AD/LYC/116 ECi Connecting Rods (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/116 ECi Connecting Rods 7/2006 TX

Applicability:

Lycoming Engines (formerly Textron Lycoming) 360 and 540 series reciprocating engines specified in Table 1 of this AD with Engine Components Incorporated (ECi) connecting rods, part number (P/N) AEL11750 installed, limited to Serial Numbers 54/6 and below and produced between January 2002 and January 2004.  They are also identified with forging P/N AEL11488 in raised letters on the web of the beam between the big and small ends of the connecting rod.

If your engine has not been overhauled or had any repair since new, no further action is required by this AD.

Table 1.

Engine models

O-360-A1A, A1AD, A1C, A1D, A1F, A1F6, A1F6D, A1G, A1G6, A1G6D, A1H, A1H6, A1LD, A1P, A2A, A2D, A2E, A2F, A2G, A2H, A3A, A3AD, A3D, A4A, A4AD, A4D, A4G, A4J, A4K, A4M, A4N, A4P, A5AD, B1A, B1B, B2A, B2B, C1A, C1C, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, C4F, C4P, D1A, D2A, D2B, F1A6, G1A6, J2A;

HO-360-A1A, B1A, B1B, C1A;

IO-360-B1A, B1B, B1C, B1D, B1E, B1F, B1F6, B1G6, B2E, B2F, B2F6, B4A, E1A, F1A, L2A;

LO-360-A1G6D, A1H6;

HIO-360-A1A, A1B, B1A, B1B;

AEIO-360-B1B, B1D, B1F, B1F6, B1G6, B2F, B2F6, B4A, H1A, H1B;

O-540-A1A, A1A5, A1B5, A1C5, A1D, A1D5, A2B, A3D5, A4A5, A4B5, A4C5, A4D5, B1A5, B1B5, B1D5, B2A5, B2B5, B2C5, B4A5, B4B5, D1A5, E4A5, E4B5, E4C5, F1A5, F1B5, G1A5, G2A5, H1A5, H1A5D, H1B5D, H2A5, H2A5D, H2B5D;

AEIO-540-D4A5, D4B5, D4C5, D4D5;

IO-540-A1A5, B1A5, B1B5, B1C5, C1B5, C1C5, C2C, C4B5, C4C5, C4D5, C4D5D, D4A5, D4B5, D4C5, E1A5, E1B5, E1C5, G1A5, G1B5, G1C5, G1D5, G1E5, G1F5, J4A5, N1A5, P1A5, R1A5, T4A5D, T4B5, T4B5D, T4C5D, V4A5, V4A5D;

LTIO-540-K1AD;

TIO-540-C1A, E1A, G1A, H1A, K1AD, AA1AD, AB1AD, AB1BD, AF1A, AF1B, AG1A.

Requirement:

1.    If the engine was overhauled or repaired since new, inspect the maintenance records and engine logbook to determine if the overhaul or repair facility used ECi connecting rods, P/N AEL11750.

If the connecting rods are not ECi, P/N AEL11750, no further action is required.

If the connecting rods are ECi, P/N AEL11750, and if the serial number is 54/7 or higher, no further action is required.

Note 1:  54 is the lot number and 7 is the serial number of the ECi connecting rod.

2.    If the connecting rods are ECi, P/N AEL11750, having forging P/N AEL11488 in raised letters on the web of the beam, and if the serial number is 54/6 or lower, do the following:

(a)   If the connecting rod has 2,000 or more hours time-in- service (TIS), replace the connecting rod with a connecting rod that has a lot number 55 or higher, or that has a P/N not specified in this AD.

(b)   If the connecting rod has fewer than 2,000 hours TIS, replace the connecting rod with a connecting rod that has a lot number 55 or higher, or that has a P/N not specified in this AD.

3.    Do not install any ECi connecting rod, P/N AEL11750, that has SN 54/6 or lower into any engine.

Note 2:  FAA AD 2006-10-21 Amdt 39-14604 dated 12 May 2006 refers.

Compliance:

1.    Before further flight, after the effective date of this AD.

2.    (a)   Within 50 hours TIS after the effective date of this AD.

2.    (b)   At the next engine overhaul, or next accessibility of the connecting rod, but no later than 2,000 hours TIS on the connecting rod.

For the purpose of this AD, connecting rod accessibility is defined as any maintenance action in which a cylinder assembly is removed for maintenance.

3.    After the effective date of this AD.

This Airworthiness Directive becomes effective on 31 May 2006.

Background: The Airmotive Engineering Corp, Division of Engine Components Incorporated (ECi), holds the Parts Manufacturer Approval (PMA) for the affected parts, and markets the parts as ECi parts.  This AD requires replacing certain lot and serial numbered connecting rods, P/N AEL11750, having forging part number AEL11488.  This AD would also prohibit installing certain ECi connecting rods, P/N AEL11750, into any Lycoming 360 or 540 series reciprocating engines.  This AD results from reports of connecting rods with excessive variation in circularity of the journal bores.  The intent of this AD is to prevent fatigue failure of the connecting rod and a possible uncommanded shutdown of the engine.

James Coyne
Delegate of the Civil Aviation Safety Authority

24 May 2006