AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive (AD) AD/ENG/4 Amdt 8 and issues the following AD under subregulation 39.1 (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.

Engines - General

AD/ENG/4

Amdt 9

Piston Engine Continuing Airworthiness Requirements

1/2004

Applicability: Piston engines and those components necessary for the operation of the engine, installed in aircraft maintained in accordance with Civil Aviation Regulation CAR 42B CASA Maintenance Schedule.

Requirement: Requirement 1. In-service maintenance.

1.1.       Private operations - as detailed in Civil Aviation Regulation (CAR) 2 (7) (d) and 2 (7A).

To ensure the continuing airworthiness of the engine, and those components necessary for the operation of the engine, in addition to the requirements of Schedule 5 of the Civil Aviation Regulations; carry out the maintenance actions detailed in Appendix A of this Directive.

1.2.       Aerial work operations - as detailed in CAR 206 (1) (a).

To ensure the continuing airworthiness of the engine, and those components necessary for the operation of the engine, in addition to the requirements of Schedule 5 of the Civil Aviation Regulation; carry out the maintenance actions detailed in Appendix A of this Directive.

1.3.       Charter operations - as detailed in CAR 206 (1) (b).

To ensure the continuing airworthiness of the engine, and those components necessary for the operation of the engine, in addition to the requirements of Schedule 5 of the Civil Aviation Regulations:

1. Carry out the maintenance actions detailed in Appendix A of this Directive; and

b.         Overhaul the engine at intervals in accordance with the engine manufacturer’s published overhaul periods; and

c.         Overhaul or replace those components necessary for the operation of the engine at intervals not to exceed:

1. As listed in the aircraft manufacturer’s maintenance schedule; or

ii.        The engine manufacturer’s published time in service between overhaul period; or

iii.      The component manufacturer’s published overhaul or replacement period.

Whichever is the greater.

Note 1: For the purpose of this Directive, airworthy is defined as when an aircraft, including its component parts, meets its type design or properly altered condition (eg; the engine incorporates an STC or a CAR 35 approved modification), and it is in a condition for safe operation.

Requirement 2. Overhaul standard.

2.1.       Overhaul procedures

When carrying out an overhaul of a piston engines or a component necessary for the operation of the engine, the overhaul shall be carried out by an organisation approved for the purpose and in accordance with:

1. The engine and component manufacturer's published overhaul procedures; or

b.         Procedures approved by CASA; or

c.         Procedures approved by a regulatory authority of a CASA recognised foreign country. CASR 21.012 lists CASA recognised foreign counties.

2.2.       Bulk strip procedures

A bulk strip of an engine shall be carried out by an organisation approved for the purpose and in accordance with approved maintenance data.

Note 2: For the purpose of this Directive, a bulk strip is defined as the partial disassembly of the engine for the purpose of inspection or repair, the extent of which requires the separation of the crankcase parting flange or removal of the crankshaft.

Compliance: Requirement 1: Effective 22 January 2004; as detailed in Appendix A of this directive.

Requirement 2: Effective 22 January 2004.

This Amendment becomes effective on 22 January 2004.

Background: This Directive mandates the requirement that all piston engines must be maintained in a manner that will monitor the airworthiness of the engine. Piston engines in aircraft maintained to the aircraft manufacturers schedule or an approved system of maintenance satisfy that requirement.

This amendment details piston engine in service maintenance requirements, overhaul and bulk strip procedures for engines installed in aircraft maintained to the CASA maintenance schedule, Schedule 5 of the Civil Aviation Regulations (1988).

Amendment 8 of this Airworthiness Directive became effective on 26 December 2001.

Amendment 7 excluded aircraft administered by sports aviation bodies, warbirds and experimental aircraft from the requirements of this directive.

Amendment 7 introduced on-condition engine maintenance requirements for private and aerial work operations.

Amendment 6 of this Directive was rescinded prior to the effective date.

The original issue of this Airworthiness Directive superseded Air Navigation Order 108.5.2.1.

Jim Coyne

Delegate of the Civil Aviation Safety Authority 5 December 2003

The above AD is notified in the Commonwealth of Australia Gazette on 24 December 2003.

AD/ENG/4 Amdt 9 Appendix A

1: INTRODUCTION

Piston Engine Condition Check AL 1/2004

To ensure any engine in service is fit to fly, the condition of the engine must be assessed at specified intervals and the results of that assessment recorded in appropriate documentation. The monitoring of piston engine condition is based primarily on assessing the following parameters.

1. Engine performance; in particular

b.        Oil pressure at idle; and

c.         Oil consumption; and

d.        Cylinder leak rates; and

e.         Inspecting the engine oil filter and oil screen for metal contamination.

2.        ENGINE PERFORMANCE

At each aircraft periodic inspection, carry out a static engine run to determine the engine performance is in accordance with approved maintenance data. Engine and aircraft details and parameters achieved during the engine run are to be recorded and certified on CASA Piston Engine Condition Report Form 728.

Note: Where possible, maximum RPM is to be attained with the aircraft stationary. However, where the aircraft manufacturer details in approved maintenance data that maximum RPM can only be achieved during take-off or climb, or the aircraft type does not permit maximum RPM to be safely obtained whilst the aircraft is stationary, an entry on the aircraft maintenance release by the pilot in command of the maximum RPM during the last flight prior to the periodic engine inspection is acceptable data.

Engine run parameters to be recorded include:

1. Take-off power. Take-off power shall be:

1. For a fixed pitch propeller aircraft - static RPM.

ii.         For a constant speed propeller, normally aspirated engine aircraft, take-off power shall be maximum RPM at a manifold pressure within 2" of static manifold pressure.

iii.       For a turbocharged/supercharged engine aircraft, take-off power shall be maximum RPM at the manifold pressure detailed in the aircraft flight manual.

b.            With the engine at operating temperature:

1. Oil pressure at idle and at take-off power.

ii.        Oil temperature at idle and at take-off power.

iii.      Cylinder head or exhaust gas temperature at take-off power.

iv.       Fuel pressure/flow at take-off power.

v.         Ambient temperature and location altitude.

3.        CYLINDER LEAK RATES

At intervals not to exceed 110 hours time in service, carry out a cylinder leak check in accordance with:

1. The procedure published by the engine manufacturer; or

b.         In the absence of a current engine manufacturer cylinder leak check procedure; carry out a cylinder leak check in accordance with the procedure detailed in Airworthiness Advisory Circular 6-32 Amdt.1.

The results of each cylinder leak check shall be recorded in the engine logbook.

4.        ENGINE OIL and ENGINE OIL FILTER REPLACEMENT

4.1    Oil change:

The engine oil and engine oil filter shall be replaced at intervals as published by the engine manufacturer with a planning tolerance of plus or minus 10%. Engine oil and the engine oil filter replacement in the period between the aircraft periodic inspections may be carried out by a pilot, other than a student pilot. CAR 42ZC (4) and Schedule 8 refer.

4.2    Engine oil filter, oil pressure screen and suction screen inspection

All engine oil and engine oil filter replacements, including those carried out in the period between the aircraft periodic inspections, unless carried out by a pilot, shall include inspecting the engine oil pressure filter, oil pressure screen and, if applicable, the oil suction screen, for evidence of metallic particles, shavings or flakes.

4.3    Engine oil uplifts

All oil uplifts shall be recorded. Oil uplift records shall be made available at the time of each aircraft periodic inspection.

5.  CERTIFICATION

At each aircraft periodic inspection, the aircraft and engine details, engine performance parameters, cylinder leak rates, oil filter inspection results shall be certified by an appropriate person on CASA Piston Engine Condition Report Form 728. The certified form shall be retained as an aircraft record.