Lycoming O-540

Airworthiness Directives; Continental Aerospace Technologies, Inc., Lycoming Engines, and Textron Lycoming/Subsidiary of Textron, Inc. Reciprocating Engines

The FAA is adopting a new airworthiness directive (AD) for certain Continental Aerospace Technologies, Inc. GTSIO-520, IO-346, IO- 470, IO-520, IO-550, LTSIO-520, O-470, TSIO-520, and TSIOL-550 series model reciprocating engines, Lycoming Engines AEIO-320, AEIO-360, AEIO- 540, AIO-320, AIO-360, GO-480, GSO-480, HIO-360, HIO-540, IGO-480, IGO- 540, IGSO-480, IGSO-540, IO-320, IO-360, IO-540, LIO-360, LTIO-540, O- 235, O-320, O-360, O-540, TIGO-541, TIO-360, TIO-540, TIO-541, TVO-435, VO-435, and VO-540 series model reciprocating engines, and Textron Lycoming/Subsidiary of Textron, Inc. IO-720 series model reciprocating engines. This AD was prompted by a report of a manufacturing quality escape of improperly lubricated roller bearings installed in certain magnetos, which may result in overheating and magneto seizure. This AD requires the replacement of affected magneto or inspection of affected magneto and, if no white grease is detected, replacement of magneto components, as applicable, and reassembly of the magneto. The FAA is issuing this AD to address the unsafe condition on these products.

Airworthiness Directives; Lycoming Engines Reciprocating Engines

We are adopting a new airworthiness directive (AD) for all Lycoming TIO-540-AJ1A reciprocating engines. This AD requires initial and repetitive inspections of engine exhaust system weld joints and torque checking the exhaust pipe flange mounting nuts. This AD was prompted by several reports of engine exhaust leaks. We are issuing this AD to correct the unsafe condition on these products.

Airworthiness Directives; Lycoming Engines Reciprocating Engines (Type Certificate Previously Held by Textron Lycoming Division, AVCO Corporation)

We are adopting a new airworthiness directive (AD) for certain Lycoming TIO-540-AJ1A reciprocating engines. This AD was prompted by several reports of cracked engine exhaust pipes. This AD requires inspection of the engine exhaust pipes for cracks and replacement of the turbocharger mounting bracket. We are issuing this AD to prevent failure of the exhaust system due to cracking, which could lead to uncontrolled engine fire, harmful exhaust gases entering the cabin resulting in crew incapacitation, and damage to the airplane.

Airworthiness Directives; AERMACCHI S.p.A. Airplanes

We are rescinding Airworthiness Directive (AD) 2013-22-23 for AERMACCHI S.p.A. Models F.260, F.260B, F.260C, F.260D, F.260E, F.260F, S.208, and S.208A airplanes equipped with a Lycoming O-540, IO-540, or AEIO-540 (depending on the airplane model) wide cylinder flange engine with a front crankcase mounted propeller governor. AD 2013-22-23 resulted from mandatory continuing airworthiness information (MCAI) issued by the aviation authority of another country to identify and correct an unsafe condition on an aviation product. We issued the AD to detect and correct improper position of the set screw, which could lead to complete loss of engine oil pressure and result in emergency landing. Since we issued AD 2013-22-23, we have determined the unsafe condition does not exist specific to the airplane design features.

Airworthiness Directives; Aermacchi S.p.A. Airplanes

We are adopting a new airworthiness directive (AD) for Aermacchi S.p.A. Models F.260, F.260B, F.260C, F.260D, F.260E, F.260F, S.208, and S.208A airplanes equipped with a Lycoming O-540 wide cylinder flange engine with a front crankcase mounted propeller governor. This AD results from mandatory continuing airworthiness information (MCAI) issued by the aviation authority of another country to identify and correct an unsafe condition on an aviation product. The MCAI describes the unsafe condition as the set screw that fixes the setting of the propeller governor idler gear shaft was not in the proper position. We are issuing this AD to require actions to address the unsafe condition on these products.

Airworthiness Directives; Lycoming Engines and Continental Motors, Inc. Reciprocating Engines

We are superseding airworthiness directive (AD) 2012-24-09 for Lycoming Engines TIO-540-AK1A, and Continental Motors, Inc. (CMI) TSIO- 360-MB, TSIO-360-SB, and TSIO-360-RB reciprocating engines, with certain Hartzell Engine Technologies (HET) turbochargers, model TA0411, installed. AD 2012-24-09 required removing certain HET turbochargers from service before further flight. This AD also requires removing certain HET turbochargers from service before further flight. This AD was prompted by a report that an additional engine, the CMI LTSIO-360- RB, has the affected HET turbochargers installed. We are issuing this AD to prevent turbocharger turbine wheel failure, reduction or complete loss of engine power, loss of engine oil, oil fire, and damage to the airplane.

Airworthiness Directives; Lycoming Engines Reciprocating Engines

We are superseding an existing airworthiness directive (AD) for certain Lycoming Engines (L)O-360, (L)IO-360, AEIO-360, O-540, IO- 540, AEIO-540, (L)TIO-540, IO-580, and IO-720 series reciprocating engines. That AD currently requires replacing certain crankshafts in the affected engines. This AD continues to require replacing certain crankshafts, corrects the start date of affected engine models in Lycoming Mandatory Service Bulletin (MSB) No. 569A to the start date in Supplement No. 1 to Lycoming MSB No. 569A, dated May 27, 2009, and includes additional (formerly experimental) IO-390, AEIO-390, and AEIO- 580 series engine models having affected crankshafts. This AD was prompted by Lycoming Engines discovering that the start date of affected engine models in MSB No. 569A is incorrect and the need to include additional engine models having the affected crankshafts. We are issuing this AD to prevent failure of the crankshaft, which will result in total engine power loss, in-flight engine failure, and possible loss of the aircraft.

Airworthiness Directives; Lycoming Engines Reciprocating Engines

We are rescinding an airworthiness directive (AD) for Lycoming Engines model TIO-540-A series reciprocating engines. The existing AD, AD 71-13-01, was prompted by a report of a failed fuel injector tube assembly. Since we issued AD 71-13-01, we became aware that Lycoming Engines no longer supports Service Bulletin (SB) No. 335A, which was incorporated by reference in AD 71-13-01. The intent of the requirements of that SB is now in Lycoming Engines Mandatory SB No. 342F, which we have incorporated by reference into AD 2008-14-07. The FAA determined, therefore, that this requirement is duplicated by another AD.

Airworthiness Directives; Lycoming Engines (L)O-360, (L)IO-360, AEIO-360, O-540, IO-540, AEIO-540, (L)TIO-540, IO-580, and IO-720 Series Reciprocating Engines.

The FAA is adopting a new airworthiness directive (AD) for certain Lycoming Engines (L)O-360, (L)IO-360, AEIO-360, O-540, IO-540, AEIO-540, (L)TIO-540, IO-580, and IO-720 series reciprocating engines. This AD requires replacing certain crankshafts. This AD results from reports of 23 confirmed failures of similar crankshafts in Lycoming Engines 360 and 540 series reciprocating engines. We are issuing this AD to prevent failure of the crankshaft, which will result in total engine power loss, in-flight engine failure, and possible loss of the aircraft.

Airworthiness Directives; Lycoming Engines (Formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 Series Reciprocating Engines

The FAA is adopting a new airworthiness directive (AD) for certain Lycoming Engines (formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 series reciprocating engines rated at 300 horsepower (HP) or lower. This AD requires replacing certain crankshafts. This AD results from reports of 12 crankshaft failures in Lycoming 360 and 540 series engines rated at 300 HP or lower. We are issuing this AD to prevent failure of the crankshaft, which could result in total engine power loss, in-flight engine failure, and possible loss of the aircraft.

Airworthiness Directives; Lycoming Engines (Formerly Textron Lycoming) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 Series Reciprocating Engines

The FAA is superseding an existing airworthiness directive (AD) for Lycoming Engines (Formerly Textron Lycoming) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 series reciprocating engines. That action requires replacing certain zinc-plated crankshaft gear retaining bolts. This action retains that requirement, but expands the population of affected engines. In addition, this AD adds five additional kits for replacing the crankshaft gear retaining bolts. This AD results from notification from the Manufacturer of 161 engines not identified in the previous AD. This AD also results from approval of the five additional kits as alternative methods of compliance with AD 2002-23-06. We are issuing this AD to prevent loss of all engine power and possible forced landing.

Airworthiness Directives; Textron Lycoming AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 Series Reciprocating Engines

This amendment supersedes an emergency airworthiness directive (AD) that was sent previously to all known U.S. owners and operators of Textron Lycoming (T/L) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 series reciprocating engines. That action requires replacing certain zinc-plated crankshaft gear retaining bolts. This action still requires replacing certain zinc-plated crankshaft gear retaining bolts, but expands the population of affected engines. This amendment is prompted by two recent failures of zinc-plated crankshaft gear retaining bolts, and a reassessment of the extent to which the suspect bolts may still be present in the field. The actions specified by this AD are intended to prevent loss of all engine power and possible forced landing.

Airworthiness Directives; Textron Lycoming IO-540, LTIO-540 and TIO-540 Series Reciprocating Engines

This amendment supersedes emergency airworthiness directive (AD) 2002-17-53 that was sent previously to all known U.S. owners and operators of Textron Lycoming LTIO-540 and TIO-540 series engines, rated at 300 horsepower (HP) or higher. That action requires, before further flight, replacing certain serial-numbered crankshafts that were hammer forged with crankshafts that were press forged. That AD was prompted by reports of crankshaft failures in LTIO-540 and TIO-540 engines, rated at 300 HP or higher. This amendment expands the suspect population of engines to include engines with crankshafts that were manufactured between March 1997 and the present and all IO-540 engines with crankshafts that were manufactured between March 1997 and the present that have been modified by supplemental type certificate (STC) by installing a turbocharger system. The actions specified by this AD are intended to prevent failure of the crankshaft, which could result in total engine power loss, in-flight engine failure and possible forced landing.

Airworthiness Directives; Textron Lycoming Reciprocating Engines IO-540 and O-540 Engines Equipped With Slick Aircraft Products Magnetos

This amendment adopts a new airworthiness directive (AD) that is applicable to Textron Lycoming IO-540 and O-540 engines equipped with Slick Aircraft Products magnetos. This action requires removal of the Slick magneto from the engine and inspection of the impulse coupling pawl for wear. This amendment is prompted by several service difficulty reports, two incidents, and an accident involving severely worn and failed impulse couplings. The actions specified in this AD are intended to prevent failure of the magneto impulse coupling, resulting in seizure of the engine.

Airworthiness Directives; Textron Lycoming Model O-540-F1B5 Reciprocating Engines

This amendment adopts a new airworthiness directive (AD) that is applicable to Textron Lycoming Model O-540-F1B5 reciprocating engines. This action requires the removal and replacement of the crankshaft gear retaining bolts. This amendment is prompted by 2 reported failures of the crankshaft gear retaining bolts. The actions specified in this AD are intended to prevent failure of the crankshaft gear retaining bolts, which can result in engine failure and subsequent autorotation and forced landing.

Airworthiness Directives; Textron Lycoming and Superior Air Parts, Inc.

This document publishes in the Federal Register an amendment adopting Airworthiness Directive (AD) 97-01-04 that was sent previously to all known U.S. owners and operators of certain Textron Lycoming TIO- 540, LTIO-540, and IO-540 series reciprocating engines with certain Superior Air Parts, Inc. Parts Manufacture Approval (PMA) replacement cylinder assemblies installed by individual letters. This AD requires removal from service of affected cylinder assemblies for higher time cylinder assemblies and replacement with serviceable parts, and initial and repetitive dye penetrant inspections for mid-time cylinder assemblies, or replacement with serviceable parts. This amendment is prompted by a report of an inflight engine failure of a Textron Lycoming TIO-540 reciprocating engine with affected Superior Air Parts, Inc. PMA cylinder assemblies installed. The actions specified by this AD are intended to prevent cylinder head separation, inflight loss of power, possible engine failure, and fire.

Airworthiness Directives; Textron Lycoming Reciprocating Engines

This document publishes in the Federal Register an amendment adopting Airworthiness Directive (AD) 96-23-03 that was sent previously to all known U.S. owners and operators of Textron Lycoming IO-320, LIO- 320, AEIO-320, IO- 360, LIO-360, AEIO-360, HIO-360, TO-360, IO-540, O- 540-L, LIO-540, and AEIO-540 series reciprocating engines by individual letters. This AD requires a maintenance records check to determine if suspect high pressure fuel pumps are installed, and inspection to determine if the high pressure fuel pump has one of the suspect date codes. If the high pressure fuel pump has a suspect date code, this AD requires disassembly and inspection of the high pressure fuel pump, and, if necessary, removal from service and replacement with a serviceable part. In addition, this AD requires reporting findings of unserviceable high pressure fuel pumps. This amendment is prompted by reports of inflight failures of high pressure fuel pumps. The actions specified by this AD are intended to prevent an inflight engine failure due to fuel starvation, which could result in a forced landing.

Airworthiness Directives; Textron Lycoming Model TIO-540-S1AD Reciprocating Engines

This amendment revises an existing airworthiness directive (AD), applicable to Textron Lycoming Model TIO-540-S1AD reciprocating engines, that currently requires the upgrade of the engine exhaust system to a new design configuration; and also establishes inspection intervals for engines incorporating the new design configuration, for engines incorporating the design configuration required by a previous AD, and for engines not yet incorporating either design configuration. This amendment clarifies that an exhaust system disassembly is not necessary when inspecting the exhaust system after the installation of the new design One-piece Exhaust Riser Kit, and Manifold Retaining Kit. This amendment is prompted by reports from operators requesting clarification of two paragraphs in the compliance section. The actions specified by this AD are intended to prevent cracking or distortion of engine exhaust system flanges, V-band coupling, and pipes, which could result in engine compartment fire and smoke entering the cabin with possible loss to the aircraft.

Airworthiness Directives; Textron Lycoming O-360, LO-360, HO-360, HIO-360, TIO-360, LIO-360, AEIO-360, O-540, IO-540, TIO-540, LTIO-540, IVO-540, AEIO-540, TIO-541, and IO-720 Series Reciprocating Engines

This document publishes in the Federal Register an amendment adopting Airworthiness Directive (AD) 95-07-01 that was sent previously to all known U.S. owners and operators of Textron Lycoming O-360, LO- 360, HO-360, HIO-360, TIO-360, LIO-360, AEIO-360, O-540, IO-540, TIO- 540, LTIO-540, IVO-540, AEIO-540, TIO-541, and IO-720 series reciprocating engines by individual letters. This AD requires removal prior to further flight of suspect unapproved connecting rod bolts and replacement with serviceable connecting rod bolts. This amendment is prompted by reports of connecting rod bolt failures. The actions specified by this AD are intended to prevent engine failure due to connecting rod bolt failure, which could result in damage to or loss of the aircraft.