO-360-B1DUnited Consultants: See-Bee
IO-360-B1EPiper Aircraft: Arrow (PA-28 “180R”)
IO-360-B1FUtva: 75
IO-360-B2EC.A.A.R.P. C.A.P. (10)
IO-360-B1F6Great Lakes: Trainer
IO-360-B1G6American Blimp: Spector 42
IO-360-B2F6Great Lakes: Trainer
LO-360-A1G6DBeech Aircraft: Duchess
LO-360-A1H6Piper Aircraft: Seminole (PA-44)
IO-360-E1AT.R. Smith Aircraft: Aerostar
IO-360-L2ACessna Aircraft: Skyhawk C-172
IO-360-M1ADiamond Aircraft: DA-40
IO-360-M1BVans Aircraft: RV6, RV7, RV8
Lancair: 360
AIO-360-B1BMoravan: Zlin (Z-526-L)
AEIO-360-B1FF.F.A.: Bravo (200)
Grob: G115/Sport-Acro
AEIO-360-B1G6Great Lakes
AEIO-360-B2FMundry: CAP-10
AEIO-360-B4APitts: S-1S
AEIO-360-H1ABellanca Aircraft: Super Decathalon (8KCAB-180)
AEIO-360-H1BAmerican Champion: Super Decathalon
TO-360-C1A6DAvions Pierre Robin
Rockwell: 112TC
TO-360-F1A6DMaule: Star Rocket (M-5-210TC)
TIO-360-C1A6DPartenavia: P68C-TC
VO-360-A1ABrantly Hynes Helicopter: (B-2)
VO-360-A1BBrantly Hynes Helicopter: (B-2, B2-A). Military (YHO-3BR)
VO-360-B1ABrantly Hynes Helicopter: (B-2, B2-A)
IVO-360-A1ABrantly Hynes Helicopter: (B2-B)
HO-360-B1AHughes Tool Co.: (269A)
HO-360-B1BHughes Tool Co.: (269A)
HO-360-C1ASchweizer: (300C)
HIO-360-B1AHughes Tool Co.: Military (269-A-1). (TH-55A)
HIO-360-B1BHughes Tool Co.: (269A)
HIO-360-G1ASchweizer: (CB)
O-540-A1ARhein-Flugzeugbau: (RF-1)
O-540-A1A5Piper Aircraft: Comanche (PA-24 “150”)
Helio: Military (H-250)
Yoeman Aviation: (YA-1)
O-540-A1B5Piper Aircraft: Aztec (PA-23 “250”), Comanche (PA-24 “250”)
O-540-A1C5Piper Aircraft: Comanche (PA-24 “250”)
O-540-A1DFound Bros.: (FBA-2C)
Dornier: (DO-28-B1)
O-540-A1D5Piper Aircraft: Aztec (PA-23 “250”), Comanche (PA-24 “250”), Military Aztec (U-11A)
Dornier: (DO-28)
O-540-A2BAero Commander: (500)
Mid-States Mfg. Co.: Twin Courier (H-500), (U-5)
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O-540-A3D5Piper Aircraft: Navy Aztec (PA-23 “250”)
O-540-B1A5Piper Aircraft: Apache (PA-23 “235”)
O-540-B1B5Piper Aircraft: Cherokee (PA-24 “250”)
Doyn Aircraft: Doyn-Piper (PA-24 “250”)
O-540-B1D5Wassmer: (WA-421)
O-540-B2B5Piper 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-B2C5Piper Aircraft: Pawnee (PA-24 “235”)
O-540-B4B5Piper 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-E4A5Piper Aircraft: Comanche (PA-24 “260”)
Aviamilano: Flamingo (F-250)
Siai-Marchetti: (SF-260), (SF-208)
O-540-E4B5Britten-Norman: (BN-2)
Piper Aircraft: Cherokee Six (PA-32 “260”)
O-540-E4C5Pilatus 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-F1B5Omega Aircraft: (BS-12D1)
Robinson: (R-44)
O-540-G1A5Piper Aircraft: Pawnee (PA-25 “260”)
O-540-H1B5DAero Boero: 260
O-540-H2A5Embraer: Impanema “AG”
Gippsland: GA-200
O-540-H2B5DAero Boero: 260
O-540-J1A5DMaule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235)
O-540-J3A5Robin: R-3000/235
O-540-J3A5DPiper Aircraft: Dakota (PA-28-236)
O-540-J3C5DCessna Aircraft: Skylane RG
O-540-L3C5DCessna Aircraft: TR-182, Turbo Skylane RG
IO-540-C1B5Piper Aircraft: Aztec B (PA-23 “250”), Comanche (PA-24 “250”)
IO-540-C1C5Riley Aircraft: Turbo-Rocket
IO-540-C4B5Piper 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-C4D5S.O.C.A.T.A.: TB-20
IO-540-C4D5DS.O.C.A.T.A.: Trinidad TB-20
IO-540-D4A5Piper Aircraft: Comanche (PA-24 “260”)
Siai-Marchetti: (SF-260)
IO-540-D4B5Cerva: (CE-43 Guepard)
IO-540-J4A5Piper Aircraft: Aztec (PA-23 “250”)
IO-540-R1A5Piper Aircraft: Comanche (PA-24)
IO-540-T4A5DGeneral Aviation: Model 114
IO-540-T4B5Commander: 114B
IO-540-T4B5DRockwell: 114
IO-540-T4C5DLake Aircraft: Seawolf
IO-540-V4A5Maule: MT-7-260, M-7-260
Aircraft Manufacturing Factory
IO-540-V4A5DBrooklands: Scoutmaster
IO-540-W1A5Maule: MX-7-235, MT-7-235, M7-235
IO-540-W1A5DMaule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235)
IO-540-W3A5DSchweizer: Power Glider
AEIO-540-D4A5Christen: Pitts (S-2S), S-2B)
Siai-Marchetti: SF-260
H.A.L.: HPT-32
Slingsby: Firefly T3A
AEIO-540-D4B5Moravan: Zlin-50L
H.A.L.: HPT-32
AEIO-540-D4D5Burkhart Grob: Grob G, 115T Aero
TIO-540-C1APiper Aircraft: Turbo Aztec (PA-23-250)
TIO-540-K1ADPiper Aircraft
TIO-540-AA1ADAerofab Inc.: Turbo Renegade (270)
TIO-540-AB1ADS.O.C.A.T.A.: Trinidad TC TB-21
TIO-540-AF1AMooney Aircraft: “TLS” M20M
TIO-540-AF1BMooney Aircraft: “TLS” M20M
TIO-540-AG1ACommander Aircraft: 114TC
TIO-540-AK1ACessna Aircraft: Turbo Skylane T182T
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LTIO-540-K1ADPiper Aircraft

Unsafe Condition

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


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

Engines Not Repaired or Overhauled Since New

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

Engines Overhauled or Repaired Since New

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

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

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

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

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

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

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

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

Definition of a Replacement Cylinder Assembly

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

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

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

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

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

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

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

Alternative Methods of Compliance

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

Related Information

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

Start Signature

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

Peter A. White,

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

End Signature End Supplemental Information

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