T113 Corporate Office • 9503 Middlex • San Antonio, TX 78217 • Tel (210) 820-8100 • Fax (210) 820-8102 • 800-ECi-2FLY (800-324-2359) 

www.eci2fly.com • sales-service@eci2fly.com • FAA Repair Station #AG2R689K 

Airmotive Steel, CermiNil, Classic Cast, Double Band, ECi, FREEDOM, IFR, Nickel+Carbide, Q3, Q4, Q5, TITAN and TITAN Advanced are Trademarks or Registered Trademarks of Engine Components, Inc. 

Mandatory Service Bulletin M.S.B. No.: 08-1

ENGINE COMPONENTS, INC. Page: 1 of 6

Issued: 04/04/2008

Revision: 1 (04/08/08) 

Title: Cylinder Assembly Inspection, Assembly Removal and Replacement 

(P/N AEL65102) for Lycoming Parallel Valve Engines

1.0 PURPOSE: This Mandatory Service Bulletin is to alert Engine Components, Inc. (ECi®) customers about possible 

fatigue cracking and head separations on a specified group of replacement cylinders P/N AEL65102 for Lycoming 

parallel valve engines. ECi has become aware of a number of cylinders that have fractured at the head to barrel interface. 

The failure history dictates that two manufacturing groups are to be addressed with two different actions. The first and 

largest group (Group ‘A’) requires a periodic inspection/pressure test to insure continued airworthiness. Group ‘A’ 

cylinders were produced between August, 2002 and December 2005. The second group (Group ‘B’) requires a one time 

inspection and then removal from service at the established operating time. Group ‘B’ cylinders were produced in 

December 2005 through February 2006, and require a one time inspection/pressure test, and then must be removed from 

service when meeting the criteria established in paragraph 4.0 below. Cylinders that are removed may be replaced with 

ECi cylinders Part Number AEL65102 Serial Numbers 37017 and higher.

2.0 MODELS AFFECTED: The cylinders (P/N AEL65102) that require inspection or removal are FAA PMA replacement 

cylinders installed in the following Textron Lycoming engines: 

O-320-A, -B, -C, -D,-E ; IO-320-A, -B, -C, -D, -E, -F; AIO-320-A, -B, -C; LIO-320-B, -C; AEIO-320-D, -E; O-360-A, 

-B, -C, -D, -F, -G; HO-360-A, -B, -C; IO-360-B, -E, -F, -L, -M; LO-360-A; HIO-360-B, -G; O-540-A, -B, -D, -E, -F, -G, 

-H, -J, -L; IO-540-C, -D, -N, -T, -V, -W; TIO-540-C, -E, -G, -H; AEIO-540-D. 

This bulletin does not apply to Lycoming cylinders repaired or overhauled at Engine Components, Inc. including 

cylinders fitted with new FAA-PMA Barrels. 

3.0 INSPECTION AND PRESSURE TEST: 

Table 1 – GROUP ‘A’ and ‘B’ CYLINDER INSPECTION 

INSPECTION 

TYPE 

INSPECTION 

PROCEDURES 

INSPECTION 

FINDINGS 

EVALUATION OF 

FINDINGS 

RECOMMENDED ACTION 

No Evidence of 

combustion products 

Indicates airworthiness Proceed with compression test 

(paragraph 3.3) 

Whitish powder observed 

on cylinder head or 

adjacent cylinder 

Indicates a combustion 

leak. Verify not an 

exhaust gasket leak 

Fix exhaust leak if found. 

Further testing suggested or 

remove cylinder for repair if 

combustion residue found. 

Visual 

Inspection 

Inspection of exhaust side of 

cylinder (deep fins) using 

bright light (see Photo 2) 

Evidence of crack visible 

between fins 

Verify not a casting 

indication. Otherwise 

indicates a head crack 

If casting indication, continue 

inspection. If cracked, remove 

cylinder for replacement. 

Table 2 – GROUP ‘A’ and ‘B’ PRESSURE TESTING 

INSPECTION 

TYPE 

INSPECTION 

PROCEDURES 

INSPECTION 

FINDINGS 

EVALUATION OF 

FINDINGS 

RECOMMENDED ACTION 

Readings are 70/80 or 

above 

Indicates airworthy 

cylinders 

Return aircraft to service 

Leakage at rings or 

valves 

Determine airworthiness i.a.w. 

AC 43.13-1B 

Readings are between 

60/80 and 70/80 

No excessive ring or 

valve leakage 

Perform soap bubble test 

(paragraph 3.4) 

Compression 

Test 

Differential pressure test 

according to AC 43.13-1B 

paragraph 8-14 

Readings are below 60/80 Marginal airworthiness Determine cause of low 

readings 

Soap Bubble Rotate Propeller to BDC of No Bubbles Indicates no cracks Return to service 

Technical Portions are FAA DER Approved.
 ENGINE COMPONENTS, INC. 

MSB 08-1 Revision 1 (04/08/08)

Cylinder Assembly Inspection, Assembly Removal and Replacement 

(P/N AEL65102) for Lycoming Parallel Valve Engines

Page 2 of 6 

Photo 2 

Test cylinder and apply 5 psi. 

Verify valves closed and 

raise pressure to 80 psi and 

apply soapy water. 

Bubbles observed between 

fins 

Indicates a cracked 

Cylinder head 

Remove cylinder for 

replacement 

3.1 Group “A” Time in Service: The Group “A” inspection/compression test described below is required after the 

cylinders have reached 350 operating hours. The initial visual inspection and compression test for cylinder 

assemblies with more than 350 operating hours are to be completed within 10 hours of operation after receipt of this 

MSB. Group “A” cylinder assemblies may be operated to their full 2000 hour TBO for airplanes, and should be 

replaced within 25 hours of reaching TBO. Group “A” cylinder assemblies installed on helicopters should be 

replaced within 25 hours after reaching 1500 operating hours. Cylinders that are removed may be replaced with ECi 

cylinders Part Number AEL65102 Serial Numbers 37017 and higher. 

3.2 Visual Inspection: An external inspection of each cylinder 

assembly will help identify conditions that could develop to 

adversely affect the airworthiness of the cylinder. With the 

cowling removed, and with the aid of a flashlight, inspect the 

deep finned side of the cylinder heads between adjacent 

cylinders to ensure that there is no powder residue that may be 

deposited by combustion gases leaking through from the 

combustion chamber. Inspect for cracks, exhaust leaks or any 

signs of oil leaks, fuel or any conditions that may indicate the 

presence of a crack. During the visual inspection, check the 

general appearance of the cylinder to determine if the cylinder 

head is operating normally, or whether there could be some high 

temperature issues. Tale-tell signs of high temperature operation 

include the appearance of carbonized oil and dark stains around 

the exhaust valve spring pocket area, and the loss of paint 

around the spark plug and exhaust port area as shown in Photo 1. If these conditions are found during inspection 

even without indications of leakage, contact the ECi Customer Service Department and describe the extent of the 

evidence of high temperature operation. Digital photographs can be emailed to the Customer Service representative 

to assist ECi and Airmotive Engineering Corp. evaluate the situation. 

3.3 Compression Test: AEL65102 Cylinder Assemblies produced from August 2002 to December 2005 are identified 

in accordance with Photo 3 and Photo 4 and as delineated in § 7.0 in this MSB, a periodic (50 hours) compression 

test must be accomplished in accordance with AC 43.13-1B § 8-14. If the compression reading is 80/70 (80 psi input 

and 70 psi between .040 orifice and cylinder) or better, then no further inspections are required. If the compression 

reading is below 80 over 70, and the cause is not obvious leakage past the rings (blow-by heard through oil level 

gage tube) or valves (blow-by heard in engine air intake or exhaust), then the soap bubble test described in 

paragraph 3.4 below should be accomplished. 

3.4 Soap Bubble Leak Check: The soap bubble leak check should 

be accomplished if the compression test accomplished in 

paragraph 3.3 above results in a reading of less than 80/70 and 

there is no obvious significant leakage past rings or valves. 

This simple test (Photo 2) serves as a reliable verification 

method to the visual test described in part ‘a’ above. The 

procedure involves pressurizing the cylinder to 5 PSI and 

positioning the piston as close to BDC on the compression 

stroke as possible while ensuring that the intake valve remains 

closed to maintain compression. This technique reduces the 

possibility of a rotating propeller causing a hazard. The 

pressure is gradually raised to 80 PSI and then the cylinder 

Photo 1 

Burned Paint 

Dark Stains 
 ENGINE COMPONENTS, INC. 

MSB 08-1 Revision 1 (04/08/08)

Cylinder Assembly Inspection, Assembly Removal and Replacement 

(P/N AEL65102) for Lycoming Parallel Valve Engines

Page 3 of 6 

head and barrel areas are saturated with mixed soap and water. The complete cylinder is then inspected for leakage 

which is indicated by an accumulation of bubbles. A mixture of 1-5% of regular dish soap in water is appropriate for 

this inspection. Leakage, if present, usually starts on the exhaust side of the head where the fins are the longest. The 

presence of white power around the fin area might also indicate the 

presence of a crack, and is cause for cylinder removal. 

4.0 GROUP ‘B’ INSPECTION/REPLACEMENT:

Group ‘B’ cylinder assemblies are identified by reference to Photo 3 and 

Photo 4, and are listed in § 8.0 in this MSB. Cylinder assemblies in this 

group must be inspected/compression tested according to §3.2 through 3.4 

time within 10 hours operating time from receipt of this MSB, and may 

continue in service until reaching 350 operating hours. Cylinder assemblies 

that have reached 350 hours operating time must be removed within 25 

operating hours. Cylinders that are removed may be replaced with ECi 

cylinders Part Number AEL65102 Serial Numbers 37017 and higher. 

5.0 CYLINDER IDENTIFICATION: 

The identification of the affected cylinders is accomplished as follows: 

Verify the engine the suspect cylinder assemblies are installed on is a 

parallel valve Lycoming 320, 360 or 540 series engines. 

5.1 Check engine records to determine if a cylinder assembly with one or 

more of the serial numbers within the range listed below is installed 

on the engine. If so, then proceed to paragraph 5.1. If not, no further 

action is required. 

5.2 Verify which cylinder(s) have serial number(s) that match any of the 

serial numbers listed in this Service Bulletin. The cylinder serial 

number can be found on the flat surface on the outside of the cylinder 

intake port as shown in Photo 3. 

5.3 Further identification of the cylinders can be seen in Photo 4 showing 

the Oberdorfer Logo, the ECi logo and casting number AEL85099. 

NOTE: The intake port side of the cylinder is distinguished by 

shallow fins. The exhaust side has deeper fins for added cooling. 

6.0 PROCEDURES TO BE FOLLOWED: 

Replacement cylinders will be sent in accordance to ECi’s written warranty policy. If you have an affected cylinder(s), go 

to ECi’s website http://www.eci.aero/pages/services.aspx and complete RMA Form T9-16-003 

(http://www.eci.aero/pages/RMA.pdf) on line. In order to properly complete the form you must have the cylinder part 

number, serial number and time in service. If you have any questions you may call us at either 1-800-324-2359 or 210-

820-8101 or, if you prefer, you may e-mail us at MSB08-1@eci.aero.

7.0 GROUP ‘A’ AFFECTED SERIAL NUMBERS: 

Group ‘A’ cylinders that require inspection or replacement are included in serial numbers 1138-02 through 35252-15, but 

excluding serial numbers 34496-12, 34352-27, 34647-09, 34886-02, 35239-11, 35239-29, 35252-11, 35252-12 which are 

part of Group ‘B’ (refer to paragraphs 8.0 and 8.1). These cylinders were produced between August 2002 and December 

5, 2005. Note that this range of serial numbers includes other products that are not subject to this inspection. Only 

cylinders identified in accordance with paragraphs above and with serial numbers within this range are affected. 

Photo 4 

Other identifying features 

(in addition to serial number) 

Oberdorfer 

Logo 

ECi Logo Casting P/N 

AEL85099 

Photo 3 

Serial Number 

Foundry Identifier 
 ENGINE COMPONENTS, INC. 

MSB 08-1 Revision 1 (04/08/08)

Cylinder Assembly Inspection, Assembly Removal and Replacement 

(P/N AEL65102) for Lycoming Parallel Valve Engines

Page 4 of 6 

8.0 GROUP ‘B’ AFFECTED SERIAL NUMBERS:

Group “B” cylinders that require a one time inspection and an operating time dictated removal in accordance with 

stipulations identified in 4.0 above are included in section 8.1 below. These cylinders were produced between Dec. 6, 

2005 and Feb. 7, 2006. As detailed in paragraph 4.0, this range of serial numbers includes other products, and only 

cylinder assemblies meeting the requirements established in Paragraph 4.0 are listed in Section 8.1. 

8.1 SERIAL NUMBERS: Refer to Photo 3 for the location of the serial number.

34496-12 

34352-27 

34647-09 

34886-02 

35239-11 

35239-29 

35252-11 

35252-12 

35252-28 

35297-02 

35297-04 

35297-05 

35297-08 

35297-16 

35297-21 

35297-22 

35297-26 

35297-27 

35297-28 

35345-01 

35345-02 

35345-03 

35345-04 

35345-05 

35345-06 

35345-07 

35345-08 

35345-09 

35345-10 

35345-11 

35345-12 

35345-13 

35345-14 

35345-15 

35345-16 

35345-17 

35345-18 

35345-19 

35345-20 

35345-21 

35345-22 

35345-23 

35345-24 

35345-25 

35345-26 

35345-27 

35345-28 

35345-29 

35345-30 

35368-01 

35368-02 

35368-03 

35368-04 

35368-05 

35368-06 

35368-07 

35368-08 

35368-09 

35368-10 

35368-11 

35368-12 

35368-13 

35368-14 

35368-15 

35368-16 

35368-17 

35368-18 

35368-19 

35368-20 

35368-21 

35368-22 

35368-23 

35368-24 

35368-25 

35368-26 

35368-27 

35368-28 

35368-29 

35368-30 

35381-01 

35381-02 

35381-03 

35381-04 

35381-05 

35381-06 

35381-07 

35381-08 

35381-09 

35381-10 

35381-11 

35381-12 

35381-13 

35381-14 

35381-15 

35381-16 

35381-17 

35381-18 

35381-19 

35381-20 

35381-21 

35381-22 

35381-23 

35381-24 

35381-25 

35381-26 

35381-27 

35381-28 

35381-29 

35381-30 

35410-01 

35410-02 

35410-03 

35410-04 

35410-05 

35410-06 

35410-07 

35410-09 

35410-13 

35410-14 

35410-15 

35410-16 

35410-17 

35410-18 

35410-19 

35410-20 

35410-21 

35410-22 

35410-23 

35410-24 

35410-25 

35410-26 

35410-27 

35410-28 

35410-29 

35410-30 

35412-01 

35412-02 

35412-03 

35412-04 

35412-05 

35412-06 

35412-07 

35412-08 

35412-09 

35412-10 

35412-11 

35412-12 

35412-13 

35412-14 

35412-15 

35412-16 

35412-17 

35412-18 

35412-19 

35412-20 

35412-21 

35412-22 

35412-23 

35412-25 

35412-26 

35412-27 

35412-28 

35412-29 

35412-30 

35437-01 

35437-02 

35437-03 

35437-04 

35437-05 

35437-07 

35437-08 

35437-09 

35437-10 

35437-11 

35437-12 

35437-13 

35437-14 

35437-15 

35437-16 

35437-17 

35437-18 

35437-19 

35437-20 

35437-21 

35437-22 

35437-23 

35437-24 

35437-25 

35437-26 

35437-27 

35437-28 

35437-29 

35437-30 

35439-01 

35439-02 

35439-03 

35439-04 

35439-05 

35439-06 

35439-07 

35439-08 

35439-09 

35439-10 

35439-11 

35439-12 

35439-13 

35439-14 

35439-15 

35509-01 

35509-02 

35509-03 

35509-04 

35509-05 

35509-06 

35509-07 

35509-08 

35509-09 

35509-10 

35509-11 

35509-12 

35509-13 

35509-14 

35509-15 

35525-01 

35525-02 

35525-03 

35525-04 

35525-05 

35525-06 

35525-07 

35525-08 

35525-09 

35525-10 

35525-11 

35525-12 

35525-13 

35525-14 

35525-15 

35525-16 

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35525-18 

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35525-21 

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35525-27 

35525-28 

35525-29 

35525-30 

35565-01 

35565-02 

35565-03 

35565-05 

35565-06 

35565-07 

35565-08 

35565-09 

35565-10 

35565-11 

35565-12 

35565-13 

35565-14 

35565-15 

35565-16 

35565-17 

35565-18 

35565-19 

35565-20 

35565-21 

35565-22 

35565-23 

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35586-01 

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35785-01 

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35794-02 

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35824-22 
 ENGINE COMPONENTS, INC. 

MSB 08-1 Revision 1 (04/08/08)

Cylinder Assembly Inspection, Assembly Removal and Replacement 

(P/N AEL65102) for Lycoming Parallel Valve Engines

Page 5 of 6 

35824-23 

35824-24 

35824-25 

35824-26 

35824-27 

35824-28 

35824-29 

35824-30 

35888-01 

35888-02 

35888-03 

35888-04 

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35888-06 

35888-07 

35888-08 

35888-09 

35888-10 

35888-11 

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35888-15 

35888-17 

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35888-25 

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35889-01 

35889-02 

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35889-22 

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35930-01 

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35934-01 

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36003-01 

36003-02 

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36003-05 

36003-06 

36003-07 

36003-08 

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 ENGINE COMPONENTS, INC. 

MSB 08-1 Revision 1 (04/08/08)

Cylinder Assembly Inspection, Assembly Removal and Replacement 

(P/N AEL65102) for Lycoming Parallel Valve Engines

Page 6 of 6 

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9.0 ECi CONTACT INFORMATION:

Contact ECi Customer Service at (toll free) 1-800-324-2359, (local) 210-820-8112 or (email) MSB08-1@eci.aero.