# Single Engine

**Service Bulletin**

December 23, 2011 SB11-28-03

**TITLE** FUEL RETURN L INE INSPECTION

**EFFECTIVITY Model Serial Numbers**  172R 17281573 thru 17281584, 17281588 thru 17281594, 17281596 thru 17281598 172S 172S11074 thru 172S11104, 172S11106, 172S11107, 172S11109 thru 172S11113, 172S11115 thru 172S11125, 172S11129 thru 172S11135, 172S11139 thru 172S11144

**REASON** A report has been received that a part number 0516031-1 Fuel Return Line Assembly was found rubbing against the right steering tube assembly during rudder pedal actuation.

**DESCRIPTION** This service bulletin provides instructions to inspect the fuel return line for damage, and if necessary, repair or replace the line assembly. Non-compliance with this service bulletin could potentially result in a fuel leak.

**COMPLIANCE** Mandatory: Shall be accomplished at the next scheduled maintenance or inspection not to exceed 100 hours of operation or 12 months, whichever occurs first.

**APPROVAL** FAA approval has been obtained on technical data in this publication that affects airplane type design.

**MANPOWER** 0.8 man-hour for inspection If necessary, add 0.3 man-hour to replace the fuel return line assembly If necessary, add 0.4 man-hour to repair the fuel return line assembly
Page 1 of 7 To obtain satisfactory results, procedures specified in this publication must be accomplished in accordance with accepted methods and prevailing government regulations. Cessna Aircraft Company cannot be responsible for the quality of work perfor med in accomplishing the requirements of this publication. **Cessna Aircraft Company** , Customer Service, P.O. Box 7706, Wichita, Kansas 67277, U.S.A. (316) 517-5800, Facsimile (316) 517-7271 www.cessnasupport.com COPYRIGHT © 2011**REFERENCES** Model 172 Serie s 1996 and On Maintenance Manual **NOTE:** Make sure all publications used are complete and current. **NOTE:** This information shall be considered an amendment to the Cessna Manufacturer's Service/Maintenance Manual or Instructions for Continued Airworthiness and must be accomplished for ongoing airworthiness compliance as required per 14 CFR Part 43.13.

**OTHER PUBLICATIONS AFFECTED** Model 172R & Model 172S Illustrated Parts Catalog **NOTE:** Make sure all publications used are complete and current.

**MATERIAL PRICE AND AVAILABILITY** The part below is available from Cessna Service Parts and Programs through an appropriate Cessna Single Engine Authorized Service Facility.

**P a**  **r t**  **N u**  **m b** **e r**  **D e**  **s c**  **r i**  **p t**  **i o**  **n Q** **t y**  **/ A**  **i r**  **p l**  **a n**  **e** 0516031-1 Fuel Line Assembly 1 (if required)

**CREDIT INFORMATION** For airplanes in warranty and identified within the Serial Effectivity: A labor allowance credit of 0.8 man-hour per airplane will be provided to inspect the fuel return line assembly as described in this service bulletin. If necessary, an additional 0.3 man-hour per airplane will be provided to replace the fuel return line assembly as described in this service bulletin. If necessary, an additional 0.4 man-hour per airplane will be provided to repair the fuel return line assembly as described in this service bulletin. Freight will be credited at the most economical method unless pre-approved by Cessna. For pre-approval contact Cessna Service Parts and Programs Warranty Administration at Telephone: 316-831-4296, Fax: 316-206-2746 or E-mail: cpd2claims@cessna.textron.com. To receive credit, the work must be completed and the Warranty Claim submitted by a Cessna Single Engine Authorized Service Facility within 30 calendar days of service bulletin compliance before the credit expiration dates shown below. **NOTE:** Part number 0516031-1 fuel lines removed based on the inspection results of this service bulletin shall be held for field scrap per standard procedures. Domestic . . . . . . . . . . . . . . . . . . . January 13, 2013 International . . . . . . . . . . . . . . . . . January 13, 2013 **Special Note to Single-Engine Authorized Service Facilities:** When you complete the Warranty Claim, the labor allowance claimed shall be itemized for each above action completed.

SB11-28-03 Page 2 December 23, 2011**ACCOMPLISHMENT INSTRUCTIONS**
**WEIGHT AND BALA NCE INFORMATION**  Negligible **Material Information** The part below may be nece ssary:

**NEW P/N QUANTITY DESCRIPTION OLD P/N DISPOSITION** 0516031-1 1 Fuel Line Assembly Same Refer to Credit Information Section.
**Instructions** 1. Prepare the airplane for maintenance. A. Make sure that all switches are in the OFF/NORM position. B. Disconnect electrical power from the airplane. (1) Disconnect the airplane battery. (2) Disconnect external electrical power. C. Attach maintenance warning tags to the battery and external power receptacle that have **"DO NOT CONNECT ELECTRICAL POWER - MAINTENANCE IN PROGRESS"**  written on them. 

### WARNING: **IF THE AIRPLANE HAS AMSAFE INFLATABLE RESTRAINTS, DO NOT REMOVE SEATS WITH THE SEAT BELTS BUCKLED OR THE**  **ELECTRONICS MODULE ASSEMBLY (EMA) CONNECTED. DAMAGE TO THE SYSTEM CAN OCCUR AND AN ACCIDENTAL DEPLOYMENT OF**  **THE SYSTEM CAN CAUSE INJURY.** 2. Remove the access panel (230BT) and the rudder pedal close-out panel below the copilot's rudder pedals. (Refer to the Model 172 Series 1996 and On Maintenance Manual, Chapter 6, Access/Inspection Plates - Description and Operation.) 3. Make sure that the AN833-4 Elbow is installed in the 6 O'clock position as shown in View A-A of Figure 1. A. If the AN833-4 Elbow outlet is in the 6 O'clock position, go to Step 4. B. If the AN833-4 Elbow outlet is not in the 6 O'clock position, do as follows: (1) Remove the upper engine cowl. (Refer to the Model 172 Series 1996 and On Maintenance Manual, Chapter 71, Cowl - Maintenance Practices.) (2) Put a backup wrench on the AN833-4 Elbow. (3) Loosen the AN924-4 Nut. (4) Put the AN833-4 Elbow outlet in the 6 O'clock position. (5) Tighten the AN924-4 Nut and torque it to 225 inch-pounds, +25 or -25 inch-pounds. 4. (Refer to Figure 1, View A-A.) Do an inspection of the 0516031-1 Fuel Return Line Assembly as follows: A. With a flashlight and a mirror, do an inspection of the 0516031-1 Fuel Return Line Assembly for damage and for sufficient line clearance in the area of the MC0543022-2C Steering Tube Assembly. (1) If there is no damage to the 0516031-1 Fuel Return Line Assembly and the 0516031-1 Fuel Return Line Assembly does not touch the MC0543022-2C Steering Tube Assembly when the rudder pedals and nose wheel travel through the full left and right positions, go to Step 8. (2) If there is no damage to the 0516031-1 Fuel Return Line Assembly, but it does touch the MC0543022-2C Steering Tube Assembly when the rudder pedals and nose wheel travel

SB11-28-03 December 23, 2011 Page 3through the full left and right positions, hand form the line until you have clearance between the 0516031-1 Fuel Return Line Assembly and the MC0543022-2C Steering Tube Assembly when the rudde r pedals and nose wheel travel through the full left and right positions. Then go to Step 6. (3) If there is damage to the 0516031-1 Fuel Return Line Assembly, do as follows: (a) Pull the fuel shutoff valve handle aft to shut off the fuel supply from the engine. (b) Remove the 0516031-1 Fuel Return Line Assembly and install protective caps on the S2218-4 Check Valve, AN833-4 Elbow at the firewall, and each end of the 0516031-1 Fuel Return Line Assembly. (c) Make sure that there is only residual fuel leakage from the S2218-4 Check Valve after you disconnect the 0516031-1 Fuel Return Line Assembly. If there is more than residual fuel leakage, you must replace the S2218-4 Check Valve. (Refer to the Model 172 Series 1996 and On Maintenance Manual, Chapter 28, Fuel Storage and Distribution - Maintenance Practices.) (d) Do an inspection of the damage on the 0516031-1 Fuel Return Line Assembly. 1 If there is damage in the area of a bend radius of the line, you must remove and discard the 0516031-1 Fuel Return Line Assembly. Then go to Step 5. 2 If there is damage on the line of a depth of more than 0.0035 inch, or you cannot measure the depth of the damage, you must remove and discard the 0516031-1 Fuel Return Line Assembly. Then go to Step 5. 3 If there is damage on the line of a depth of 0.0035 inch or less and it is not in the area of a bend radius of the line, repair the damage to the 0516031-1 Fuel Return Line Assembly with blending procedures in accordance with FAA Advisory Circular 43.13-1B Acceptable Methods, Techniques, and Practices Aircraft Inspection and Repair. Then go to Step 5. 5. Install the 0516031-1 Fuel Return Line Assembly as follows: A. Remove the protective caps from the 0516031-1 Fuel Return Line Assembly, S2218-4 Check Valve, and AN833-4 Elbow at the firewall. B. Hand tighten the B-nuts at the two ends of the 0516031-1 Fuel Return Line Assembly. C. Put the 0516031-1 Fuel Return Line Assembly in the position that gives correct clearance between the airplane structure and the MC0543022-2C Steering Tube Assembly when the rudder pedals and nosewheel move through the full left and right positions. D. Hold the 0516031-1 Fuel Return Line Assembly in the correct position while you torque the B-nuts to 120 inch-pounds, +20 or −20 inch-pounds. E. Turn the nosewheel with a tow bar and move the copilot's rudder pedals at the same time while you look at the MC0543022-2C Steering Tube Assembly as it moves through its full range of motion. Make sure that the MC0543022-2C Steering Tube Assembly does not touch the 0516031-1 Fuel Return Line Assembly or the airplane structure. (1) If the 0516031-1 Fuel Return Line Assembly touches the right MC0543022-2C Steering Tube Assembly or the airplane structure, you must hand form the line until you have clearance between the 0516031-1 Fuel Return Line Assembly and the MC0543022-2C Steering Tube Assembly when the rudder pedals and nose wheel travel through the full left and right positions. Then go to Step 6. (2) If the 0516031-1 Fuel Return Line Assembly does not touch the right MC0543022-2C Steering Tube Assembly or the airplane structure, go to Step 6. 6. Push the fuel shutoff valve handle forward to the ON position. 7. Do a check for leaks at the 0516031-1 Fuel Return Line Assembly. 8. Install the access plate (230BT) and the rudder panel close-out panel. (Refer to the Model 172 Series 1996 and On Maintenance Manual, Chapter 6, Access/Inspection Plates - Description and Operation.)

SB11-28-03 Page 4 December 23, 20119. If removed, install the upper engine cowl. (Refer to the Model 172 Series 1996 and On Maintenance Manual, Chapter 71, Cowl - Maintenance Practices.) 10. Remove mainten ance warning tags from battery and external power receptacle and connect the battery. 11. Make an entry in the airplane logbook that states compliance and method of compliance with this service bulletin.

SB11-28-03 December 23, 2011 Page 5Figure 1. Fuel Return Line Inspection (Sheet 1)

SB11-28-03 Page 6 December 23, 2011**OWNER NOTIFICA TION**  On December 23, 2011, the following message will be sent to applicable owners of record: Dear Cessna Skyhawk Owner:
This owner adv isory is to inform you that Service Bulletin SB11-28-03, Fuel Return Line Inspection, has been issued. A report has be en received that a part number 0516031-1 Fuel Return Line Assembly was found rubbing against the right steering tube assembly during full rudder pedal actuation.
This service b ulletin provides instructions to inspect the fuel return line for damage, and if necessary, repair or replace the line assembly. Non-compliance with this service bulletin could potentially result in a fuel leak. Compliance is Mandatory: Shall be accomplished at the next scheduled maintenance or inspection not to exceed 100 hours of operation or 12 months, whichever occurs first. The informat ion contained in the referenced Cessna Service Bulletin shall be considered an amendment to the Cessna Manufacturer's Service/Maintenance Manual or Instructions for Continued Airworthiness, and must be accomplished for ongoing airworthiness compliance as required per 14 CFR Part 43.13. For airplanes in warranty and identified within the Serial Effectivity:
A labor allowance credit of 0.8 man-hour per airplane will be provided to inspect the fuel return line assembly as described in this service bulletin. If necessary , an additional 0.3 man-hour per airplane will be provided to replace the fuel return line assembly as described in this service bulletin. If necessary , an additional 0.4 man-hour per airplane will be provided to repair the fuel return line assembly as described in this service bulletin. Freight wil l be credited at the most economical method unless pre-approved by Cessna. For pre-approval contact Cessna Service Parts and Programs Warranty Administration at Telephone: 316-831-4296, Fax: 316-206-2746 or E-mail: cpd2claims@cessna.textron.com. To receive credit, the work must be completed and the Warranty Claim submitted by a Cessna Single Engine Authorized Service Facility within 30 calendar days of service bulletin compliance before the credit expiration dates show n below. **NOTE:** Part number 0516031-1 fuel lines removed based on the inspection results of this service bulletin shall be held for field scrap per standard procedures. Domestic . . . . . . . . . . . . . . . . . . . January 13, 2013 International . . . . . . . . . . . . . . . . . January 13, 2013 Please contact a Cessna Single Engine Authorized Service Facility for detailed information and arrange to have Cessna Service Bulletin SB11-28-03 accomplished on your airplane. As a convenience, service documents are now available online to all our customers through a simple, free-of-charge registration process. If you would like to sign up, please visit the www.cessnasupport.com Customer Access link to register.

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SB11-28-03 December 23, 2011 Page 7