AD/LYC/114 Improper Maintenance (Cth)

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

Lycoming Piston Engines

AD/LYC/114 Improper Maintenance 3/2006

Applicability:

All Textron Lycoming reciprocating engines that have been overhauled, repaired or disassembled between 1 February 2002 and 18 July 2004, to the extent where the main crankcase halves have been split, by B.C. Aero Engines Ltd., an approved maintenance organization (AMO) 84-02, of 5-9566 Hurricane Road, Sidney, British Columbia, Canada.

Requirement:

1.    Engine Log Book Review

Review the Technical Records including the engine logbook to determine if the engine had been inspected, repaired or disassembled to the extent the crankcase halves were split, or if the engine had been overhauled by B.C. Aero Engines Ltd.  Between 1 February 2002 and 18 July 2004.

If no engine inspection, repair or disassembly to the extent the crankcase halves were split, or no engine overhaul work was performed by B.C. Aero Engines Ltd., no further action is required by this directive.

2.    For Single Engine-Powered Aircraft:

Inspect the affected engine for evidence of non-conformity, including the excessive use of crankcase split-line sealant to that recommended by the applicable overhaul manual, crankcase split-line fretting, excessive split-line oil leaks, loss of crankcase through-bolt torque and unapproved repairs.  If necessary, restore the engine’s conformity.

3.    For Twin Engine-Powered Aircraft:

Inspect the affected engine for evidence of non-conformity, including excessive use of crankcase split-line sealant to that recommended by the applicable overhaul manual, crankcase split-line fretting, excessive split-line oil leaks, loss of crankcase through-bolt torque and unapproved repairs.  If necessary, restore the engine’s conformity.

No further action is required by this directive after the affected engine complies with the requirements of either requirement 2 or 3 of this directive.

Note:  Transport Canada AD CF-2005-40 refers.

Compliance:

1.    Engine Log Book Review

Within 30 days after the effective date of this directive.

2.    For Single Engine-Powered Aircraft:

For engines which exhibited in-service difficulties (such as oil leaks or oil filter contamination) prior to the effective date of this directive, within five (5) hours time in service or 30 days after the effective date of this directive, whichever occurs first.

For all other engines, within the next 50 hours time in service, or 6 months after the effective date of this directive, whichever occurs first.

3.    For Twin Engine-Powered Aircraft:

For engines which exhibited in-service difficulties (such as oil leaks or oil filter contamination) prior to the effective date of this directive, within ten (10) hours time in service or 60 days after the effective date of this directive, whichever occurs first.

For all other engines, within the next 100 hours time in service, or 12 months after the effective date of this directive, whichever occurs first.

This Airworthiness Directive becomes effective on 16 March 2006.

Background:

Transport Canada has received several reports of disassembly of engines (to correct in-service defects) that were overhauled or repaired by B.C. Aero Engines Ltd.  With numerous non-conformities on the engines.  Further investigation carried out by Transport Canada has determined certain Textron Lycoming reciprocating engines that have been overhauled, repaired or disassembled by B.C. Aero Engines Ltd. are not in conformance with the manufacturer’s overhaul data and have serious quality issues that may result in an unsafe situation.  Transport Canada cancelled B.C. Aero Engines’ AMO (84-02) on 18 July 2004.

The above situation, if not corrected, may result in an in-flight engine failure.

James Coyne
Delegate of the Civil Aviation Safety Authority

1 February 2006