SAIB NE-05-89 —

1 SPECIAL AIRWORTHINESS INFORMATION BULLETIN

Aircraft Certification Service Washington, DC

U.S. Department of Transportation Federal Aviation Administration

NE-05-89 September 30, 2005 http://www.faa.gov/aircraft/safety/alerts/SAIB This is information only. Recommendations aren’t mandatory.

Introduction

This Special Airworthiness Information Bulletin (SAIB) updates information we issued in SAIB NE-01-22, May 11, 2001. This SAIB alerts you, owners, operators, and certified repair stations of Textron Lycoming Engines O-235; O-290; O-340; (L)O and IO-320, -360, -540; AIO-320, -360; AEIO- 320, -360, -540; HIO-360; and TO-360 series reciprocating engines, with fuel pumps, part number (P/N) LW-15399, LW-15472, P/N LW-15473, or P/N LW-16335 installed, and that has one of the manufacturing date codes shown in Figure 1 scribed on the edge of the pump mounting flange.

These reciprocating engines are installed on, but not limited to Aerospatiale, American Champion, Bellanca, Cessna, The New Piper Aircraft Company, Beech, Maule, Mooney, and Schweizer 269, series aircraft.

Background

Initially, Lycoming Engines reported three events of high pressure fuel pump failures in their Production Test Cell and issued Service Bulletin (SB) No. 548. Now that there has been one reported failure in the field, Lycoming has issued SB No. 548A (see attached) to expand the affected population of fuel pumps because there is no way to predict when a failure may occur. We are still investigating and if the situation changes, we may issue an Airworthiness Directive. These fuel pumps were either purchased as replacements or shipped from Lycoming and installed on new, repaired, rebuilt, and overhauled engines between February 22, 2000 and September 15, 2005.

When an internal failure occurs, the check valve seat separates from its shaft due to an inadequate or improper assembly crimp. This allows the liberated parts to move within the housing and might cause a blockage of fuel flow. This failure may not be evident on the exterior of the pump, but might result in a decrease or loss of fuel flow and a corresponding decrease or loss of engine power.

Recommendations

To prevent a failure of Lycoming Engine fuel pump with P/N LW-15399, LW-15472, LW- 15473, or LW-16335, we highly recommend you inspect your engines for the applicable fuel pumps, as shown in Figure 1, and replace the pumps as described in Textron Lycoming Service Bulletin (SB) No. 548A. We also recommend that you check your maintenance records for affected replacement fuel pumps received after September 15, 2005 in the event that Lycoming’s September 1, 2005 fuel pump recall didn’t retrieve all affected pumps. Prior compliance with Lycoming SB No. 548 requires re-inspection of the fuel pump to ensure that a fuel pump from one of the date codes added by Revision “A” was not installed when originally complying with Lycoming SB No. 548.

2 • Textron Lycoming engine that has a diaphragm-type fuel pump, P/N LW-15399, LW- 15472, LW-15473, or LW-16335 installed, with one of the following date codes in the 6th through 9th digit locations scribed on the pump:

0101 0201 0301 0700 0800 1100 1200 1300 1400 1500 1600 1800 2000 2100 2200 2300 2400 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 0401

Example: 163354800 needs to be replaced as specified in Textron Lycoming Service Bulletin No. 548A.

• If the letter “A” is marked as a suffix to the date code, the pump manufacturer has repaired the pump and replacement is not necessary.

Example: 163354800A

Figure 1

For Further Information Contact

Norm Perenson, Aerospace Engineer, FAA NYACO, ANE-171, 1600 Stewart Ave, Westbury NY 11590; phone: (516) 228- 7337; fax: (516) 794-5531; email: [email protected]. For Service Bulletin Information

Lycoming, 652 Oliver St, Williamsport, PA 17701, phone (570) 323-6181; fax (570) 327-7101; or go to t heir web site at: http://www.lycoming.textron.com/support/pub lications/maintenancePublications/serviceBull etins

MANDATORY SERVICE BULLETIN

652 Oliver Street Williamsport, PA 17701 U.S.A.

Tel. 570-323-6181 Fax. 570-327-7101 www.lycoming.textron.com

DATE:

August 31, 2005 Service Bulletin No. 548A (Supersedes Service Bulletin No. 548)

SUBJECT:

Diaphragm-Type Fuel Pump Inspection/Replacement

MODELS AFFECTED: New, rebuilt and overhauled engines from Lycoming with fuel pumps P/N LW-15399, LW-15472, LW-15473, and LW-16335 shipped between February 1, 2000 and September 15, 2005. Engine models affected are O- 235; O-290; O-340; (L)O and IO-320, -360, -540; AIO-320, -360; AEIO-320, -360, -540; HO-360; HIO-360; and TO-360.

Fuel pumps P/N LW-15399, LW-15472, LW-15473, and LW-16335 purchased through distribution between February 22, 2000 and September 15, 2005.

TIME OF COMPLIANCE: Compliance is required within 180 calendar days from the date of this Service Bulletin, or as specified below, whichever occur first: 1. Inspect within 50 hours of operation: 2. If affected, replace within 100 hours of operation or earlier at owner’s discretion.

NOTE

Prior compliance with Service Bulletin No. 548 does not preclude compliance with this Service Bulletin.

Lycoming has determined that a number of lots of diaphragm-type fuel pumps, Lycoming P/N LW-15399, LW-15472, LW-15473, and LW-16335, may not have been manufactured in conformance with acceptable standards. In the event operation of the pump is compromised, restricted fuel flow or loss of fuel pressure could result.

If your Lycoming engine has a diaphragm-type fuel pump with Lycoming P/N LW-15399, LW- 15472, LW-15473, or LW-16335 installed, and has a date code of 0700 through 0401, the pump must be replaced within the next 100 hours of operation or 180 calendar days from the date of this Service Bulletin, whichever occurs first.

To identify affected pumps, check the manufacturer’s code scribed on the flange of the pump (See Figure 1). If the first five digits are 15399, 15472, 15473, or 16335, and the 6th through 9th digits are 0700, 0800, 1100, 1200, 1300, 1400, 1500, 1600, 1800, 2000, 2100, 2200, 2300, 2400, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, 4000, 4100, 4200, 4300, 4400, 4500, 4600, 4700, 4800, 4900, 5000, 5100, 5200, 0101, 0201, 0301 or 0401, the pump is affected and must be replaced.

NOTE

If the letter “A” is marked as a suffix to the date code, the pump has been brought into conformity and need not be replaced. Page 1 of 2 © 2005 by Lycoming “All Rights Reserved”

Service Bulletin No. 548A

WARRANTY:

If replacement is required, reimbursement is available for a replacement fuel pump and for up to 1.5 hours labor through a Lycoming Distributor. The engine serial number must be furnished when a replacement pump is ordered. Lycoming requires the replaced pump be returned with a valid warranty claim for warranty consideration.

Figure 1

NOTE: Revision “A” adds new date codes and part number LW-15399.

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