Single Engine

Service Bulletin

December 23, 2011 SB11-28-03

TITLE

FUEL RETURN LINE 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 performed 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 Series 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.

Part Number Description Qty/Airplane

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 BALANCE INFORMATION

Negligible

Material Information

The part below may be necessary:

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 3
through 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 rudder 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, 2011
9. 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 maintenance 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 5
Figure 1. Fuel Return Line Inspection (Sheet 1)

SB11-28-03

Page 6 December 23, 2011
OWNER NOTIFICATION

On December 23, 2011, the following message will be sent to applicable owners of record:

Dear Cessna Skyhawk Owner:

This owner advisory is to inform you that Service Bulletin SB11-28-03, Fuel Return Line Inspection, has

been issued.

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 full rudder pedal actuation.

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 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 information 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 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

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.

*******

SB11-28-03

December 23, 2011 Page 7