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  #1  
Old 01-01-2010, 12:55 PM
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newtech newtech is offline
 
Join Date: Mar 2006
Location: Evansville, Indiana
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Angry NEW ECi Cylinder AD - Bummer!!!!

I had to replace one cylinder of my new rebuilt engine before I even had the chance to start it for the first time. Well, happy friggin new year, There is a new ECi AD just out and now my 2000 hour TBO engine is now a 350 hours TBO engine. Since I have 70 hours on it, since first flight in June, my one cylinder that falls within the serial number range needs to be replaced within the next 280 hours.

Heading over to the hangar now to perform the visual and compression checks to see if I can fly the plane to Florida in two weeks or if it needs to be grounded pending cylinder replacement. At lest it is Experimental so I am not at the mercy of an A&P.

Here is the AD:
http://cdn1.atp.com/ADs/pdf/092612.p...ad10jnmpo1.JS1
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Last edited by newtech : 01-01-2010 at 12:58 PM.
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  #2  
Old 01-01-2010, 01:46 PM
rv4ator rv4ator is offline
 
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Location: Northern CA
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I'm in the same situation with all 4 cylinders on an O-360 that fall into Group B with a 350 hour limit. It has been a little over 1.5 years since the first engine start & total time around 200 hours. Does anybody know if ECI will replace these defective cylinders under warranty? It doesn't seem fair or good business practice to not make things right. That said, I don't have a lot of confidence that even new replacement ECI jugs won't be subject to new AD's in the future.
The list of serial numbers seems to be growing.
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  #3  
Old 01-01-2010, 03:23 PM
David-aviator David-aviator is offline
 
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This is a big one and I feel for you guys.

From the last page of the AD - We estimate the total cost of the AD to U.S. operators to be $10,172,000.

This thing is so big, I wonder if ECI has the resources to make good on it. Hopefully, there will be some warrantee money flowing your way to help off set the pain.
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  #4  
Old 01-01-2010, 03:57 PM
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RV6_flyer RV6_flyer is offline
 
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The way I read the AD is that it is a replacement for an existing AD and it just expands the Serial Number Range of the existing AD to include MORE cylinders.

The Cylinders have a three (3) year warranty from time placed into service as long as they were placed in service within one year of manufacture.
http://www.eci.aero/pages/news_relea...il.aspx?n=1010
http://www.eci.aero/pages/warranty_titan.aspx

Contact ECI about replacements on Monday 1-3-2010.
http://www.eci.aero/pages/contact.aspx

I looked on the web site to see if they had something about this new AD that takes effect in February 2010.
Here is a link to an ECI Mandatory Service Bulletin (MSB # 08-01) that appears to match the AD S/N range.
http://www.eci.aero/pdf/08-1.pdf
--- insert from MSB 08-01 ---
6.0 PROCEDURES TO BE FOLLOWED:
Replacement cylinders will be sent in accordance to ECi’s written warranty policy. If you have an affected cylinder(s), go to ECi’s website http://www.eci.aero/pages/services.aspx and complete the Warranty Application Form (T800.1) (http://www.eci.aero/pages/WarrantyAp...(03-13-08).doc) online. In order to properly complete the form you must have the cylinder part number, serial number and time in service. If you have any questions you may call us at either 1-800-324-2359 or 210-820-8101 or, if you prefer, you may e-mail us at MSB08-1@eci.aero.
9.0 ECi CONTACT INFORMATION:
Contact ECi Customer Service at (toll free) 1-800-324-2359, (local) 210-820-8101 or (email) MSB08-1@eci.aero.
--- end insert from MSB 08-01 ---

Here is a link to the FAA web site with the FAA AD.
http://www.airweb.faa.gov/Regulatory_and_Guidance_Library/rgAD.nsf/0/fd1c80194ba\
0b8da8625769d00695ada/$FILE/2009-26-12.pdf


--- insert AD Quote ---
SUMMARY: The FAA is superseding an existing airworthiness directive (AD) for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, ``Parallel Valve'' reciprocating engines, with certain Engine Components, Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series ``Titan,'' installed. That AD currently requires initial and repetitive visual inspections and compression tests to detect cracks at the head-to-barrel interface, replacement of cylinder assemblies found cracked, and replacement of certain cylinder assemblies at new, reduced times-in-service. This AD requires the same actions, but for an expanded population of cylinder assemblies. This AD results from reports of 10 additional cylinder head separations since issuing AD 2008-19-05, on cylinder serial numbers not listed in that AD. We are issuing this AD to prevent loss of engine power due to cracks at the head-to-barrel interface and possible engine failure caused by separation of a cylinder head, which could result in loss of control of the aircraft.
DATES: This AD becomes effective February 4, 2010.

Applicability
(c) If your engine has not been overhauled, or not had any cylinder assemblies replaced since new, no further action is required.
(d) This AD applies to the Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, ``Parallel Valve,'' reciprocating engines listed in Table 1 of this AD, with ECi cylinder assembly, part number (P/N) AEL65102 series ``Titan,'' and with cylinder head, P/N AEL85099, installed.
(1) The applicable cylinder assembly serial numbers (S/Ns) are S/N 1138-02
through S/N 35171-22 (referred to in this AD as Group ``A'' cylinder assemblies); and
(2) S/N 35239-01 through S/N 42179-30 (referred to in this AD as Group ``B'' cylinder assemblies).
(3) The cylinder assembly P/N is at the crankcase end of the cylinder assembly, and might be difficult to see. As a guide in determining if your cylinder assemblies are affected, all affected cylinder assemblies have cylinder head P/N AEL85099. The cylinder head P/N is at the top of the cylinder head, near the intake and exhaust valve springs, and is easier to locate than the cylinder assembly P/N.
(4) The set of numbers appearing on the cylinder, above and to the left of the S/N, in the form of ``123456'' is not used for determining this AD's applicability.
--- end insert AD Quote ---

I have the S/Ns of my ECI TITAN Steel cylinders listed in my engine logbook and this AD will not apply to them. BTW, I change oil at 50 hour intervals and have not added any oil the last two oil changes because the ECI cylinders on my airplane does not use enough oil between changes to add any. It is using oil but only about 1 quart in 50 hours. The ECI cylinders are using less oil than the Superior cylinders did when they had the same time on them but that was over 2,000 hours ago.

From my 28-years of aviation experience, IMHO, ECI has the best customer service of any aircraft engine part manufacturer.
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Last edited by RV6_flyer : 01-01-2010 at 04:11 PM. Reason: add link to ECI Customer Service
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  #5  
Old 01-01-2010, 05:07 PM
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lostpilot28 lostpilot28 is offline
 
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Hey fellas, after looking at this AD, isn't it the same group of serial numbers from the last AD? Looks like they just updated the inspection requirements.
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  #6  
Old 01-01-2010, 05:09 PM
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mburch mburch is offline
 
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Uh-oh, I have the "bad" cylinder head part numbers on my (not yet run) engine, so now I need to narrow down which serial number group I fall into. But where the heck are the serial numbers? Perhaps they're not visible without pulling a jug? If so, guess I'll be calling Mattituck after the weekend...

mcb
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  #7  
Old 01-01-2010, 05:14 PM
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scard scard is offline
 
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Ugh. Double bummer. I have two from "Group A", and two from "Group B". Am I reading this correctly that "Group B" should be replaced at 350hrs. (period)? No inspection cycle like Group A. We're going to do a little soul searching (and talking to the old wise ones) to figure out what we're going to do. Maybe nothing at all for a while! They haven't exploded yet. Lets see, 10 out of 18,000... I might have many other critical components with a much higher MTBF than that. Ok, the possible results aren't really something to play the numbers with, but that is exactly what this is all about.

Edit: engine builder serial number documentation not quite perfect. I have one Group B and three Group A. We ended up deciding to replace all.
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Last edited by scard : 01-07-2010 at 09:38 AM.
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  #8  
Old 01-01-2010, 05:19 PM
KirkGrovesRV8 KirkGrovesRV8 is offline
 
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Guess poor Mahlon is going get slammed on Monday
My jugs were in the group that just required a compression check and visual inspection last time, they were good matter of fact at my annual in Sept everything was mid 70's and up. SoI know my jugs are in this group guess I gotta figure out which group they fall in and take it from their
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  #9  
Old 01-01-2010, 05:25 PM
odlee odlee is offline
 
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Location: Greensboro,NC
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Default There are two serial numbers.

One for the cylinder, hard to read on a complete engine, and one for the cylinder head along the side of the cylinder head. Just inside the baffling, if you have installed the engine. Refer to page 4 of the AD.

Good luck,
David
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  #10  
Old 01-01-2010, 06:35 PM
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N941WR N941WR is offline
 
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It makes me wonder if my yet to be delivered ECi cylinders will be part of this AD. The way my rebuild is going, it wouldn't surprise me one bit.

BTW, there is a story on AOPA's web site about a guy who did a 180 and returned to land after one cylinder gave up. The picture showed the piston at TDC and the top of the cylinder missing. Makes me wonder if that was an ECi cylinder or not.
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