Document ID: FAA-2012-0002-0027
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Continental Motors, Inc. Reciprocating Engines
Posted Date: 2013-08-12T04:00Z

[Federal Register Volume 78, Number 155 (Monday, August 12, 2013)]
[Proposed Rules]
[Pages 48828-48832]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2013-19414]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2012-0002; Directorate Identifier 2011-NE-42-AD]
RIN 2120-AA64

Airworthiness Directives; Continental Motors, Inc. Reciprocating 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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[[Page 48829]]

SUMMARY: We propose to adopt a new airworthiness directive (AD) for 
certain Airmotive Engineering Corp. replacement parts manufacturer 
approval (PMA) cylinder assemblies marketed by Engine Components 
International Division (ECi), used on the Continental Motors, Inc. 
(CMI) models 520 and 550 reciprocating engines, and all other engine 
models approved for the use of CMI models 520 and 550 cylinder 
assemblies such as the CMI model 470 when modified by supplemental type 
certificate (STC). This proposed AD was prompted by failure reports of 
multiple cylinder head-to-barrel separations and cracked and leaking 
aluminum cylinder heads. This proposed AD would require initial and 
repetitive inspections, replacement of cracked cylinders, and 
replacement of cylinder assemblies at reduced times-in-service. This 
proposed AD would also prohibit the installation of affected cylinder 
assemblies into any engine. We are proposing this AD to prevent 
cylinder head cracks, engine failure, and loss of the airplane.

DATES: We must receive comments on this proposed AD by October 11, 
2013.

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 certain service information identified in this proposed AD, 
contact Continental Motors, Inc., PO Box 90, Mobile, AL 36601; phone: 
251-438-3411, Internet: http://tcmlink.com/servicebulletins.cfm. For 
certain other service information identified in this proposed AD, 
contact Engine Components International Division, 9503 Middlex Drive, 
San Antonio, TX 78217; phone 210-820-8101; Internet: http//
www.eci.aero/pages/tech_svcpubs.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; 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: Jurgen E. Priester, Aerospace 
Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 
2601 Meacham Blvd., Fort Worth, TX 76137; phone: 817-222-5159; fax: 
817-222-5785; email: jurgen.e.priester@faa.gov.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2012-0002; 
Directorate Identifier 2011-NE-42-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD 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 substantive verbal contact we 
receive about this proposed AD.

Discussion

    We received multiple failure reports of Airmotive Engineering Corp. 
PMA cylinder assemblies, part number (P/N) AEC631397, ECi Class 71 and 
Class 76, installed on certain CMI models IO-520, TSIO-520, IO-550, and 
IOF-550 reciprocating engines and other engines approved for the use of 
CMI models 520 and 550 cylinder assemblies such as the CMI model 470 
when modified by STC. ECi part numbering includes four Classes of P/N 
AEC631397 cylinder assemblies based upon their intended use. Only 
Classes 71 and 76 are affected; Classes 68 and 70 are not affected. The 
Class number appears in the ECi P/N cylinder marking immediately 
following AEC631397. These markings are found on the bottom flange of 
the cylinder. We identified two independent failure modes resulting in 
the cylinder head separations; however, the exact root cause of each 
failure mode could not be definitively identified. One failure mode is 
cracking that initiates in the internal dome radius of the cylinder 
head and the second is cracking at the cylinder head-to-barrel threads. 
The affected cylinder assemblies are separated into two manufacturing 
groups that would require the actions in this proposed AD. Those two 
groups are defined by serial number (S/N) ranges. One group consists of 
cylinder assemblies with S/N 1 through S/N 33696. The second group 
consists of cylinder assemblies with S/N 33697 through S/N 61176. The 
unsafe condition, if not corrected, could result in cylinder head 
cracks, engine failure, and loss of the airplane.
    Airmotive Engineering Corp. held a meeting, which we attended, on 
December 11, 2012, to discuss certain active PMA projects. Also on 
their agenda was a briefing to us on their meeting with the National 
Transportation Safety Board (NTSB) regarding the subject of this 
proposed AD. Although that briefing was not intentioned by us, because 
it occurred, we are placing a summary and a copy of what they provided 
for our consideration, into the AD docket for public review.
    Airmotive Engineering Corp. held another meeting, with us and the 
NTSB in attendance, on February 14, 2013. The purpose of the meeting 
was to further discuss the causes of their cylinder failures and what 
they have done to address these failures. We are placing all of the 
information from this meeting in the AD docket for public review.
    Knowing the likely impact that compliance with the AD will have 
upon the owners and operators, a detailed review was performed to 
consider all aspects of the information provided by Airmotive 
Engineering Corp. After considering all factors, which included, for 
example, the efforts of two Chief Scientific and Technical Advisors, 
data from the FAA/Airmotive Engineering Corp. meetings, and the 
application of the FAA Policy Statement on Risk Assessment 08/07/13for 
Reciprocating Engine Airworthiness Directives (PS-ANE100-1999-00006), 
we concluded that proceeding with this proposed AD to correct the 
unsafe condition was appropriate.

Relevant Service Information

    We reviewed Continental Motors, Inc. Service Bulletin (SB) No. 
SB96-12, dated September 10, 1996. Part 1 Section C of the SB describes 
procedures for leak checking cylinder assemblies. We also reviewed ECi 
Service Instruction No. 99-8-1,

[[Page 48830]]

Revision 9, dated February 23, 2009, Sections 4.3, 4.4, 6.1, and 6.2, 
which provide information on cylinder identification and part 
numbering.

FAA's Determination

    We are proposing this AD 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 proposed AD divides ECi cylinder assemblies, P/N AEC631397, 
Class 71 and Class 76, into two groups; Group A cylinder assemblies and 
Group B cylinder assemblies. Group A cylinder assemblies are those 
cylinder assemblies with S/N 1 through S/N 33696. Group B cylinder 
assemblies are those cylinder assemblies with S/N 33697 through S/N 
61176. This proposed AD would require removing Group A cylinder 
assemblies from service within 25 operating hours if, on the effective 
date of the AD, the cylinder operating hours are fewer than 500 hours, 
or more than 1,000 hours. This proposed AD would also require removing 
Group B cylinder assemblies from service within 25 operating hours if, 
on the effective date of the AD, the cylinder operating hours are 1,000 
or more.
    This proposed AD would also require repetitive visual inspections, 
compression tests, and leak checks for cracks, for Group A cylinder 
assemblies with between 500 and 1,000 operating hours, and for Group B 
cylinder assemblies with fewer than 1,000 operating hours, until they 
are removed from service.
    Finally, this proposed AD would also prohibit installing affected 
ECi cylinder assemblies onto any engine and would require reporting to 
the FAA all removed cylinder assemblies.

Costs of Compliance

    We estimate that this proposed AD would affect about 6,000 
Continental Motors, Inc. models IO-520, TSIO-520, IO-550, and IOF-550 
reciprocating engines and all other engine models approved for the use 
of CMI models 520 and 550 cylinder assemblies (such as the CMI model 
470 when modified by STC), installed on airplanes of U.S. registry. We 
also estimate that each affected ECi cylinder will be inspected on 
average four times in the first year. We also estimate that about six 
hours per engine would be required to perform the visual inspection, 
compression test, and leak check. The average labor rate is $85 per 
hour. Finally, we estimate that about 18 hours would be required to 
replace all six cylinder assemblies during scheduled overhaul 
maintenance, and that a replacement cylinder assembly would cost about 
$1,700. Based on these figures, we estimate the total cost of this 
proposed AD to U.S. operators to change all ECi cylinders to be 
$82,620,000. 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):

Continental Motors, Inc. (formerly Teledyne Continental Motors, 
Inc., formerly Continental): Docket No. FAA-2012-0002; Directorate 
Identifier 2011-NE-42-AD.

(a) Comments Due Date

    We must receive comments by October 11, 2013.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to the following Continental Motors, Inc. (CMI) 
models 520 and 550 reciprocating engines, and all other engine 
models approved for the use of CMI models 520 and 550 cylinder 
assemblies such as the CMI model 470 when modified by supplemental 
type certificate (STC), with Airmotive Engineering Corp. replacement 
parts manufacturer approval (PMA) cylinder assemblies, marketed by 
Engine Components International Division (hereinafter referred to as 
ECi), part number (P/N) AEC631397, with ECi Class 71 or Class 76, 
serial number (S/N) 1 through S/N 33696, or S/N 33697 through S/N 
61176, installed on, but not limited to:
    (1) IO-520-A, -B, -BA, -BB, -C, -CB, -D, -E, -F, -J, -K, -L, -M, 
-MB, -N, -NB, and LIO-520-P.
    (2) TSIO-520-A, -AE, -AF, -B, -BB, -BE, -C, -CE, -D, -DB, -E, -
EB, -G, -H, -J, -JB, -K, -KB, -L, -LB, -M, -N, -NB, -P, -R, -T, -U, 
-UB, -VB, -WB, and LTSIO-520-AE.
    (3) IO-550-A, -B, -C, -D, -E, -F, and -L.
    (4) IOF-550-B, -C, -D, -E, -F, and -L.
    (5) Other engines using CMI models 520 and 550 cylinder 
assemblies, such as the CMI model 470 when modified by STC.

(d) Unsafe Condition

    This AD was prompted by reports of multiple cylinder head-to-
barrel separations and cracked and leaking aluminum cylinder heads. 
We are issuing this AD to prevent cylinder head cracks, engine 
failure, and loss of the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) Review the engine maintenance records to determine if any 
affected cylinders were

[[Page 48831]]

installed at the time of engine overhaul or during any other 
maintenance event, or were installed when the engine was modified 
and are currently installed.
    (2) If you do not have any of the affected ECi cylinders 
installed on your engine, no further action is required.

(f) Cylinder Identification and Serial Number Location

    (1) Check the cylinder assembly P/N and Class number. The ECi 
cylinder assembly, P/N AEC631397, Class 71 or Class 76, is stamped 
on the bottom flange of the cylinder barrel. Guidance on the P/N and 
Class number description and location can be found in ECi Service 
Instruction No. 99-8-1, Revision 9, dated February 23, 2009.
    (2) For ECi cylinder assemblies, P/N AEC631397, manufactured 
through 2008, find the cylinder assembly S/N stamped on the intake 
port boss two inches down from the top edge of the head.
    (3) For ECi cylinder assemblies, P/N AEC631397, manufactured on 
or after January 1, 2009, find the cylinder assembly S/N stamped 
just below the top edge of the head on the exhaust port side.
    (4) If you cannot see the cylinder assembly P/N when the 
cylinder assembly is installed on the engine, an alternative method 
of identification may be used as follows:
    (i) Remove the cylinder rocker box cover.
    (ii) Find the letters ECi, cast into the cylinder head between 
the valve stems.
    (iii) Check the cylinder head casting P/N. Affected cylinder 
assemblies have the cylinder head casting P/N, AEC65385, cast into 
the cylinder head between the valve stems.
    (iv) Find the cylinder assembly S/N as specified in paragraph 
(f)(2) or (f)(3) of this AD as applicable.

(g) Removal From Service

    (1) For those Group A cylinder assemblies, P/N AEC631397, ECi 
Class 71 or 76, S/N 1 through S/N 33696, with fewer than 500 
operating hours time-in-service (TIS) or with more than 1,000 
operating hours TIS on the effective date of this AD, remove the 
cylinder assemblies from service within the next 25 operating hours 
TIS.
    (2) For those Group B cylinder assemblies, P/N AEC631397, ECi 
Class 71 or 76, S/N 33697 through S/N 61176, with more than 1,000 
operating hours TIS on the effective date of this AD, remove the 
cylinder assemblies from service within the next 25 operating hours 
TIS.

(h) Inspection of Group A Cylinder Assemblies With Between 500 and 
1,000 Operating Hours TIS and Group B Cylinder Assemblies With Fewer 
Than 1,000 Operating Hours TIS

    (1) Within the next 10 operating hours TIS after the effective 
date of this AD, visually inspect, compression test, and leak check 
the Group A cylinder assemblies with between 500 and 1,000 operating 
hours TIS, and Group B cylinder assemblies with fewer than 1,000 
operating hours TIS. Use paragraphs (h)(2) through (h)(5) of this AD 
to do the inspection, test, and leak check.
    (2) Visually inspect the exterior of each cylinder head and 
barrel interface around the perimeter of the cylinder as follows:
    (i) Before any engine cleaning, with good lighting, look for 
signs of white or black combustion products between cooling fins, 
especially on the exhaust valve side of the cylinder assembly.
    (ii) Remove the cylinder from service if you find any indication 
of a crack or black combustion products on the side of a cylinder.
    (iii) The presence of oil or a normal dirty appearance may not 
indicate a head crack.
    (3) Perform a standard differential compression test to the 
cylinder assembly. If the cylinder assembly has a pressure reading 
of less than 55/80 pounds per square inch gauge pressure, on the 
differential pressure test gauges, remove the cylinder assembly from 
service.
    (4) Use Part 1 Section C ``Leak Check'' of Teledyne Continental 
Motors Service Bulletin (SB) No. SB96-12, dated September 10, 1996, 
to perform the leak checks required by this AD.
    (5) Remove from service any cylinder assembly found cracked and/
or leaking.
    (6) Repeat paragraphs (h)(2) though (h)(5) of this AD within 
every 50 operating hours TIS since last inspection. Remove from 
service any cylinder assembly before accumulating 1,000 operating 
hours TIS.

(i) Installation Prohibitions

    After the effective date of this AD:
    (1) Do not repair, or reinstall onto any engine, any cylinder 
assembly removed per this AD.
    (2) Do not install any ECi cylinder assemblies, P/N AEC631397, 
ECi Class 71 or 76, with the S/Ns listed in paragraph (c) of this 
AD, onto any engine.
    (3) Do not install any engine having one or more ECi cylinder 
assemblies, P/N AEC631397, ECi Class 71 or 76, with the S/Ns listed 
in paragraph (c) of this AD, into any aircraft.
    (4) Do not return to service any aircraft that has an engine 
with an ECi cylinder assembly subject to this AD, if the cylinder 
assembly has 1,000 or more operating hours TIS.

(j) Alternative Methods of Compliance (AMOCs)

    The Manager, Special Certification Office, may approve AMOCs for 
this AD. Use the procedures found in 14 CFR 39.19 to make your 
request.

(k) Reporting Requirements

    Report to the FAA all cylinder assemblies that you removed per 
this AD. Send your report to the Special Certification Office, FAA, 
Rotorcraft Directorate, Attn: Jurgen E. Priester, Aerospace 
Engineer, 2601 Meacham Blvd., Fort Worth, TX 76137; phone: 817-222-
5159; fax: 817-222-5785; email: 9-ASW-190-COS@faa.gov. Include the 
following information:
    (1) Aircraft model.
    (2) Continental Motors, Inc. engine model number.
    (3) ECi cylinder assembly S/N.
    (4) Cylinder assembly total operating hours.
    (5) Installation date of ECi cylinder assembly.
    (6) Airplane utilization average per year (flight hours per 
year).
    (7) Number of flight hours since last mandatory inspection 
required by this AD.
    (8) Reason for cylinder removal, i.e., leaking head with cracks 
or other indications found, failed compression test, valves or rings 
leaking, or a head separation.
    (9) How the defect was found, i.e., visual inspection, leak 
check, compression test, etc.
    (10) Source of leak(s).
    (11) Location of crack(s). Locate by counting the number of 
cooling fins up from the head/barrel interface.
    (12) Length of crack(s).
    (13) Location of separation. Locate by counting the number of 
cooling fins up from the head/barrel interface.
    (14) Your contact information (optional).

(l) Paperwork Reduction Act Burden Statement

    A federal agency may not conduct or sponsor, and a person is not 
required to respond to, nor shall a person be subject to a penalty 
for failure to comply with a collection of information subject to 
the requirements of the Paperwork Reduction Act unless that 
collection of information displays a current valid OMB Control 
Number. The OMB Control Number for this information collection is 
2120-0056. Public reporting for this collection of information is 
estimated to be approximately 5 minutes per response, including the 
time for reviewing instructions, completing and reviewing the 
collection of information. All responses to this collection of 
information are mandatory. Comments concerning the accuracy of this 
burden and suggestions for reducing the burden should be directed to 
the FAA at: 800 Independence Ave. SW., Washington, DC 20591, Attn: 
Information Collection Clearance Officer, AES-200.

(m) Related Information

    (1) For more information about this AD, contact Jurgen E. 
Priester, Aerospace Engineer, Special Certification Office, FAA, 
Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; 
phone: 817-222-5159; fax: 817-222-5785; email: 
jurgen.e.priester@faa.gov.
    (2) For ECi Service Instruction No. 99-8-1, Revision 9, dated 
February 23, 2009, which is not incorporated by reference in this 
AD, contact Engine Components International Division, 9503 Middlex 
Drive, San Antonio, TX 78217; phone 210-820-8101; Internet: http//
www.eci.aero/pages/tech_svcpubs.aspx.
    (3) For other service information referenced in this AD, contact 
Continental Motors, Inc., PO Box 90, Mobile, AL 36601; phone: 251-
438-3411, Internet: http://tcmlink.com/servicebulletins.cfm.
    (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.

[[Page 48832]]

    Issued in Burlington, Massachusetts, on August 5, 2013.
Colleen M. D'Alessandro,
Assistant Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2013-19414 Filed 8-9-13; 8:45 am]
BILLING CODE 4910-13-P