AD 2009-02-03 Airworthiness Directives; Lycoming Engines IO, (L)IO, TIO, (L)TIO, AEIO, AIO, IGO, IVO, and HIO Series Reciprocating Engines, Teledyne Continental Motors (TCM) LTSIO-360-RB and TSIO-360-RB Reciprocating Engines, and Superior Air Parts, Inc. IO-360 Series Reciprocating Engines With Certain Precision Airmotive LLC RSA-5 and RSA-10 Series, and Bendix RSA-5 and RSA-10 Series, Fuel Injection Servos

Makes named: lycoming, continental, teledyne, precision airmotive, superior air parts, bendix. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to the following reciprocating engines with a Precision Airmotive LLC, RSA-5 or RSA-10 series, or Bendix, RSA-5 or RSA-10 series, fuel injection servo, having a servo plug gasket, part number (P/N) 365533, that was installed under the fuel injection servo plug, P/N 383493, on or after August 22, 2006: (1) Lycoming Engines IO, (L)IO, TIO, (L)TIO, AEIO, AIO, IGO, IVO, and HIO series reciprocating engines. (2) Teledyne Continental Motors LTSIO-360-RB and TSIO-360-RB reciprocating engines. (3) Superior Air Parts, Inc. IO-360 series reciprocating engines. (d) This AD also applies to any other Precision Airmotive LLC RSA-5 or RSA-10 series, or Bendix, RSA-5 or RSA-10 series, fuel injection servo: (1) That was received for installation on an engine on or after August 22, 2006 without a P/N 2577258 gasket and it does not have a letter “G” on the fuel injection servo plug, P/N 383493; or (2) Any fuel injection servo that the installation history is not known.

You are responsible for having the actions required by this AD performed before further flight, unless the actions have already been done. Initial Inspection (g) Before further flight, 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. (h) If the plug is not loose, go to paragraph (j) of this AD. (i) 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 and gasket, P/N 365533, that is behind the plug. 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 (i)(3) of this AD, the servo is not eligible for any installation and must be replaced before further flight. (5) Replace the gasket, P/N 365533, with a new improved gasket, P/N 2577258. (6) While the hex plug is removed, stamp or scribe the letter “G” onto the face of the hex plug. Information on stamping or scribing can be found in Precision Airmotive LLC Mandatory Service Bulletin (MSB) No. PRS-107 Revision 4, dated July 16, 2008. (7) When reassembling, do not install any servo plug or regulator cover that is not eligible for installation. Install a new gasket, P/N 2577258, onto the servo plug and reassemble the servo plug to the regulator cover. (8) Torque the servo plug to a new, higher torque of 90-100 in-lbs, to maintain the proper clamp-up force between the plug and cover. (9) Safety wire the servo plug with 0.015 thru 0.025 inch diameter wire to the regulator cover screws. Information on properly safety wiring the plug can be found in Precision Airmotive LLC MSB No. PRS-107, Revision 4, dated July 16, 2008. (10) Inspect all other safety wire on the servo. Replace any that are damaged. Repetitive Inspections (j) For servo plugs that passed inspection with a gasket, P/N 365533 installed, 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 (g) through (i)(10) of this AD. Mandatory Terminating Action (k) By December 31, 2009, as mandatory terminating action to the repetitive inspections required by this AD, replace all servo plug gaskets, P/N 365533 that are installed on servos affected by this AD, with gasket, P/N 2577258. (l) Use paragraphs (i)(1) through (i)(10) of this AD, to do the gasket replacements. Prohibition of Installing Gasket P/N 365533 (m) After the effective date of this AD, do not install gasket, P/N 365533, onto any fuel injection servo. Identification of Servo Plug Gaskets (n) Servo plug gaskets, P/N 365533, are identified as being made of either a paper or fiber material, impregnated with synthetic rubber. They are relatively flexible and have a rough surface. (o) Servo plug gaskets, P/N 2577258, are identified as being made of metal with a coating of synthetic rubber. They are relatively rigid and have a smooth surface. Special Flight Permits Prohibited (p) Under 14 CFR part 39.23, we are prohibiting special flight permits. Alternative Methods of

This AD results from Precision Airmotive LLC introducing the installation of a new improved servo plug gasket, P/N 2577258, to the affected Precision Airmotive LLC RSA-5 and RSA-10 series, and Bendix, RSA-5 and RSA-10 series, fuel injection servos. 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.