Document ID: chunk:federal_register_of_legislation:F2009L03981:body:0:p2
Version: federal_register_of_legislation:F2009L03981
Segment Type: other
Provision Reference: 
Character Range: 2600–5580

cylinder for cracks using Step 2, paragraph B, of MSB09-1B.
                3. For EQ3 cylinders with fewer than 400 hours total time of operation on the effective date of this Directive, perform an initial visual inspection of the cylinder for cracks, using Step 2, paragraph B, of TCM MSB09-1B.
                4. Remove from service any cylinders that are found to be cracked during the Requirement 2 or 3 visual inspections.
                5. Remove from service all EQ3 cylinders.
                6. EQ3 cylinders may not be installed onto any engine and any EQ3 cylinder-equipped engine may not be installed onto any aircraft.
             Initial visual inspections accomplished before the effective date of this Directive per TCM MSB09-1A, dated 11 March 2009, comply with the initial inspection requirements specified in this Directive.
             Later revisions of the above MSB, approved by the United States Federal Aviation Administration (FAA) as an Alternate Method of Compliance (AMOC) to FAA AD 2009-19-07, are considered acceptable for compliance with the equivalent Requirements of this Directive.
             Note 2:  FAA AD 2009-19-07 Amdt 39-16023 refers.
Compliance:  For Requirement 1 - Remains unchanged as 'Within 20 flight hours after the effective date of the original issue of this Directive'.
             For Requirement 2 - Remains unchanged as 'Within 20 flight hours after the effective date of the original issue of this Directive and thereafter at intervals not to exceed 50 hours of operation'.
             For Requirement 3 - Before reaching 400 hours total time of operation and thereafter at intervals not to exceed 50 hours of operation.
             For Requirement 4 - Before further flight after the visual inspection.
             For Requirement 5 - Remains unchanged as 'Within 1,300 hours total time of operation after the effective date of the original issue of this Directive'.
             For Requirement 6 - As of the effective date of this Amendment.
             This Amendment becomes effective on 19 November 2009.

Background:  In February 2009, the FAA was made aware by TCM of reports of 35 EQ3 cylinders found with cracks during inspection.  Cracked cylinders occurred on engines with times ranging from about 430 to 1,300 hours of operation.  TCM investigated the cause and discovered that their EQ3 configuration cylinder head casting tool used in the cylinder manufacturing process created an area of reduced wall thickness.  This reduced wall thickness can result in a crack in the area between the upper spark plug bore and the fuel injector/primer nozzle bore during operation.  TCM shipped engines with EQ3 cylinders and shipped individual EQ3 cylinders from 1 November 2007, through 30 January 2009.  Also, TCM produced a group of about 300 EQ3 cylinders in August and September of 2006.
             This condition, if not corrected, could result in loss of engine power due to cracks in the cylinder