2009-16-03: Cylinder assemblies

2009-16-03 Superior Air Parts, Inc. (SAP): Amendment 39-15986. Docket No. FAA-2007-0051; Directorate Identifier 2007-NE-37-AD. Effective Date (a) This airworthiness directive (AD) becomes effective September 9, 2009. Affected ADs (b) None. Applicability (c) This AD applies to Teledyne Continental Motors (TCM) IO-520, TSIO-520, and IO-550 series reciprocating engines with SAP investment cast cylinder assemblies, part numbers (P/Ns) SA52000-A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000-A20P, installed. These engines are installed on, but not limited to, the airplanes listed in Table 1 of this AD. Table 1--Teledyne Continental Motors-Related Aircraft Models Engine Model Aircraft Manufacturer Aircraft Model Designation IO-520-A Cessna 210 D, E, F, G, & H IO-520-A Cessna 206 IO-520-A Cessna P206 IO-520-A Rockwell 200 D IO-520-B Beechcraft 36 Bonanza IO-520-B Beechcraft A36 IO-520-B Navion Range Master IO-520-BA Beechcraft A36 IO-520-BA Beechcraft S & V35, V35A, V35B IO-520-BA Beechcraft C33 A IO-520-BA Beechcraft E33 A & C IO-520-BA Beechcraft F33 A & C IO-520-BA Navion Range Master IO-520-BB Beechcraft A36 IO-520-BB Beechcraft V35B IO-520-BB Beechcraft F33 A IO-520-C & CB Beechcraft C55 - E55 Baron IO-520-D Bellanca 17-30 Viking IO-520-D Cessna A188-300 AG Truck IO-520-D Cessna 185 IO-520-E (Cessna 310) Exec 600 IO-520-E (Beech Baron) Pres 600 IO-520-F Cessna 207 IO-520-F Cessna U206 IO-520-K Bellanca 17-30A IO-520-L Cessna 210 K, L, M, N & R IO-520-L Cessna 210N II IO-520-L Cessna 210R IO-520-M Cessna 310R IO-520-MB Cessna 310R IO-550-A Cessna 310 Conversion IO-550-B Beechcraft A36 IO-550-B (Beech Bonanza) Foxstar IO-550-C Beechcraft 58 Baron IO-550-D Cessna 185/188 Conversion IO-550-E Cessna 310 Conversion IO550-F Cessna 206/207 Conversion IO-550-L Cessna 210 Conversion UnsafeCondition (d) This AD results from reports of cracks in the area of the exhaust valve and separation of cylinder heads from the barrels of SAP cylinder assemblies with certain part numbers. We are issuing this AD to prevent the separation of the cylinder head, which could result in immediate loss of engine power, possible structural damage to the engine, and possible fire in the engine compartment. Compliance (e) You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. Inspecting SAP Cylinder Assemblies (f) If the engine records don't contain the P/N of the cylinder heads, do the following: (1) Remove the valve cover from the cylinder assembly. (2) Look at the cylinder head for the P/N SAC 52001 I or SAC 55001 I and the word "AMCAST.'' (g) For TCM IO-520, TSIO-520, and IO-550 series reciprocating engines with SAP investment cast cylinder assemblies, P/Ns SA52000- A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000- A1, or SA55000-A20P, installed, with over 750 flight hours (FH) time-in-service (TIS), do the following within 25 FH TIS after the effective date of this AD: (1) Inspect each cylinder head around the exhaust valve side for visual cracks or any signs of black combustion leakage. (2) Replace any cracked or leaking cylinders before further flight. (3) Perform a standard cylinder compression test. Guidance on standard cylinder compression tests can be found in Teledyne Continental Aircraft Engine Service Bulletin SB03-3, Differential Pressure Test and Borescope Inspection Procedures for Cylinders, dated March 28, 2003. (i) If the cylinder pressure gauge reads below 60 pounds per- square inch, determine if the unacceptable pressure is due to a cracked cylinder. (ii) To check the cylinder, apply a 2 percent soapy water solution to the side of the leaking cylinder. (iii) If you see air bubbles, indicating air leakage, on the side of the cylinder head, or near the head-to-cylinder interface, replace the cylinder assembly before further flight. (h) Thereafter, repeat the cylinder visual inspections and compression tests within 50 FH time-since-last inspection (TSLI) until the cylinders reach their time-between-overhaul (TBO) limits specified in Teledyne Continental Aircraft Engine Service Information Letter SIL98-9A, Revision A, dated March 28, 2003. Replacing SAP Cylinder Assemblies (i) For TCM IO-520, TSIO-520, and IO-550 series reciprocating engines with SAP investment cast cylinder assemblies, P/Ns SA52000- A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000- A1, or SA55000-A20P, replace the SAP cylinder head assembly at the first TBO after the effective date of this AD. Engines that were already overhauled may continue in service until the first TBO after the effective date of this AD. Prohibition Against Installing Certain P/N SAP Cylinder Assemblies (j) After the effective date of this AD, do not install any SAP investment cast cylinder assembly, P/Ns SA52000-A1, SA52000-A20P, SA52000-A21P, SA52000-A22P, SA52000-A23P, SA55000-A1, or SA55000- A20P, in any engine. Alternative Methods of Compliance (k) The Manager, Special Certification Office, has the authority to approve alternative methods of compliance for this AD if requested using the procedures found in 14 CFR 39.19. Special Flight Permits (l) Under 14 CFR part 39.23, we will not approve special flight permits for this AD for engines that have failed the visual inspection or the 50 hour periodic cylinder assembly compression test required by this AD. Related Information (m) Teledyne Continental Service Bulletin No. SB03-3 "Differential Pressure Test and Borescope Inspection Procedures for Cylinders'', dated March 28, 2003. (n) Contact Peter W. Hakala, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76137; e-mail: peter.w.hakala@faa.gov; telephone (817) 222-5145; fax (817) 222-5785, for more information about this AD. Material Incorporated by Reference (o) You must use Teledyne Continental Aircraft Engine Service Information Letter SIL98-9A, Revision A, dated March 28, 2003 to determine the times-between-overhaul required by this AD. The Director of the Federal Register approved the incorporation by reference of this service information in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Contact Teledyne Continental Motors, Inc., P.O. Box 90, Mobile, Alabama; telephone (251) 438-3411, or go to: http://www.genuinecontinental.aero, for a copy of this service information. You may review copies at the FAA, New England Region, 12 New England Executive Park, Burlington, MA; or at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.