Airworthiness Directive

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EASA AD No.: 2023-0163 TE.CAP.00110-011 © European Union Aviation Safety Agency. All rights reserved. ISO9001 Certified. Proprietary document. Copies are not controlled. Confirm revision status through the EASA-Internet/Intranet. An agency of the European Union Page 1 of 4 Airworthiness Directive AD No.: 2023-0163 Issued: 18 August 2023 Note: This Airworthiness Directive (AD) is issued by EASA, acting in accordance with Regulation (EU) 2018/1139 on behalf of the European Union, its Member States and of the European third countries that participate in the activities of EASA under Article 129 of that Regulation. This AD is issued in accordance with Regulation (EU) 748/2012, Part 21.A.3B. In accordance with Regulation (EU) 1321/2014 Annex I Part M.A.301, or Annex Vb Part ML.A.301, as applicable, the continuing airworthiness of an aircraft shall be ensured by accomplishing any applicable ADs. Consequently, no person may operate an aircraft to which an AD applies, except in accordance with the requirements of that AD, unless otherwise specified by the Agency [Regulation (EU) 1321/2014 Annex I Part M.A.303, or Annex Vb Part ML.A.303, as applicable] or agreed with the Authority of the State of Registry [Regulation (EU) 2018/1139, Article 71 exemption]. Design Approval Holder’s Name: AUSTRO ENGINE GmbH Type/Model designation(s): E4 and E4P engines Effective Date: 01 September 2023 TCDS Number(s): EASA.E.200 Foreign AD: Not applicable Supersedure: This AD supersedes EASA AD 2022-0240R1 dated 15 December 2022. ATA 72 – Engine – Pistons – Oil Analysis / Replacement Manufacturer(s): Austro Engine GmbH Applicability: Model E4 and E4P engines, all serial numbers (s/n) listed in Table 1, 2, 3 and 4 of the Mandatory Service Bulletin (MSB), as defined in this AD. These engines are known to be installed on, but not limited to, Diamond Aircraft Industries DA 40 NG, DA 42 NG, DA 42 M-NG and DA 62 aeroplanes. Definitions: For the purpose of this AD, the following definitions apply: The MSB: Austro Engine MSB MSB-E4-039 Revision 2. Groups: Group 1 engines are those having an s/n listed in Table 1 of the MSB. Group 2 engines are those having an s/n listed in Table 2 of the MSB. Group 3 engines are those having an s/n listed in Table 3 of the MSB. Group 4 engines are those having an s/n listed in Table 4 of the MSB. EASA AD No.: 2023-0163 TE.CAP.00110-011 © European Union Aviation Safety Agency. All rights reserved. ISO9001 Certified. Proprietary document. Copies are not controlled. Confirm revision status through the EASA-Internet/Intranet. An agency of the European Union Page 2 of 4 Group 1 and Group 3 engines are model E4 engines in “-A” configuration (installed on single engine aeroplanes). Group 2 and Group 4 engines are model E4 engines in “-B” or “-C” configuration, and all model E4P engines (installed on twin-engine aeroplanes). Reason: Occurrences were reported of piston failures on E4 and E4P engines. Subsequent investigation determined that certain batches of pistons were manufactured with dimensional deviations in the piston pin bore and in the piston diameter. This condition, if not detected and corrected, could lead to piston failure, with consequent oil loss and engine power loss, possibly resulting in reduced control of the aeroplane and (for single engine aeroplanes) in an emergency landing, possibly resulting in damage to the aeroplane and injury to occupants. To address this potential unsafe condition, Austro Engine published MSB-E4-039 (at original issue) to provide instructions for oil analysis and parts replacement. Consequently, EASA issued AD 2022- 0240 to require repetitive oil analyses and replacement of certain engine parts or, as an alternative, replacement of the complete engine core. That AD also prohibited release to service of an affected engine until receipt of the result of each oil analysis and, depending on findings, accomplishment of applicable corrective action(s). After that AD was issued, it was determined that high aluminium levels, above the limit, would only be found during the first oil analysis and unlikely to be found during subsequent oil analyses. Consequently, EASA revised AD 2022-0240 to allow release to service of the engine after the second and subsequent oil analyses for a limited number of flight hours (FH), depending on the defined Group to which the engine belongs; after the first oil analysis still the analysis result must be completed before an engine could be released to service. That revised AD also provided more precise information on the replacement of parts. Since AD 2022-0240R1 was issued, Austro Engine identified errors in the lists of affected engines (s/n) in the published MSB (Revision 1) and issued the MSB, as defined in this AD, to add the s/n of additional affected engines and to remove the s/n of several non-affected engines. For the reason described above, this AD retains the requirements of EASA AD 2022-0240R1, which is superseded, and amends the applicability, in accordance with the updated tables with s/n of affected engines in the MSB. Required Action(s) and Compliance Time(s): Required as indicated, unless accomplished previously: Oil Analysis: (1) Within the compliance time and, thereafter, at intervals as specified in Table 1 of this AD, as applicable, accomplish an oil analysis in accordance with the instructions of the MSB (see Note 1 of this AD). EASA AD No.: 2023-0163 TE.CAP.00110-011 © European Union Aviation Safety Agency. All rights reserved. ISO9001 Certified. Proprietary document. Copies are not controlled. Confirm revision status through the EASA-Internet/Intranet. An agency of the European Union Page 3 of 4 Table 1 – Oil Analysis Engine Groups Compliance Time (after 20 December 2022 [the effective date of AD 2022-0240R1]) Interval 1 and 3 Within 15 FH 50 FH 2 and 4 Within 25 FH 100 FH Note 1: Following the first oil analysis as required by paragraph (1) of this AD, the engine may be