Document ID: FAA-2014-0940-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Lycoming Engines Reciprocating Engines (Type Certificate previously held by Textron Lycoming Division, AVCO Corporation)
Posted Date: 2015-02-02T05:00Z

[Federal Register Volume 80, Number 21 (Monday, February 2, 2015)]
[Proposed Rules]
[Pages 5489-5491]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2015-01835]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2014-0940; Directorate Identifier 2014-NE-15-AD]
RIN 2120-AA64

Airworthiness Directives; Lycoming Engines Reciprocating Engines 
(Type Certificate Previously Held by Textron Lycoming Division, AVCO 
Corporation)

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for 
certain Lycoming TIO-540-AJ1A reciprocating engines. This proposed AD 
was prompted by several reports of cracked engine exhaust pipes. This 
proposed AD would require inspection of the engine exhaust pipes for 
cracks and replacement of the turbocharger mounting bracket. We are 
proposing this AD to prevent failure of the exhaust system due to 
cracking, which could lead to uncontrolled engine fire, harmful exhaust 
gases entering the cabin resulting in crew incapacitation, and damage 
to the airplane.

DATES: We must receive comments on this proposed AD by April 3, 2015.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Lycoming Engines, 652 Oliver Street, Williamsport, PA 17701; phone: 
800-258-3279; fax: 570-327-7101; Internet: www.lycoming.com/Lycoming/SUPPORT/TechnicalPublications/ServiceBulletins.aspx. You may view this 
service information at the FAA, Engine & Propeller Directorate, 12 New 
England Executive Park, Burlington, MA. For information on the 
availability of this material at the FAA, call 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2014-
0940; or in person at the Docket Management Facility between 9 a.m. and 
5 p.m., Monday through Friday, except Federal holidays. The AD docket 
contains this proposed AD, the regulatory evaluation, any comments 
received, and other information. The street address for the Docket 
Office (phone: 800-647-5527) is in the ADDRESSES section. Comments will 
be available in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Norm Perenson, Aerospace Engineer, New 
York Aircraft Certification Office, FAA, Engine & Propeller 
Directorate, 1600 Stewart Avenue, Suite 410, Westbury, NY 11590; phone: 
516-228-7337; fax: 516-794-5531; email: norman.perenson@faa.gov.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this NPRM. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2014-0940; 
Directorate Identifier 2014-NE-15-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this NPRM. We will 
consider all comments received by the closing date and may amend this 
NPRM because of those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each

[[Page 5490]]

substantive verbal contact we receive about this NPRM.

Discussion

    We issued Special Airworthiness Information Bulletin (SAIB) CE-04-
22 on December 17, 2003. The SAIB recommended pre-flight and repetitive 
inspection of exhaust system components for signs of cracking. This 
NPRM was prompted by additional reports of exhaust pipe cracking. 
Probable causes of exhaust pipe cracks are questionable exhaust pipe 
welds or misalignment of the exhaust pipe during installation. 
Additionally, non-conforming turbocharger mounting brackets were found 
during Lycoming engine assembly trials of new engine exhaust pipes. 
These out-of-tolerance mounting brackets may place stresses on exhaust 
system components. Taken alone, or in combination, these conditions may 
overstress certain exhaust pipe locations and cause cracks to develop. 
With the presence of cracks, hot exhaust gases collect in the engine 
compartment and carbon monoxide gas is now able to enter the airplane 
cabin. The conditions identified above, if not corrected, could result 
in uncontrolled engine fire, harmful exhaust gases entering the cabin 
resulting in crew incapacitation, and damage to the airplane.

Relevant Service Information

    We reviewed Lycoming Engines Mandatory Service Bulletin (MSB) No. 
614A, dated October 10, 2014. The MSB describes procedures for exhaust 
system inspection and turbocharger mounting bracket replacement.

FAA's Determination

    We are proposing this NPRM because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

Proposed AD Requirements

    This NPRM would require inspection of the exhaust system and 
replacement of the turbocharger mounting bracket.

Costs of Compliance

    We estimate that this proposed AD would affect about 111 engines 
installed on airplanes of U.S. registry. We also estimate that it will 
take about 8 hours per engine to comply with this AD. The average labor 
rate is $85 per hour. Parts replacement will cost about $6,782 per 
engine. Based on these figures, we estimate the cost of this proposed 
AD on U.S. operators to be $828,282. Our cost estimate is exclusive of 
possible warranty coverage.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority 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 because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

Regulatory Findings

    We determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would not 
have a substantial direct effect on the States, on the relationship 
between the national 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 this proposed 
regulation:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and
    (4) Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.

List of Subjects in 14 CFR Part 39

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

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
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]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

Lycoming Engines (Type Certificate previously held by Textron 
Lycoming Division, AVCO Corporation): Docket No. FAA-2014-0940; 
Directorate Identifier 2014-NE-15-AD.

(a) Comments Due Date

    We must receive comments by April 3, 2015.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all Lycoming TIO-540-AJ1A reciprocating 
engines listed by engine serial number (S/N) in Figure 1 to 
paragraph (c) of this AD and to any TIO-540-AJ1A reciprocating 
engine with a replacement turbocharger mounting bracket installed 
that was purchased between April 5, 2012 and May 29, 2014.

  Figure 1 to Paragraph (c)--Lycoming Engine TIO-540-AJ1A Affected S/Ns
------------------------------------------------------------------------
    Engine S/N         Engine S/N        Engine S/N        Engine S/N
------------------------------------------------------------------------
L-6748-61E         L-13828-61E        L-13832-61E       L-13843-61E
L-13817-61E        L-13831-61E        L-13833-61E       L-13847-61E
L-13819-61E        L-13823-61E        L-13839-61E       L-13855-61E
L-13856-61E        L-13947-61E        L-14011-61E       RL-2551-61E
L-13857-61E        L-13948-61E        L-14013-61E       RL-2848-61E
L-13866-61E        L-13949-61E        L-14014-61E       RL-3450-61E
L-13867-61E        L-13950-61E        L-14015-61E       RL-4138-61E
L-13873-61E        L-13960-61E        L-14017-61E       RL-7243-61E
L-13882-61E        L-13961-61E        L-14024-61E       RL-7512-61E
L-13883-61E        L-13962-61E        L-14025-61E       RL-8435-61E

[[Page 5491]]

 
L-13884-61E        L-13967-61E        L-14026-61E       RL-8767-61E
L-13885-61E        L-13973-61E        L-14028-61E       RL-8914-61E
L-13886-61E        L-13975-61E        L-14034-61E       RL-8979-61E
L-13895-61E        L-13976-61E        L-14054-61E       RL-9399-61E
L-13896-61E        L-13979-61E        L-14055-61E       RL-9466-61E
L-13898-61E        L-13981-61E        L-14056-61E       RL-9618-61E
L-13900-61E        L-13983-61E        L-14057-61E       RL-9663-61E
L-13902-61E        L-13984-61E        L-14062-61E       RL-10098-61E
L-13907-61E        L-13993-61E        L-14063-61E       RL-10194-61E
L-13913-61E        L-13996-61E        L-14066-61E       RL-10249-61E
L-13915-61E        L-13997-61E        L-14067-61E       RL-10615-61E
L-13930-61E        L-13998-61E        L-14069-61E       RL-11011-61E
L-13931-61E        L-13999-61E        L-14071-61E       RL-12121-61E
L-13934-61E        L-14000-61E        L-14076-61E       RL-12163-61E
L-13936-61E        L-14001-61E        L-14077-61E       RL-12343-61E
L-13938-61E        L-14003-61E        RL-1726-61E       RL-13352-61E
L-13939-61E        L-14004-61E        RL-1810-61E       RL-13601-61E
L-13946-61E        L-14005-61E        RL-1862-61E       ................
------------------------------------------------------------------------

(d) Unsafe Condition

    This AD was prompted by several reports of cracked engine 
exhaust pipes. We are issuing this AD to prevent failure of the 
exhaust system due to cracking, which could lead to uncontrolled 
engine fire, harmful exhaust gases entering the cabin resulting in 
crew incapacitation, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) For affected engines with an S/N listed in Figure 1 to 
paragraph (c) of this AD with 400 hours or less time since new (TSN) 
or time since last overhaul (TSLO), and for any TIO-540-AJ1A 
reciprocating engine with a replacement turbocharger mounting 
bracket installed that was purchased between April 5, 2012 and May 
29, 2014, that has accumulated 400 hours or less time-in-service 
(TIS), within 25 hours after the effective date of this AD, replace 
the turbocharger mounting bracket with a part eligible for 
installation, and inspect the exhaust pipes for cracks. Use Lycoming 
Engines Mandatory Service Bulletin (MSB) No. 614A, dated October 10, 
2014, Exhaust System Disassembly and Removal, paragraphs 1 through 
22 to replace the bracket, and Exhaust System Inspection, paragraphs 
1 through 5 to do the inspection.
    (2) For affected engines with an S/N listed in Figure 1 to 
paragraph (c) of this AD with more than 400 hours TSN or TSLO, and 
for any TIO-540-AJ1A reciprocating engine with a replacement 
turbocharger mounting bracket installed that was purchased between 
April 5, 2012 and May 29, 2014, that has accumulated more than 400 
hours TIS, replace the turbocharger mounting bracket with a part 
eligible for installation, and inspect the exhaust pipes for cracks 
at the next engine overhaul, separation of the crankcase halves, or 
twelve years from the effective date of this AD, whichever comes 
first. Use Lycoming Engines MSB No. 614A, dated October 10, 2014, 
Exhaust System Disassembly and Removal, paragraphs 1 through 22 to 
replace the bracket, and Exhaust System Inspection, paragraphs 1 
through 5 to do the inspection.

(f) Installation Prohibition

    After the effective date of this AD, do not return to service 
any engine with a TIO-540-AJ1A turbocharger mounting bracket that 
was removed from an engine identified in Figure 1 to paragraph (c) 
of this AD or that was purchased between April 5, 2012 and May 29, 
2014.

(g) Credit for Previous Action

    (1) If, before the effective date of this AD, you replaced the 
turbocharger mounting bracket with one eligible for installation you 
may take credit for your prior corrective action. No further 
turbocharger mounting bracket replacement is required.
    (2) If, before the effective date of this AD, you performed the 
crack inspection using either of the following:
    (i) Lycoming Engines MSB No. 614A, dated October 10, 2014, 
Exhaust System Inspection, paragraphs 1 through 5, or
    (ii) Cessna Service Letter No. SEL-78-01, dated May 30, 2014, 
you may take credit for your prior corrective action. No further 
inspection is required. However, you must still replace the 
turbocharger mounting bracket.

(h) Alternative Methods of Compliance (AMOCs)

    The Manager, New York Aircraft Certification Office, FAA, may 
approve AMOCs to this AD. Use the procedures found in 14 CFR 39.19 
to make your request.

(i) Related Information

    (1) For more information about this AD, contact Norm Perenson, 
Aerospace Engineer, New York Aircraft Certification Office, FAA, 
Engine & Propeller Directorate, 1600 Stewart Avenue, Suite 410, 
Westbury, NY 11590; phone: 516-228-7337; fax: 516-794-5531; email: 
norman.perenson@faa.gov.
    (2) Lycoming Engines MSB No. 614A, dated October 10, 2014, which 
is not incorporated by reference, can be obtained from Lycoming 
Engines using the contact information in paragraph (i)(3) of this 
AD.
    (3) For service information identified in this AD, contact 
Lycoming Engines, 652 Oliver Street, Williamsport, PA 17701; phone: 
800-258-3279; fax: 570-327-7101; Internet: www.lycoming.com/Lycoming/SUPPORT/TechnicalPublications/ServiceBulletins.aspx.
    (4) You may view this service information at the FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, 
MA. For information on the availability of this material at the FAA, 
call 781-238-7125.

    Issued in Burlington, Massachusetts, on January 21, 2015.
Colleen M. D'Alessandro,
Assistant Directorate Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2015-01835 Filed 1-30-15; 8:45 am]
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