Document ID: FAA-2008-0052-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Engine Components Inc. (ECi) Reciprocating Engine Cylinder Assemblies
Posted Date: 2008-05-19T04:00Z

[Federal Register: May 19, 2008 (Volume 73, Number 97)]
[Proposed Rules]               
[Page 28756-28764]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr19my08-12]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2008-0052; Directorate Identifier 2008-NE-01-AD]
RIN 2120-AA64

 
Airworthiness Directives; Engine Components Inc. (ECi) 
Reciprocating Engine Cylinder Assemblies

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 
540 series, ``Parallel Valve'' reciprocating engines, with certain 
Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) 
AEL65102 series ``Titan'', installed. This proposed AD would require 
initial and repetitive visual inspections and compression tests to 
detect cracks at the head-to-barrel interface, replacement of cylinder 
assemblies found cracked, and replacement of certain cylinder 
assemblies, at new reduced times-in-service. This proposed AD results 
from reports of 45 failures with head separations of ECi cylinder 
assemblies. We are proposing this AD to prevent loss of engine power 
due to cracks at the head-to-barrel interface in the cylinder 
assemblies and possible engine failure caused by separation of a 
cylinder head, which could result in loss of control of the aircraft.

DATES: We must receive any comments on this proposed AD by July 18, 
2008.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     Federal eRulemaking Portal: Go to http://
www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 New Jersey Avenue, SE., West Building Ground 
Floor, Room W12-140, Washington, DC 20590-0001.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5

[[Page 28757]]

p.m., Monday through Friday, except Federal holidays.
     Fax: (202) 493-2251.
    You can get the service information identified in this proposed AD 
from Engine Components, Inc., 9503 Middlex, San Antonio, TX 78217; 
Phone (800) 324-2359; fax (210) 820-8102.

FOR FURTHER INFORMATION CONTACT: Peter W. Hakala, Aerospace Engineer, 
Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76193; e-mail: peter.w.hakala@faa.gov; telephone 
(817) 222-5145; fax (817) 222-5785.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2008-0052; Directorate 
Identifier 2008-NE-01-AD'' in the subject line of your comments. We 
specifically invite comments on the overall regulatory, economic, 
environmental, and energy aspects of the proposed AD. We will consider 
all comments received by the closing date and may amend the proposed AD 
in light of those comments.
    We will post all comments we receive, without change, to http://
www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact 
with FAA personnel concerning this proposed AD. Using the search 
function of the Web site, anyone can find and read the comments in any 
of our dockets, including, if provided, the name of the individual who 
sent the comment (or signed the comment on behalf of an association, 
business, labor union, etc.). You may review the DOT's complete Privacy 
Act Statement in the Federal Register published on April 11, 2000 (65 
FR 19477-78).

Examining the AD Docket

    You may examine the AD docket on the Internet at http://
www.regulations.gov; or in person at the Docket Operations office 
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 Operations office (telephone (800) 647-5527) is 
the same as the Mail address provided in the ADDRESSES section. 
Comments will be available in the AD docket shortly after receipt.

Discussion

    In November 2005, we started receiving reports from the National 
Transportation Safety Board, FAA Flight Standards District Offices, and 
other FAA offices, of failures of ECi cylinder assemblies, P/N AEL65102 
series, installed on Lycoming Engines models 320, 360, and 540 series, 
parallel valve reciprocating engines. ECi holds the Parts Manufacturer 
Approval (PMA) for the affected cylinder assemblies. Parallel valve 
Lycoming reciprocating engines are identified by the intake and exhaust 
valves in a parallel configuration. We investigated the failures and 
determined they were caused by fatigue cracking of the aluminum alloy 
cylinder head at the head-to-barrel interface.
    We identified two manufacturing groups of cylinder assemblies 
requiring action. Group ``A'' cylinder assemblies (serial number (SN) 
1138-02 through SN 35171-22) require initial and repetitive visual 
inspections and compression tests, and removal from service at 2,000 
operating hours time-in-service (TIS), unless installed in helicopters. 
If installed in helicopters, group ``A'' cylinder assemblies require 
the same actions, but must be removed from service at 1,500 operating 
hours TIS. The helicopter ECi cylinder assemblies are removed at 1,500 
hours, because the more strenuous operating conditions require a 
shorter time between overhaul (TBO). Group ``B'' cylinder assemblies 
(SN 35239-01 through SN 37016-28) require the same initial visual 
inspection and compression test, but must be removed from service 
before exceeding 350 operating hours TIS. All of the affected cylinder 
assemblies are marked with cylinder head P/N AEL85099. This unsafe 
condition, if not corrected, could result in loss of engine power due 
to cracks in the cylinder assembly and possible engine failure caused 
by cylinder head separation.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design.
    We are proposing this AD, which would require:
     Determining if Group ``A'' or Group ``B'' ECi cylinder 
assemblies, P/N AEL65102 series ``Titan'', with cylinder head P/N 
AEL85099, are installed on your engine.
     For any Group ``A'' cylinder assembly, performing initial 
and repetitive visual inspections and compression tests, and 
replacement not later than 2,000 operating hours TIS or within 25 
operating hours TIS if the cylinder assembly exceeds 2,000 operating 
hours TIS on the effective date of the proposed AD.
     For any Group ``A'' cylinder assembly installed in a 
helicopter, performing the same initial and repetitive visual 
inspections and compression tests, but replacement not later than 1,500 
operating hours TIS or within 25 operating hours TIS if the cylinder 
assembly exceeds 1,500 operating hours TIS on the effective date of the 
proposed AD.
     For any Group ``B'' cylinder assembly, performing the same 
initial visual inspection and compression test, and replacement not 
later than 350 operating hours TIS or within 25 operating hours TIS if 
the cylinder assembly exceeds 350 operating hours TIS on the effective 
date of the proposed AD.

Costs of Compliance

    We estimate that this proposed AD would affect 13,000 ECi cylinder 
assemblies installed in aircraft of U.S. registry. The visual 
inspection and compression tests would take about 4 work-hours for each 
engine. An individual cylinder replacement would require $1,100 for 
parts and 6 work-hours. Lycoming engines with a set of 4 ECi cylinders 
would require 12 work-hours for the cylinder replacement. Lycoming 
engines with a set of 6 ECi cylinders would require 16 work-hours for 
the cylinder replacement. We estimate 18 percent of the affected 
population of cylinders will be replaced. The total cost of the 
proposed AD to U.S. operators to be $7,952,000. Our estimate is 
exclusive of any 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 of the 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 III, 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

[[Page 28758]]

because it addresses an unsafe condition that is likely to exist or 
develop on products identified in this rulemaking action.

Regulatory Findings

    We have 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 Government and the States, or on the distribution 
of power and responsibilities among the various levels of government.
    For the reasons discussed above, I certify that the proposed AD:
    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); and
    3. Would not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this proposed AD. You may get a copy of this summary at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Under the authority delegated to me by the Administrator, the 
Federal Aviation Administration 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), 40113, 44701.

Sec.  39.13  [Amended]

    2. The FAA amends Sec.  39.13 by adding the following new 
airworthiness directive:

Engine Components Inc. (ECi): Docket No. FAA-2008-0052; Directorate 
Identifier 2008-NE-01-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by July 18, 
2008.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to the Lycoming Engines (formerly Textron 
Lycoming) models 320, 360, and 540 series, ``Parallel Valve'', 
reciprocating engines listed in Table 1 of this AD, with ECi 
cylinder assembly, part number (P/N) AEL65102 series ``Titan'', and 
with cylinder head, P/N AEL85099, installed.
    (1) The applicable cylinder assembly serial numbers (SNs) are SN 
1138-02 through SN 35171-22, (referred to in this AD as Group ``A'' 
cylinder assemblies); and
    (2) SN 35239-01 through SN 37016-28 (referred to in this AD as 
Group ``B'' cylinder assemblies).
    (3) Note that the cylinder assembly P/N is at the crankcase end 
of the cylinder assembly, and might be difficult to see. As a guide 
in determining if your cylinder assemblies are affected, all 
affected cylinder assemblies have cylinder head P/N AEL85099. The 
cylinder head P/N is at the top of the cylinder head, near the 
intake and exhaust valve springs, and is easier to locate than the 
cylinder assembly P/N.
    (4) Note that the set of numbers appearing on the cylinder, 
above and to the left of the SN, in the form of ``123456'' is not 
used for determining applicability.

                         Table 1.--Engine Models
------------------------------------------------------------------------
      Cylinder assembly part No.           Installed on engine models
------------------------------------------------------------------------
AEL65102-NST04........................  O-320-A1B, A2B, A2C, A2D, A3A,
                                         A3B, B2B, B2C, B2D, B2E, B3B,
                                         B3C, C2B, C2C, C3B, C3C, D1A,
                                         D1AD, D1B, D1C, D1D, D1F, D2A,
                                         D2B, D2C, D2F, D2G, D2H, D2J,
                                         D3G, E1A, E1B, E1C, E1F, E1J,
                                         E2A, E2B, E2C, E2D, E2E, E2F,
                                         E2G, E2H, E3D, E3H.
                                        IO-320-A1A, A2A, B1A, B1B, B1C,
                                         B1D, B1E, B2A, D1A, D1AD, D1B,
                                         D1C, E1A, E1B, E2A, E2B.
                                        AEIO-320-D1B, D2B, E1A, E1B,
                                         E2A, E2B.
                                        AIO-320-A1A, A1B, A2A, A2B, B1B,
                                         C1B.
                                        LIO-320-B1A.
AEL65102-NST05........................  IO-320-C1A, C1B, C1F, F1A.
                                        LIO-320-C1A.
AEL65102-NST06........................  O-320-A1A, A2A, A2B, A2C, A3A,
                                         A3B, A3C, E1A, E1B, E2A, E2C,
                                         (also, an O-320 model with no
                                         suffix).
                                        IO-320-A1A, A2A.
AEL65102-NST07........................  IO-320-B1A, B1B.
                                        LIO-320-B1A.
AEL65102-NST08........................  O-320-B1A, B1B, B2A, B2B, B3A,
                                         B3B, B3C, C1A, C1B, C2A, C2B,
                                         C3A, C3B, C3C, D1A, D1B, D2A,
                                         D2B, D2C.
AEL65102-NST10........................  O-360-A1A, A1C, A1D, A2A, A2E,
                                         A3A, A3D, A4A, B1A, B1B, B2A,
                                         B2B, C1A, C1C, C1G, C2A, C2B,
                                         C2C, C2D, D1A, D2A, D2B.
                                        IO-360-B1A, B1B, B1C.
                                        HO-360-A1A, B1A, B1B.
                                        HIO-360-B1A, B1B.
                                        AEIO-360-B1B.
                                        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, E4C5, F1A5, F1B5,
                                         G1A5, G2A5.
                                        IO-540-C1B5, C1C5, C2C, C4B5,
                                         C4B5D, C4C5, D4A5, D4B5, N1A5,
                                         N1A5D.
AEL65102-NST12........................  O-360-A1A, A1AD, A1D, A1F, A1F6,
                                         A1F6D, A1G, A1G6, A1G6D, A1H,
                                         A1H6, A1J, A1LD, A1P, A2A, A2D,
                                         A2F, A2G, A2H, A3A, A3AD, A3D,
                                         A4A, A4AD, A4D, A4G, A4J, A4JD,
                                         A4K, A4M, A4N, A4P, A5AD, B1A,
                                         B2C, C1A, C1C, C1E, C1F, C1G,
                                         C2A, C2B, C2C, C2D, C2E, C4F,
                                         C4P, D2A, F1A6, G1A6.
                                        HO-360 -C1A.
                                        LO-360-A1G6D, A1H6.
                                        HIO-360-B1A, B1B, G1A.
                                        LTO-360-A1A6D.
                                        TO-360-A1A6D.
                                        IO-360-B1B, B1BD, B1D, B1E, B1F,
                                         B1F6, B1G6, B2E, B2F, B2F6,
                                         B4A, E1A, L2A, M1A, M1B.
                                        AEIO-360-B1B, B1D, B1E, B1F,
                                         B1F6, B1G6, B1H, B2F, B2F6,
                                         B4A, H1A, H1B.
                                        O-540-A4D5, B2B5, B2C5, B2C5D,
                                         B4B5, B4B5D, E4A5, E4B5, E4B5D,
                                         E4C5, G1A5, G1A5D, G2A5, H1A5,
                                         H1A5D, H1B5, H1B5D, H2A5,
                                         H2A5D, H2B5D.

[[Page 28759]]

                                        IO-540-C4B5, C4B5D, C4D5, C4D5D,
                                         D4A5, D4B5, D4C5, N1A5, N1A5D,
                                         T4A5D, T4B5, T4B5D, T4C5D,
                                         V4A5, V4A5D.
                                        AEIO-540-D4A5, D4B5, D4C5, D4D5.
AEL65102-NST26........................  IO-540-J4A5, R1A5.
                                        TIO-540-C1A, E1A, G1A, H1A.
AEL65102-NST38........................  IO-360-F1A.
                                        TIO-540-AA1AD, AB1AD, AB1BD,
                                         AF1A, AG1A, AK1A, C1A, C1AD,
                                         K1AD.
                                        LTIO-540-K1AD.
AEL65102-NST43........................  O-360-J2A.
                                        O-540-F1B5, J1A5D, J1B5D, J1C5D,
                                         J1D5D, J2A5D, J2B5D, J2C5D,
                                         J2D5D, J3A5, J3A5D, J3C5D.
                                        IO-540-AB1A5, W1A5, W1A5D,
                                         W3A5D.
AEL65102-NST44........................  O-540-L3C5D.
------------------------------------------------------------------------

For information, the Lycoming Engines (formerly Textron Lycoming) 
models 320, 360, and 540 series, ``Parallel Valve'', reciprocating 
engines are installed on, but not limited to, the aircraft listed in 
the following Table 2:

           Table 2.--Engines Installed On, But Not Limited To
------------------------------------------------------------------------
             Engine models              Installed on, but not limited to
------------------------------------------------------------------------
O-320-A1A.............................  Piper Aircraft: Tri-Pacer (PA-22
                                         ``150'', PA-22S ``150''),
                                         Apache (PA-23), Pawnee (PA-25).
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
                                        Mooney Aircraft: Mark (20A).
                                        Dinfia: Ranquel (1A-46).
                                        Simmering-Graz Pauker: Flamingo
                                         (SGP-M-222).
                                        Aviamilano: Scricciolo (P-19).
                                        Vos Helicopter Co.: Spring Bok.
O-320-A1B.............................  Piper Aircraft: Tri-Pacer (PA-22
                                         ``150'', PA-22S ``150''),
                                         Apache (PA-23).
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
                                        S.O.C.A.T.A.: Horizon (Gardan).
O-320-A2A.............................  Piper Aircraft: Tri-Pacer (PA-22
                                         ``150'', PA-22S ``150''),
                                         Agriculture (PA-18A ``150''),
                                         Super Cub (PA-18 ``150''),
                                         Caribbean (PA-22 ``150''),
                                         Pawnee (PA-25).
                                        Intermountain Mfg. Co.: Call Air
                                         Texas (A-5, A-5T).
                                        Lake Aircraft: Colonial (C-1).
                                        Rawdon Bros.: Rawdon (T-1, T-15,
                                         T-15D).
                                        Shinn Engineering: Shinn (2150-
                                         A).
                                        Dinfia: Ranquel (1A-46).
                                        Neiva: (1PD-5802).
                                        Sud: Gardan-Horizon (GY-80).
                                        LaVerda: Falco (F8L Series II,
                                         America).
                                        Malmo: Vipan (MF1-10).
                                        Kingsford Smith: Autocrat (SCRM-
                                         153).
                                        Aero Commander: 100.
O-320-A2B.............................  Piper Aircraft: Tri-Pacer (PA-22
                                         ``150'', PA-22S ``150''),
                                         Cherokee (PA-28 ``150''), Super
                                         Cub (PA-18 ``150'').
                                        Champion Aircraft: Challenger
                                         (7GCA, 7GCB, 7KC), Citabria
                                         (7GCAA, 7GCRC), Agriculture
                                         (7GCBA).
                                        Beagle: Pup (150).
                                        Artic: Interstate S1B2.
                                        Robinson: R-22.
                                        Varga: Kachina 2150A.
O-320-A2C.............................  Robinson: R-22.
                                        Cicare: Cicare AG.
                                        Bellanca Aircraft: Citabria 150
                                         (7GCAA), Citabria 150S (7GCBC).
O-320-A2D.............................  Piper Aircraft: Apache (PA-23).
O-320-A3A.............................  Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
                                        Corben-Fettes: Globe Special
                                         (Globe GC-1B).
O-320-A3B.............................  Piper Aircraft: Apache (PA-23).
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
                                        Teal II: TSC (1A2).
O-320-B1A.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
                                        Malmo: Vipan (MF1-10).
O-320-B1B.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
O-320-B2A.............................  Piper Aircraft: Tri-Pacer (PA-22
                                         ``160'', PA-22S ``160'').
O-320-B2B.............................  Piper Aircraft: Tri-Pacer (PA-22
                                         ``160'', PA-22S ``160'').
                                        Beagle: Airedale (D5-160).
                                        Fuji-Heavy Industries: Fuji (F-
                                         200).
                                        Uirapuru: Aerotec 122.
O-320-B2C.............................  Robinson: R-22.
O-320-B2D.............................  Maule: MX-7-160.

[[Page 28760]]

O-320-B2E.............................  Lycon.
O-320-B3A.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
O-320-B3B.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
                                        Doyn Aircraft: Doyn-Cessna (170,
                                         170A, 170B).
                                        Sud: Gardan (GY80-160).
O-320-C1A.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
                                        Riley Aircraft: Rayjay (Apache).
O-320-C1B.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
O-320-C3A.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
O-320-C3B.............................  Piper Aircraft: Apache (PA-23
                                         ``160'').
O-320-D1A.............................  Sud: Gardan (GY-80).
                                        Gyroflug: Speed Cancard.
                                        Grob: G115.
O-320-D1F.............................  Slingsby: T67 Firefly.
O-320-D2A.............................  Piper Aircraft: Cherokee (PA-28S
                                         ``160'').
                                        Robin: Major (DR400-140B),
                                         Chevalier (DR-360), (R-3140).
                                        S.O.C.A.T.A.: Tampico TB9.
                                        Slingsby: T67C Firefly.
                                        Daetwyler: MD-3-160.
                                        Nash Aircraft Ltd.: Petrel.
                                        Aviolight: P66D Delta.
                                        General Avia: Pinguino.
O-320-D2B.............................  Beech Aircraft: Musketeer (M-
                                         23).
                                        Piper Aircraft: Cherokee (PA-28
                                         ``160'').
O-320-D2J.............................  Cessna Aircraft: Skyhawk 172.
O-320-D3G.............................  Piper Aircraft: Warrior II,
                                         Cadet (PA-28-161).
O-320-E1A.............................  Grob: G115.
O-320-E1C.............................  M.B.B. (Messerschmitt-Boelkow-
                                         Blohm): Monsun (BO-209-B).
O-320-E1F.............................  M.B.B.: Monsun (BO-209-B).
O-320-E2A.............................  Piper Aircraft: Cherokee (PA-28
                                         ``140'', PA-28 ``150'').
                                        Robin: Major (DR-340), Sitar,
                                         Bagheera (GY-100-135).
                                        S.O.C.A.T.A.: Super Rallye (MS-
                                         886), Rallye Commodore (MS-
                                         892).
                                        Siai-Marchetti: (S-202).
                                        F.F.A.: Bravo (AS-202/15).
                                        Partenavia: Oscar (P66B), Bucker
                                         (131 APM).
                                        Aeromot: Paulistina P-56.
                                        Pezetel: Koliber 150.
O-320-E2C.............................  Beech Aircraft: Musketeer III (M-
                                         23III).
                                        M.B.B.: Monsun (BO-209-B).
O-320-E2D.............................  Cessna Aircraft: Cardinal (172-
                                         I, 177).
O-320-E2F.............................  M.B.B.: Monsun (BO-209-B),
                                         Wassmer Pacific (WA-51).
O-320-E2G.............................  American Aviation Corp.:
                                         Traveler.
O-320-E3D.............................  Piper Aircraft: Cherokee (140).
                                        Beech Aircraft: Sport.
IO-320-B2A............................  Piper Aircraft: Twin Comanche
                                         (PA-30).
IO-320-B1C............................  Hi. Shear: Wing.
IO-320-B1D............................  Ted Smith Aircraft: Aerostar.
IO-320-C1A............................  Piper Aircraft: Twin Comanche
                                         (PA-30 Turbo).
IO-320-D1A............................  M.B.B.: Monsun (BO-209-C).
IO-320-D1B............................  M.B.B.: Monsun (BO-209-C).
IO-320-E1A............................  M.B.B.: Monsun (BO-209-C).
IO-320-E1B............................  Bellanca Aircraft.
IO-320-E2A............................  Champion Aircraft: Citabria.
IO-320-E2B............................  Bellanca Aircraft.
IO-320-F1A............................  CAAR Engineering: Carr Midget.
LIO-320-B1A...........................  Piper Aircraft: Twin Comanche
                                         (PA-39).
LIO-320-C1A...........................  Piper Aircraft: Twin Comanche
                                         (PA-39).
AIO-320-B1B...........................  M.B.B.: Monsun (BO-209-C).
AEIO-320-D1B..........................  Slingsby: T67M Firefly.
AEIO-320-D2B..........................  Hundustan Aeronautics Ltd.: HT-
                                         2.
AEIO-320-E1A..........................  Bellanca Aircraft.
                                        Champion Aircraft.
AEIO-320-E1B..........................  Bellanca Aircraft.
                                        Champion Aircraft: Decathalon
                                         (8KCAB-CS).
AEIO-320-E2B..........................  Bellanca Aircraft.
                                        Champion Aircraft: Decathalon
                                         (8KCAB).
O-320-A1A.............................  Riley Aircraft: Riley Twin.
O-360-A1A.............................  Beech Aircraft: Travel Air (95,
                                         B-95).
                                        Piper Aircraft: Comanche (PA-
                                         24).
                                        Intermountain Mfg. Co.: Call Air
                                         (A-6).
                                        Lake Aircraft: Colonial (C-2, LA-
                                         4, 4A or 4P).

[[Page 28761]]

                                        Doyn Aircraft: Doyn-Cessna
                                         (170B, 172, 172A, 172B).
                                        Mooney Aircraft: Mark ``20B'' (M-
                                         20B).
                                        Earl Horton: Pawnee (Piper PA-
                                         25).
                                        Dinfia: Ranquel (1A-51).
                                        Neiva: (1PD-5901).
                                        Regente: (N-591).
                                        Wassmer: Super 4 (WA-50A), Sancy
                                         (WA-40), Baladou (WA-40),
                                         Pariou (WA-40).
                                        Sud: Gardan (GY-180).
                                        Bolkow: (207).
                                        Partenavia: Oscar (P-66).
                                        Siai-Marchetti: (S-205).
                                        Procaer: Picchio (F-15-A).
                                        S.A.A.B.: Safir (91-D).
                                        Malmo: Vipan (MF-10B).
                                        Aero Boero: AB-180.
                                        Beagle: Airedale (A-109).
                                        DeHavilland: Drover (DHA-3MK3).
                                        Kingsford-Smith: Bushmaster (J5-
                                         6).
                                        Aero Engine Service Ltd.: Victa
                                         (R-2).
O-360-A1AD............................  S.O.C.A.T.A.: Tabago TB-10.
O-360-A1D.............................  Piper Aircraft: Comanche (PA-
                                         24).
                                        Lake Aircraft: Colonial (LA-4,
                                         4A or 4P).
                                        Doyn Aircraft: Doyn-Beech (Beech
                                         95).
                                        Mooney Aircraft: Master ``21''
                                         (M-20E), Mark ``20B'', ``20D'',
                                         (M20B, M20C), Mooney Statesman
                                         (M-20G).
                                        Dinfia: Querandi (1A-45).
                                        Wassmer: (WA-50).
                                        Malmo: Vipan (MF1-10).
                                        Cessna Aircraft: Skyhawk.
                                        Doyn Aircraft: Doyn-Piper (PA-23
                                         ``160'').
O-360-A1F6............................  Cessna Aircraft: Cardinal.
O-360-A1F6D...........................  Cessna Aircraft: Cardinal 177.
                                        Teal III: TSC (1A3).
O-360-A1G6............................  Aero Commander.
O-360-A1G6D...........................  Beech Aircraft: Duchess 76.
O-360-A1H6............................  Piper Aircraft: Seminole (PA-
                                         44).
O-360-A1LD............................  Wassmer: Europa WA-52.
O-360-A1P.............................  Aviat: Husky.
O-360-A2A.............................  Center Est Aeronautique: Regente
                                         (DR-253).
                                        S.O.C.A.T.A.: Rallye Commodore
                                         (MS-893).
                                        Societe Aeronautique Normande:
                                         Mousquetaire (D-140).
                                        Bolkow: Klemm (K1-107C).
                                        Partenavia: Oscar (P-66).
                                        Beagle: Husky (D5-180) (J1-U).
O-360-A2D.............................  Piper Aircraft: Comanche (PA-
                                         24), Cherokee ``C'' (PA-28
                                         ``180'').
                                        Mooney Aircraft: Master ``21''
                                         (M-20D), Mark ``21'' (M-20E).
O-360-A2E.............................  Std. Helicopter.
O-360-A2F.............................  Aero Commander: Lark (100).
                                        Cessna Aircraft: Cardinal.
O-360-A2G.............................  Beech Aircraft: Sport.
O-360-A3A.............................  C.A.A.R.P.S.A.N.: (M-23III).
                                        Societe Aeronautique Normande:
                                         Jodel (D-140C).
                                        Robin: Regent (DR400/180),
                                         Remorqueur (DR400/180R), R-
                                         3170.
                                        S.O.C.A.T.A.: Rallye 180GT,
                                         Sportavia Sportsman (RS-180).
                                        Norman Aeroplace Co.: NAC-1
                                         Freelance.
                                        Nash Aircraft Ltd.: Petrel.
O-360-A3AD............................  S.O.C.A.T.A.: TB-10.
                                        Robin: Aiglon (R-1180T).
O-360-A4A.............................  Piper Aircraft: Cherokee ``D''
                                         (PA-28 ``180'').
O-360-A4D.............................  Varga: Kachina.
O-360-A4G.............................  Beech Aircraft: Musketeer Custom
                                         III.
O-360-A4K.............................  Grumman American: Tiger.
                                        Beech Aircraft: Sundowner 180.
O-360-A4M.............................  Piper Aircraft: Archer II (PA-28
                                         ``18'').
                                        Valmet: PIK-23.
O-360-A4N.............................  Cessna Aircraft: 172 (Optional).
O-360-A4P.............................  Penn Yan: Super Cub Conversion.
O-360-A5AD............................  C. Itoh and Co.: Fuji FA-200.
O-360-B2C.............................  Seabird Aviation: SB7L.
O-360-C1A.............................  Intermountain Mfg. Co.: Call Air
                                         (A-6).
O-360-C1E.............................  Bellanca Aircraft: Scout (8GCBC-
                                         CS).
O-360-C1F.............................  Maule: Star Rocket MX-7-180.
O-360-C1G.............................  Christen: Husky (A-1).

[[Page 28762]]

O-360-C2B.............................  Hughes Tool Co.: (269A).
O-360-C2D.............................  Hughes Tool Co.: (269A).
O-360-C2E.............................  Hughes Tool Co.: (YHO-2HU)
                                         Military.
                                        Bellanca Aircraft: Scout (8GCBC
                                         FP).
O-360-C4F.............................  Maule: MX-7-180A.
O-360-C4P.............................  Penn Yan: Super Cub Conversion.
O-360-F1A6............................  Cessna Aircraft: Cutlass RG.
O-360-J2A.............................  Robinson: R22.
IO-360-B1A............................  Beech Aircraft: Travel-Air (B-
                                         95A).
                                        Doyn Aircraft: Doyn-Piper (PA-23
                                         ``200'').
IO-360-B1B............................  Beech Aircraft: Travel-Air (B-
                                         95B).
                                        Doyn Aircraft: Doyn-Piper (PA-23
                                         ``200'').
                                        Fuji: (FA-200).
IO-360-B1D............................  United Consultants: See-Bee.
IO-360-B1E............................  Piper Aircraft: Arrow (PA-28
                                         ``180R'').
IO-360-B1F............................  Utva: 75.
IO-360-B2E............................  C.A.A.R.P. C.A.P. (10).
IO-360-B1F6...........................  Great Lakes: Trainer.
IO-360-B1G6...........................  American Blimp: Spector 42.
IO-360-B2F6...........................  Great Lakes: Trainer.
LO-360-A1G6D..........................  Beech Aircraft: Duchess.
LO-360-A1H6...........................  Piper Aircraft: Seminole (PA-
                                         44).
IO-360-E1A............................  T.R. Smith Aircraft: Aerostar.
IO-360-L2A............................  Cessna Aircraft: Skyhawk C-172.
IO-360-M1A............................  Diamond Aircraft: DA-40.
IO-360-M1B............................  Vans Aircraft: RV6, RV7, RV8.
                                        Lancair: 360.
AEIO-360-B1F..........................  F.F.A.: Bravo (200).
                                        Grob: G115/Sport-Acro.
AEIO-360-B1G6.........................  Great Lakes.
AEIO-360-B2F..........................  Mundry: CAP-10.
AEIO-360-B4A..........................  Pitts: S-1S.
AEIO-360-H1A..........................  Bellanca Aircraft: Super
                                         Decathalon (8KCAB-180).
AEIO-360-H1B..........................  American Champion: Super
                                         Decathalon.
VO-360-A1A............................  Brantly Hynes Helicopter: (B-2).
VO-360-A1B............................  Brantly Hynes Helicopter: (B-2,
                                         B2-A), Military (YHO-3BR).
VO-360-B1A............................  Brantly Hynes Helicopter: (B-2,
                                         B2-A).
IVO-360-A1A...........................  Brantly Hynes Helicopter: (B2-
                                         B).
HO-360-B1A............................  Hughes Tool Co.: (269A).
HO-360-B1B............................  Hughes Tool Co.: (269A).
HO-360-C1A............................  Schweizer: (300C).
HIO-360-B1A...........................  Hughes Tool Co.: Military (269-A-
                                         1), (TH-55A).
HIO-360-B1B...........................  Hughes Tool Co.: (269A).
HIO-360-G1A...........................  Schweizer: (CB).
O-540-A1A.............................  Rhein-Flugzeugbau: (RF-1).
O-540-A1A5............................  Piper Aircraft: Comanche (PA-24
                                         ``180'').
                                        Helio: Military (H-250).
                                        Yoeman Aviation: (YA-1).
O-540-A1B5............................  Piper Aircraft: Aztec (PA-23
                                         ``250''), Comanche (PA-24
                                         ``250'').
O-540-A1C5............................  Piper Aircraft: Comanche (PA-24
                                         ``250'').
O-540-A1D.............................  Found Bros.: (FBA-2C).
                                        Dornier: (DO-28-B1).
O-540-A1D5............................  Piper Aircraft: Aztec (PA-23
                                         ``250''), Comanche (PA-24
                                         ``250''), Military Aztec (U-
                                         11A).
                                        Dornier: (DO-28).
O-540-A2B.............................  Aero Commander: (500).
                                        Mid-States Mfg. Co.: Twin
                                         Courier (H-500), (U-5).
O-540-A3D5............................  Piper Aircraft: Navy Aztec (PA-
                                         23 ``250'').
O-540-B1A5............................  Piper Aircraft: Apache (PA-23
                                         ``235'').
O-540-B1B5............................  Piper Aircraft: Comanche (PA-24
                                         ``250'').
                                        Doyn Aircraft: Doyn-Piper (PA-24
                                         ``250'').
O-540-B1D5............................  Wassmer: (WA-421).
O-540-B2B5............................  Piper Aircraft: Pawnee (PA-25
                                         ``235''), Cherokee (PA-28
                                         ``235''), Aztec (PA-23
                                         ``235'').
                                        Intermountain Mfg. Co.: Call Air
                                         (A-9).
                                        Rawdon Bros.: Rawdon (T-1).
                                        S.O.C.A.T.A.: Rallye 235CA.
O-540-B2C5............................  Piper Aircraft: Pawnee (PA-25
                                         ``235'').
O-540-B4B5............................  Piper Aircraft: Cherokee (PA-28
                                         ``235'').
                                        Embraer: Corioca (EMB-710).
                                        S.O.C.A.T.A.: Rallye 235GT,
                                         Rallye 235C.
                                        Maule: Star Rocket (MX-7-235),
                                         Super Rocket (M-6-235), Super
                                         Std. Rocket (M-7-235).
O-540-E4A5............................  Piper Aircraft: Comanche (PA-24
                                         ``260'').
                                        Aviamilano: Flamingo (F-250).

[[Page 28763]]

                                        Siai-Marchetti: (SF-260), (SF-
                                         208).
O-540-E4B5............................  Britten-Norman: (BN-2).
                                        Piper Aircraft: Cherokee Six (PA-
                                         32 ``260'').
O-540-E4C5............................  Pilatus Britten-Norman: Islander
                                         (BN-2A-26), Islander (BN-2A-
                                         27), Islander II (BN-2B-26),
                                         Islander (BN-2A-21), Trislander
                                         (BN-2A-Mark III-2).
O-540-F1B5............................  Omega Aircraft: (BS-12D1).
                                        Robinson: (R-44).
O-540-G1A5............................  Piper Aircraft: Pawnee (PA-25
                                         ``260'').
O-540-H1B5D...........................  Aero Boero: 260.
O-540-H2A5............................  Embraer: Impanema ``AG''.
                                        Gippsland: GA-200.
O-540-H2B5D...........................  Aero Boero: 260.
O-540-J1A5D...........................  Maule: Star Rocket (MX-7-235),
                                         Super Rocket (M-6-235), Super
                                         Std. Rocket (M-7-235).
O-540-J3A5............................  Robin: R-3000/235.
O-540-J3A5D...........................  Piper Aircraft: Dakota (PA-28-
                                         236).
O-540-J3C5D...........................  Cessna Aircraft: Skylane RG.
O-540-L3C5D...........................  Cessna Aircraft: TR-182, Turbo
                                         Skylane RG.
IO-540-C1B5...........................  Piper Aircraft: Aztec B (PA-23
                                         ``250''), Comanche (PA-24
                                         ``250'').
IO-540-C1C5...........................  Riley Aircraft: Turbo-Rocket.
IO-540-C4B5...........................  Piper Aircraft: Aztec C (PA-23
                                         ``250''), Aztec F.
                                        Wassmer: (WA4-21).
                                        Avions Pierre Robin: (HR100/
                                         250).
                                        Bellanca Aircraft: Aries T-250.
                                        Aerofab: Renegade 250.
IO-540-C4D5...........................  S.O.C.A.T.A.: TB-20.
IO-540-C4D5D..........................  S.O.C.A.T.A.: Trinidad TB-20.
IO-540-D4A5...........................  Piper Aircraft: Comanche (PA-24
                                         ``260'').
                                        Siai-Marchetti: (SF-260).
IO-540-D4B5...........................  Cerva: (CE-43 Guepard).
IO-540-J4A5...........................  Piper Aircraft: Aztec (PA-23
                                         ``250'').
IO-540-R1A5...........................  Piper Aircraft: Comanche (PA-
                                         24).
IO-540-T4A5D..........................  General Aviation: Model 114.
IO-540-T4B5...........................  Commander: 114B.
IO-540-T4B5D..........................  Rockwell: 114.
IO-540-T4C5D..........................  Lake Aircraft: Seawolf.
IO-540-V4A5...........................  Maule: MT-7-260, M-7-260.
                                        Aircraft Manufacturing Factory.
IO-540-V4A5D..........................  Brooklands: Scoutmaster.
IO-540-W1A5...........................  Maule: MX-7-235, MT-7-235, M7-
                                         235.
IO-540-W1A5D..........................  Maule: Star Rocket (MX-7-235),
                                         Super Rocket (M-6-235), Super
                                         Std. Rocket (M-7-235).
IO-540-W3A5D..........................  Schweizer: Power Glider.
AEIO-540-D4A5.........................  Christen: Pitts (S-2S, S-2B).
                                        Siai-Marchetti: SF-260.
                                        H.A.L.: HPT-32.
                                        Slingsby: Firefly T3A.
AEIO-540-D4B5.........................  Moravan: Zlin-50L.
                                        H.A.L.: HPT-32.
AEIO-540-D4D5.........................  Burkhart Grob: Grob G, 115T
                                         Aero.
TIO-540-C1A...........................  Piper Aircraft: Turbo Aztec (PA-
                                         23-250).
TIO-540-K1AD..........................  Piper Aircraft.
TIO-540-AA1AD.........................  Aerofab Inc.: Turbo Renegade
                                         (270).
TIO-540-AB1AD.........................  S.O.C.A.T.A.: Trinidad TC TB-21.
TIO-540-AB1BD.........................  Schweizer.
TIO-540-AF1A..........................  Mooney Aircraft: ``TLS'' M20M.
TIO-540-AG1A..........................  Commander Aircraft: 114TC.
TIO-540-AK1A..........................  Cessna Aircraft: Turbo Skylane
                                         T182T.
LTIO-540-K1AD.........................  Piper Aircraft.
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from reports of 45 failures with head 
separations of ECi cylinder assemblies. We are issuing this AD to 
prevent loss of engine power due to cracks at the head-to-barrel 
interface in the cylinder assemblies and possible engine failure 
caused by separation of a cylinder head, which could result in loss 
of control of the aircraft.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

Engines Not Overhauled or Cylinder Assemblies Not Replaced Since New

    (f) If your engine has not been overhauled or had any cylinder 
assemblies replaced since new, no further action is required.

Engines Overhauled or Cylinder Assemblies Replaced Since New

    (g) If your engine was overhauled or had a cylinder assembly 
replaced since new, do the following:
    (1) Before further flight, inspect the maintenance records and 
engine logbook to determine if the overhaul or repair facility used 
ECi cylinder assemblies, P/N AEL65102, with cylinder head, P/N 
AEL85099, with a SN 1138-02 through SN

[[Page 28764]]

35171-22, or a SN 35239-01 through SN 37016-28, installed.
    (2) If the cylinder assemblies are not ECi, P/N AEL65102, no 
further action is required.
    (3) If the cylinder assemblies are ECi, P/N AEL65102, and if the 
serial number is not listed in this AD, no further action is 
required.
    (4) If the cylinder assemblies are ECi, P/N AEL65102, and if the 
serial number is listed in this AD, do the following:

Group ``A'' Cylinder Assemblies

    (i) For Group ``A'' cylinder assemblies:
    (A) Perform an initial visual inspection as specified in 
paragraphs (h) through (j) of this AD, and an initial compression 
test as specified in paragraphs (k) through (o) of this AD, within 
the next 10 operating hours time-in-service (TIS), if the cylinder 
assembly has 350 or more operating hours TIS on the effective date 
of this AD, but fewer than 2,000 operating hours TIS.
    (B) Perform an initial visual inspection as specified in 
paragraphs (h) through (j) of this AD, and an initial compression 
test as specified in paragraphs (k) through (o) of this AD, before 
exceeding 350 operating hours TIS, if the cylinder assembly has 
fewer than 350 operating hours TIS on the effective date of this AD.
    (C) Replace cylinder assemblies installed in helicopter engines 
within the next 25 operating hours TIS after the effective date of 
this AD if the cylinder assembly has 1,500 operating hours TIS or 
more on the effective date of this AD.
    (D) Replace cylinder assemblies installed in airplane engines 
within the next 25 operating hours TIS after the effective date of 
this AD if the cylinder assembly has 2,000 operating hours TIS or 
more on the effective date of this AD.
    (E) Perform repetitive visual inspections as specified in 
paragraphs (h) through (j) of this AD, and repetitive compression 
tests as specified in paragraphs (k) through (o) of this AD, within 
every 50 operating hours TIS.
    (F) Replace cylinder assemblies installed in helicopter engines 
that pass the visual inspections and compression tests, no later 
than 1,500 operating hours TIS after the effective date of this AD.
    (G) Replace cylinder assemblies installed in airplane engines 
that pass the visual inspections and compression tests, no later 
than 2,000 operating hours TIS after the effective date of this AD.

Group ``B'' Cylinder Assemblies

    (ii) For Group ``B'' cylinder assemblies:
    (A) Perform an initial visual inspection as specified in 
paragraphs (h) through (j) of this AD, and initial compression test 
as specified in paragraphs (k) through (o) of this AD, within an 
additional 10 operating hours TIS.
    (B) Replace the cylinder assembly within the next 25 operating 
hours TIS after the effective date of this AD if the cylinder 
assembly has 350 or more operating hours TIS on the effective date 
of this AD.
    (C) Replace cylinder assemblies that pass the initial visual 
inspections and compression tests, before exceeding 350 operating 
hours TIS after the effective date of this AD.

Visual Inspection

    (h) Visually inspect around the exhaust valve side, for cracks 
or any signs of black or white residue of combustion leakage from 
cracks.
    (i) Replace cracked cylinder assemblies before further flight.
    (j) Information on cylinder assembly visual inspection can be 
found in ECi Mandatory Service Bulletin (MSB) No. 08-1, Revision 1, 
dated April 8, 2008.

Cylinder Assembly Compression Test

    (k) Compression test the cylinder assembly.
    (l) Information on cylinder assembly compression testing can be 
found in ECi MSB No. 08-1, Revision 1, dated April 8, 2008.
    (m) During the compression test, if the cylinder pressure gauge 
reads below 70 pounds-per-square-inch, apply a water and soap 
solution to the side of the leaking cylinder, near the head-to-
barrel interface.
    (n) Replace the cylinder assembly before further flight, if air 
leakage and bubbles are observed on the side of the cylinder 
assembly, near the head-to-barrel interface.
    (o) Repair or replace the engine cylinder assembly before 
further flight if the cause of the low gauge reading in paragraph 
(m) of this AD is from leaking intake or exhaust valves, or from 
leaking piston rings.

Prohibition of ECi Cylinder Assemblies Affected By This AD

    (p) After the effective date of this AD, do not install any ECi 
cylinder assembly, P/N AEL65102, with cylinder head, P/N AEL85099, 
and with SN 1138-02 through SN 35171-22, or SN 35239-01 through SN 
37016-28, onto any engine, and do not attempt to repair or reuse 
these ECi cylinder assemblies.

Alternative Methods of Compliance

    (q) The Manager, Special Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Special Flight Permits

    (r) Under 14 CFR 39.23, we will not approve special flight 
permits for this AD for engines that have failed the visual 
inspection or the cylinder assembly compression test required by 
this AD.

Related Information

    (s) ECi Mandatory Service Bulletin No. 08-1, Revision 1, dated 
April 8, 2008, pertains to the subject of this AD.
    (t) Contact Peter W. Hakala, Aerospace Engineer, Special 
Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76193; e-mail: peter.w.hakala@faa.gov; 
telephone (817) 222-5145; fax (817) 222-5785, for more information 
about this AD.

    Issued in Burlington, Massachusetts, on May 13, 2008.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E8-11116 Filed 5-16-08; 8:45 am]

BILLING CODE 4910-13-P