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Airmotive Steel, CermiNil, Classic Cast, D ouble Band, ECi, FREEDOM, IFR, Nickel+Carbide , Q3, Q4, Q5, TITAN and TITAN Advanced a re Trademarks or Registered Trademarks of Engine Components, Inc. T113 

### S.B. No .: 05-8 

# Mandatory Service Bulletin

ENGINE COMPONENTS, INC. Page : 1 of 2

Issued : 09/01/05

Revision : 1 (12/29/05) Title: REPLACEMENT OF CLASSIC CAST CYLINDERS IN

COMPLIANCE WITH AIRWORTH INESS DIRECTIVE 2005-26-10

1.0 PURPOSE: To announce a replacement program for Engi ne Components, Inc. (ECi®) Classic CastTM i cylinders (P/N AEL65102) manufactured using Closa Foundry head castings for Lycoming parallel valve engines, in accordance with the FAA’s Airworthiness Directive (AD) 2005-26-10 which becomes effective January 31, 2006.

2.0 BACKGROUND: ECi produced and sold Classic Cast cylinders addres sed in this Mandatory Service Bulletin and FAA’s Airworthiness Directive beginning in January 1997 through September 2001. These cylinders were the subject of a Special

Airworthiness Information Bulletin No. NE-01-32 issued July 18, 2001. Subseq uent to the issuance of the SAIB, the FAA

and ECi have continued to receive re ports of cracks in these cylinders.

3.0 TIME OF COMPLIANCE : If the cylinder assemblies are identified as bei ng affected by this AD per sections 4.0 and 5.0 of this Mandatory Service Bulletin, then:

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

3.2 If, on the effective date of this AD, the cylinder asse mbly has 800 operating HIS or more, replace the cylinder assembly within 60 operating HIS af ter the effective date of the AD.

4.0 MODELS AFFECTED: The Classic Cast replacement cylinders to be replaced are eligible for installation on the following engines:

O-320 -A1A, A1B, A2A, A2B, A2C, A2D, A3A, A3B, A3C, B1A, B1B, B2A, B2B, B2C, B3A, B3B, B3C, C1A, C1B, C2A, C2B, C2C, C3A, C3B, C3C, D1A, D1AD, D1B, D1C, D1D, D1F, D2A, D2B, D2C, D2F, D2G, D2H, D2J, D3G, E1A, E1B, E1C, E1F, E1J, E2A, E2B, E2 C, E2D, E2E, E2F, E2G, E2H, E3D, E3H; IO-320 -A1A, A2A, B1A, B1B, B1C, B1D, B1E, B2A, C1A, C1B, C1F, D1A, D1AD , D1B, D1C, E1A, E1B, E2A, E2B, F1A; AIO-320 -A1A, A1B, A2A, A2B, B1B, C1B; AEIO-320 -D1B, D2B, E1A, E1B, E2A, E2B; LIO-320 -B1A, C1A; O-360 -A1A, A1AD, A1C, A1D, A1F, A1F6, A1F6D, A1G, A1G6, A1G6D, A1H, A1H6, A1J, A1LD, A2A, A2D, A2E, A2F, A2G, A2H, A3A, A3AD, A3D, A4A, A4AD, A4D, A4G, A4J, A4JD, A4K, A4M, A4N, A5AD, B1A, B2A, B2B, C1A, C1C, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, D1A, D2A, D2B, F1A6, G1A6; LO-360-A1G6D, A1H6; IO-360 -B1A, B1B, B1BD, B1C, B1D, B1E, B1F, B1F6, B2E, B2F, B2F6, B4A, E1A; TO-360 -A1G6D; LTO-360 -A1G6D; HO-360 -A1A, B1A, B1B, C1A;

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, E4B5D, E4C5, F1A5, F1B5, G1A5, G1A5D, G2A5, H1A5, H1A5D, H1B5, H1B5D, H2A5, H2A5D, H2B5D, J1A5D, J1B5D, J1C5D, J1D5D, J3A5, J3A5D, J3C5D;

IO-540 - A1A, C1B5, C1C5, C2C, C4A5, C4B5, C4B5D, C4C5, C4D5D, D4A5, D4B5, D4C5, J4A5, N1A5, N1A5D, R1A5, T4A5, T4A5D, T4B5D, T4C5D, V4A5D, W1A5D, W3A5D; LTIO-540 -K1AD

5.0 CYLINDER IDENTIFICATION : The ECi Classic Cast cylinders that are affected by this AD are identified through several unique features. The primary identifi cation feature is the casting part number, AEL 6 5099, which is cast into the cylinder rocker flange above the exhaust port as shown in Photograph 1 (next page.) Classic Cast replacement cylinders for Lycoming parallel valve engines have this unique number while the TITAN® brand cylinders, which are NOT the subject of this Mandatory Service Bulletin, have casting number AEL 8 5099 (See photograph 2 next page.) NOTE: The Subject Matter of This Service Bulletin Is Incorporated In Whole Or In Part in an FAA Airworthiness Directive. Technical Portions are FAA DER Approved.ENGINE COMPONENTS, INC.
Mandatory Service Bulletin No. 05-8, Revision 1 (12/29/05)

REPLACEMENT OF CLASSIC CAST CYLINDERS IN COMPLIANCE WITH

AIRWORTHINESS DIRECTIVE 2005-26-10 Page 2 of 2

Photograph 2 TITAN Cylinder (Oberdorfer Casting)

NOT AFFECTED BY AD Photograph 1 Classic Cast (Closa Casting ) Affected by AD

Photograph 3 Location of cylinder serial number (Must be between 110 and 9879) The “EC” logo on the Classic Cast heads is also on the rocker flange toward the intake port side of the cylinder head (Photograph 1), whereas the TITAN cylinder ha s the Oberdorfer logo as well as the ECi logo, instead of just “EC” (Photograph 2. )

The cylinder serial number is marked on the side of the cylinder below the rocker cover flange on the intake side. Cylinders wi th part number AEL65099 as described in Photograph 1 (above) AND with serial numbers that are between 110 and 9879 are affected by this service bulletin and AD 2005-26-10. Photograph 3 (below) describes the location of the serial number which

must be 9879 or lower. Cylinders with serial numbers 9880 or higher are not affected.

6.0 REPLACEMENT PROGRAM : ECi will exchange each Classic Cast cylinde r returned under this program with a new TITAN cylinder complete assembly at a special lower exchange price. The discount will be based on the actual hours in service for the cylinder(s). ECi will also provide pro-rated la bor reimbursement for removal and installation. Owners or operators that wish to exchange their cylinders should c ontact ECi Customer Service to obtain a Returned Material Authorization (RMA) number and a completed Warranty Application (Form T800.1a). The customer can then ship the Classic Cast cylinders to EC i (freight pre-paid), and then ECi will ship the new replacement cylinders ground-freight prepaid. NOTE : To receive proper discount and labor credit, cylinders MUST be in an “as-removed” condition. Do not send piston pins or rocker arms.

i Classic Cast and TITAN brand cylinders are trademarks of Engine Components, Inc. Casting P/N

AEL65099 EC Logo Oberdorfer Logo Casting P/N

AEL85099 ECi Logo