2008-08-14: Fuel injection servo plugs

2008-08-14 Precision Airmotive LLC: Amendment 39-15466. Docket No. FAA-2008-0420; Directorate Identifier 2008-NE-10-AD. Effective Date (a) This airworthiness directive (AD) becomes effective April 29, 2008, to all persons except those persons to whom it was made immediately effective by emergency AD 2008-06-51, issued March 12, 2008, which contained the requirements of this amendment. Affected ADs (b) This AD supersedes AD 2008-06-51. Applicability (c) This AD applies to the following reciprocating engines with an installed Precision Airmotive LLC, RSA-5 or RSA-10 series fuel injection servo, having a servo plug gasket, part number (P/N) 365533, installed under the fuel injection servo plug, P/N 383493: (1) Lycoming Engines IO, (L)IO, TIO, (L)TIO, AEIO, AIO, IGO, IVO, and HIO series reciprocating engines, regardless of displacement, either new, rebuilt, overhauled, or repaired since August 22, 2006, and/or with an affected fuel injection servo installed either new, rebuilt, overhauled, or repaired since August 22, 2006. (2) Teledyne Continental Motors TSIO-360-RB reciprocating engines, either new, rebuilt, overhauled, or repaired since August 22, 2006, and/or with an affected fuel injection servo installed either new, rebuilt, overhauled, or repaired since August 22, 2006. (3) Superior Air Parts, Inc. IO-360 series reciprocating engines, either new, rebuilt, overhauled, or repaired since August 22, 2006, and/or with an affected fuel injection servo installed either new, rebuilt, overhauled, or repaired since August 22, 2006. (4) This AD also applies to any other Precision Airmotive LLC fuel injection servos received since August 22, 2006, or any fuel injection servos that have had the fuel injection servo plug, P/N 383493, removed during maintenance since August 22, 2006. Unsafe Condition (d) This AD results from eighteen reports of fuel injection servo plugs, P/N 383493, that had loosened or completely backed out of the threaded plug hole on the regulator cover of the fuel injection servo. We are issuing this AD to prevent a lean running engine, which could result in a substantial loss of engine power and subsequent loss of control of the airplane. Compliance (e) You are responsible for having the actions required by this AD performed before further flight, unless the actions have already been done. The actions required by this AD must be done by an FAA- licensed mechanic. Initial Inspection (f) Inspect the fuel injection servo plug, P/N 383493, for looseness, by attempting to turn it by hand, while being careful not to damage the safety wire or seal. If the plug moves, it is loose. (g) If the plug is not loose, go to paragraph (i) of this AD. (h) If the plug is loose, do the following: (1) Carefully cut and remove the safety wire that spans between the servo plug and regulator cover only. (2) Remove the servo plug while ensuring that the gasket, P/N 365533, that is behind the plug, is not lost. The gasket may be slightly stuck to the regulator cover. (3) Examine the threads on the servo plug and regulator cover for damage. Threads should be smooth and consistent, with no burrs or chips. The servo plug outer diameter threads should also measure within 0.7419-0.7500-inch. (4) If the threads on either the servo plug or the regulator cover are damaged, or do not measure within the limits in paragraph (h)(3) of this AD, the servo is not eligible for any installation and must be replaced before further flight. (5) Inspect the gasket, P/N 365533, for tears and other damage. We are allowing the re-use of undamaged gaskets. Replace damaged gaskets with a new gasket, P/N 365533. (6) When reassembling, do not install any servo plug or regulator cover that is not eligible for installation. Install the gasket onto the servo plug and reassemble the servo plug to the regulator cover. (7) Torque the servo plug to a new, higher torque of 90-100 in- lbs, to help maintain the proper clamp-up force against the plug and cover. (8) Safety wire the servo plug with 0.025-inch diameter wire to the regulator cover. Information on properly safety wiring the plug can be found in Precision Airmotive LLC Mandatory Service Bulletin No. PRS-107, Revision 1, dated March 6, 2008. (9) Inspect all other safety wire on the servo. Replace any that are damaged. Repetitive Inspections (i) At every engine oil change or within every 50 hours of engine run time, whichever occurs first, repeat the inspection and remedial steps specified in paragraphs (f) through (h)(9) of this AD. Special Flight Permits Prohibited (j) Under 14 CFR part 39.23, we are prohibiting special flight permits. Alternative Methods of Compliance (k) The Manager, Seattle Aircraft Certification Office, may approve alternative methods of compliance for this AD if requested using the procedures found in 14 CFR 39.19. Related Information (l) Precision Airmotive LLC Mandatory Service Bulletin No. PRS- 107, Revision 1, dated March 6, 2008, pertains to the subject of this AD. You can get the service information identified in this AD from http://www.precisionairmotive.com. (m) For Precision Airmotive LLC, Richard Simonson, Aerospace Engineer, Propulsion Branch, FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington 98055; e-mail: Richard.simonson@faa.gov; telephone: (425) 917-6507; fax: (425) 917- 6590. (n) For Lycoming Engines, Norm Perenson, Aerospace Engineer, New York Aircraft Certification Office, FAA, Engine & Propeller Directorate, 1600 Stewart Avenue, Suite 410, Westbury, NY 11590; e- mail: Norman.perenson@faa.gov; telephone: (516) 228-7337; fax: (516) 794-5531. (o) For Teledyne Continental Motors, Kevin Brane, Aerospace Engineer, Atlanta Aircraft Certification Office, FAA, Small Airplane Directorate, One Crown Center, 1895 Phoenix Blvd., Suite 450, Atlanta, GA 30349; e-mail: kevin.brane@faa.gov; telephone: (770) 703-6063; fax: (770) 703-6097. (p) For Superior Air Parts, Inc., Tausif Butt, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, Southwest Regional Headquarters, 2601 Meacham Blvd., Fort Worth, Texas 76137; e-mail: Tausif.butt@faa.gov; telephone: (817) 222-5195; fax: (817) 222-5785.