DEPARTMENT OF TRANSPORTATION 

Federal Aviation Administration 

14 CFR Part 39 

[Docket No. FAA-2014-0940; Directorate Identifier 2014-NE-15-AD] 

RIN 2120-AA64 

4910-13-P] 

Airworthiness Directives; Lycoming Engines Reciprocating Engines (Type 

Certificate previously held by Textron Lycoming Division, A VCO Corporation) 

AGENCY: federal Aviation Administration (fAA), DOT. 

ACTION: Notice of proposed rulemaking (NPRM). 

SUMMARY: We propose to adopt a new airworthi ness directive (AD) for certain 

Lycoming TI0-540-A.I 1 A reciprocating engines. This proposed AD was prompted by 

several reports of cracked engine exhaust pipes. This proposed AD would require 

inspection of the engine exhaust pipes for cracks and replacement of the turbocharger 

mounting bracket. We are proposing this AD to prevent failure of the exhaust system clue 

to cracking, which could lead to uncontrolled engine fire, harmful exhaust gases entering 

the cabin resulting in crew incapacitation, and damage to the airplane. 

DATES: We must receive comments on this proposed AD by [lNSERT DATE 60 

DAYS AFTER DATE OF PUBLICATION IN THE Federal Register]. 

ADDRESSES: You may send comments, using the procedures found in 14 CFR 11.43 

and 11.45, by any of the following methods: 

• Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the 

instructions for submitting comments. 

• Fax: 202-493-2251. 

• Mail: U.S. Department ofTransportation, Docket Operations, M-30, West 

Building Ground Floor, Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 

20590. 
• Hand Delivery: Deliver to Mail address above between 9 a.m. and 5 p.m., 

Monday through Friday, except Federal holidays. 

For service information identified in this proposed AD, contact Lycoming 

Engines, 652 Oli ver Street, Williamsport, PA 17701; phone: 800-258-3279; fax: 570-

327-7101; Internet: 

www.lycOJping.com/Lycoming/SUPPORT/TechnicalPublications/ServiceBulletins.aspx. 

You may view this service infom1ation at the FAA, Engine & Propeller Directorate, 12 

New England Executive Park, Burlinf,rton, MA. For information on the availability of this 

material at the FAA, call 781-238-7125. 

Examining the AD Docket 

You may examine the AD docket on the Internet at http://www.regulations.gov by 

searching for and locating Docket No. F AA-20 14-0940; or in person at the Docket 

Management Facility between 9 a.m. and 5 p.m., Monday through Friday, except Federal 

holidays. The AD docket contains this proposed AD, the regulatory evaluation, any 

comments received, and other information. The street address for the Docket Office 

(phone: 800-647-5527) is in the ADDRESSES section. Comments will be available in the 

AD docket shortly after receipt. 

FOR FURTHER INFORMATION CONTACT: Norm Perenson, Aerospace Engineer, 

New York Aircraft Certification Office, FAA, Engine & Propeller Directorate, 1600 

Stewart Avenue, Suite 410, Westbury, NY 11590; phone: 516-228-7337; fax: 516-794-

5531 ; email: nonnan.perenson@faa.gov. 

SUPPLEMENTARY INFORMATION: 

Comments Invited 

We invite you to send any written relevant data, views, or arguments about this 

NPRM. Send your comments to an address listed under the ADDRESSES section. 

Include "Docket No. F AA-2014-0940; Directorate fdentifier 20 14-NE-15-AD" at the 

begi1ming of your comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of tllis NPRM. We will consider all 

comments received by the closing date and may amend this NPRM because of those 

comments. 

We will post all comments we receive, without change, to 

http://www.regulations.gov, including any personal infonnation you provide. We will 

also post a repott summarizing each substantive verbal contact we receive about this 

NPRM. 

Discussion 

We issued Special Airworthiness Information Bulletin (SATB) CE-04-22 on 

December 17, 2003. The SAIB recommended pre-flight and repetitive inspection of 

exhaust system components for signs of cracking. This NPRM was prompted by 

additional reports of exhaust pipe cracking. Probable causes of exhaust pipe cracks are 

questionable exhaust pipe welds or misalignment of the exhaust pipe during installation. 

Additionally, non-conforming turbocharger mounting brackets were found during 

Lycoming engine assembly trials of new engine exhaust pipes. These out-of-tolerance 

mounting brackets may place stresses on exhaust system components. Taken alone, or in 

combination, these conditions may overstress certain exhaust pipe locations and cause 

cracks to develop. With the presence of cracks, hot exhaust gases collect in the engine 

compartment and carbon monoxide gas is now able to enter the airplane cabin. The 

conditions identified above, if not corrected, could result in uncontrolled engine fire, 

ham1ful exhaust gases entering the cabin resulting in crew incapacitation, and damage to 

the airplane. 

Relevant Service Information 

We reviewed Lycoming Engines Mandatory Service Bulletin (MSB) No. 614A, 

dated October I 0, 2014. The MSB describes procedures for exhaust system inspection 

and turbocharger mounting bracket replacement. ' 
FAA's Determination 

We are proposing this NPRM because we evaluated all the relevant information 

and determined the unsafe condition described previously is likely to exist or develop in 

other products of the same type design. 

Proposed AD Requirements 

This NPRM would require inspection of the exhaust system and replacement of 

the turbocharger mounting bracket. 

Costs of Compliance 

We estimate that this proposed AD would affect about 111 engines installed on 

airplanes of U.S. registry. We also estimate that it will take about 8 hours per engine to 

comply with this AD. The average labor rate is $85 per hour. Parts replacement will cost 

about $6,782 per engine. Based on these figures, we estimate the cost of this proposed 

AD on U.S. operators to be $828,282. Our cost estimate is exclusive of 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 ofthe 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 Til, 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 determined that this proposed AD would not have federalism implications 

under Executive Order 13132. This proposed AD would not have a substantial direct 

effect on the States, on the relationship between the national Govenunent and the States, 

or on the distri bution of power and responsibilities among the various levels of 

government. 

For the reasons discussed above, I certify this proposed regulation: 

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

(2) Is not a "significant rule" under the DOT Regulatory Policies and Procedures 

(44 FR 11034, February 26, 1979), 

(3) Will not affect intrastate aviation in Alaska to the extent that it justifies 

making a regulatory distinction, and 

(4) 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. 

List of Sub.jects in 14 CFR Part 39 

Air transportation, Aircraft, Aviation safety, Incorporation by reference, Safety. 

The Proposed Amendment 

Accordingly, under the authority delegated to me by the Administrator, the FAA 

proposes to amend 14 CFR part 39 as follows: 

PART 39 -AIRWORTHINESS DIRECTIVES 

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

Authority: 49 U.S.C. 106(g), 4011 3, 4470 1. 

§ 39.13 [Amended! 

2. The FAA amends§ 39.1 3 by adding the following new airworthiness directive 

(AD): 
Lycoming Engines (Type Certificate previously held by Textron Lycoming Division, 

A VCO Corporation): Docket No. F AA-20 14-0940; Directorate Identifier 20 14-NE-15-

AD. 

(a) Comments Due Date 

We must receive comments by [INSERT DATE 60 DAYS AFTER DATE OF 

PUBLICATION IN THE Federal Register]. 

(b) Affected ADs 

None. 

(c) Applicability 

This AD applies to all Lycoming TJ0-540-A.J I A reciprocating engines listed by 

engine serial number (SIN) in Figure I to paragraph (c) of this AD and to any TI0-540-

AJ I A reciprocating engine with a replacement turbocharger mounting bracket installed 

that was purchased between April 5, 2012 and May 29, 2014. 

qgure lt 0 p aragrap1 h () c - L ycommg E ngme . TIO -540 -AJlA Aft ec t e d SIN 

Engine SIN Engine S/N Engine S/N Engine SIN 

L-6748-61 E L-13828-61 E L-1 3832-6 1 E L-13843-61E 

L-1 3 81 7-61 E L-13831-61£ L-1 3833-6 1 E L- 13 84 7-61 E 

L-1 38 19-61 E L-13823-61 E L-13839-61 E L-13855-61E 

L- 13856-61 E L-13947-61 E L-140 I 1-6 I E RL-2551-61 E 

L-13857-61 E L-13948-61£ L-140 1 3-61 E RL-2848-61 E 

L-13866-61 E L-13949-61 E L-140 14-61 E RL-3450-61 E 

L-1 3867-6 1 E L-13950-61 E L-140 15-6 1 E RL-4138-61 E 

L-13873-61 E L-1 3960-61 E L-140 I 7-61 E RL-7243-61E 

L-13882-61 E L-13961-61£ L-14024-61 E RL-7512-61 E 

L-13883-6 1 E L-13962-61£ L-1 4025-61 E RL-8435-61 E 

L-13884-61 E L-13967-61£ L-14026-61 E RL-8767-61 E 

L- 13885-6 1 E L-13973-61 E L- 14028-61 E RL-8914-61 E 

L-1 3886-61 E L-13975-61 E L-14034-61 E RL-8979-61 E 

L-13895-61 E L-13976-61 E L-14054-61 E RL-9399-61 E 

L-13896-61 E L-13979-61 E L-1 4055-61 E RL-9466-61 E 

s 
L-13898-61 E L-13981-61 E L-14056-61 E RL-9618-61 E 

L-13900-61 E L-13983-61 E L-14057-61£ RL-9663-61£ 

L-13902-61 E L-13984-61 E L-14062-61 E RL-1 0098-6 1 E 

L-13907-61 E L- 13993-61 E L-14063-61 E RL-1 0194-61 E 

L-1391 3-61 E L-13996-61 E L-14066-61 E RL-1 0249-61 E 

L-1 3915-6 1£ L-13997-6 1 E L-14067-61£ RL-1 0615-61£ 

L-1 3930-61 E L-13998-61 E L- 14069-61 E RL-11011-61E 

L-13 93 1-61 E L-13999-61 E L-14071-61 E RL-12121-61 E 

L-13934-61 E L-14000-61 E L-14076-61 E RL-12163-61£ 

L-13936-61 E L- 1400 l -61 E L- 14077-61 E RL-12343-61 E 

L-13938-61 £ L-14003-61 E RL-1726-61 E RL-13352-61 E 

L-13939-61 E L-14004-6 1 E RL-181 0-61 E RL- 13601-61£ 

L-13946-61 E L-14005-61 E RL-1862-61 E 

(d) Unsafe Condition 

This AD was prompted by several reports of cracked engine exhaust pipes. We 

are issuing this AD to prevent failure of the exhaust system due to cracking, which could 

lead to uncontroll ed engine fire, harmful exhaust gases entering the cabin resulting in 

crew incapacitation, and damage to the airplane. 

(e) Compliance 

Comply with this AD within the compliance times specified, unless already clone. 

(1) For affected engines with an S/N listed in Figure 1 to paragraph (c) of this AD 

with 400 hours or less time since new (TSN) or time since last overhaul (TSLO), and for 

any TI0-540-AJ I A reciprocating engine with a replacement turbocharger mounting 

bracket installed that was purchased between April 5, 2012 and May 29, 20 14, that has 

accumulated 400 hours or less time-in-service (TIS), within 25 hours after the effective 

elate of this AD, replace the turbocharger mounting bracket with a part eligible for 

installation, and inspect the exhaust pipes for cracks. Use Lycoming Engines Mandatory 

Service Bulletin (MSB) No. 614A, dated October I 0, 2014, Exhaust System Disassembly 
and Removal, paragraphs 1 through 22 to replace the bracket, and Exhaust System 

Inspection, paragraphs l through 5 to do the inspection. 

(2) For affected engines with an SIN listed in f-igure I to paragraph (c) of this AD 

with more than 400 hours TSN or TSLO, and for any TI0-540-AJ I A reciprocating 

engine with a repl acement turbocharger mounting bracket installed that was purchased 

between April 5, 2012 and May 29,2014, that has accumulated more than 400 hours TIS, 

replace the turbocharger mounting bracket with a part e ligible for installation, and inspect 

the exhaust pipes for cracks at the next engine overhaul, separation of the crankcase 

halves, or twelve years from the effective date of this AD, whi chever comes first. Use 

Lycoming Engines MSB No. 614A, dated October 10, 2014, Exhaust System 

Disassembly and Removal, paragraphs 1 through 22 to replace the bracket, and Exhaust 

System Inspection, paragraphs 1 through 5 to do the inspection. 

(f) Installation Prohibition 

After the effective date of this AD, do not return to service any engine with a 

TI0-540-AJ I A turbocharger mounting bracket that was removed from an engine 

identified in Figure I to paragraph (c) of this AD or that was purchased between April 5, 

20 12 and May 29,2014. 

(g) Credit for Previous Action 

(I) If, be lore the effective date of this AD, you replaced the turbocharger 

mounting bracket with one eligible for installation you may take credit for your prior 

corrective action. No further turbocharger mounting bracket replacement is required. 

(2) If, before the effective date of this AD, you performed the crack inspection 

using either of the following: 

(i) Lycoming Engines MSB No. 614A, dated October I 0, 20 14, Exhaust System 

Inspection, paragraphs 1 through 5, or 
(ii) Cessna Service Letter No. SEL-78-0 1, dated May 30, 2014, you may take 

credit for your prior corrective action. No further inspection is required. However, you 

must sti ll replace the turbocharger mounting bracket. 

(h) Alternative Methods of Compliance (AMOCs) 

The Manager, New York Aircraft Certification Office, fAA, may approve 

AMOCs to this AD. Use the procedures found in 14 CFR 39.19 to make your request. 

(i) Related Information 

(1) For more information about this AD, contact Norm Perenson, Aerospace 

Engineer, New York Aircraft Certification Office, FAA, Engine & Propeller Directorate, 

1600 Stewart Avenue, Suite 410, Westbury, NY 11590; phone: 5 16-228-7337; fax: 516-

794-5531 ; ema il: norman.perenson@faa.gov. 

(2) Lycoming Engines MSB No. 614A, dated October 10, 2014, which is not 

incorporated by reference, can be obtained from Lycoming Engines using the contact 

information in paragraph (i)(3) of this AD. 

(3) For service information identified in this AD, contact Lycoming Engines, 652 

Oliver Street, Williamsport, PA 17701 ; phone: 800-258-3279; fax: 570-327-7101; 

Internet: 

www.l ycom i ng.com/Lycomi ng/S U PPORT /Technical Pub I ications/ServiceB u11etins.aspx. 

(4) You may view this service information at the FAA, Engine & Propeller 

Directorate, 12 New England Executive Park, Burlington, MA. For inforn1ation on the 

availability of this material at the FAA, call 781-238-7125. 

Issued in Burlington, Massachusetts, on January 21, 2015. 

Colleen M. D' Alessandro, 

Assistant Directorate Manager, Engine & Propeller Directorate, 

Aircraft Certification Service.