{"id":"F2008L01387","name":"AD/TURBO/2 - Kelly Aerospace Turbochargers","slug":"ad-turbo-2-kelly-aerospace-turbochargers","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":73641,"registerId":"commonwealth-F2008L01387-current","compilationNumber":null,"startDate":"2026-04-02","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"Turbochargers","sectionType":"division","heading":"Turbochargers","content":"### Turbochargers\n\n| AD/TURBO/2 | Kelly Aerospace Turbochargers | 7/2008 TX |\n| ---------- | ----------------------------- | --------- |\n\n| Applicability: | This Directive applies to the following turbochargers:1. Kelly Aerospace Power Systems (KAPS) turbochargers, part number (P/N) 409170-0001 (Lycoming P/N LW-12463), installed on Lycoming Engines (L)TIO-540-J2B and (L)TIO-540-J2BD engines:(a) With the engine serial numbers (SNs) listed in Table 1 of Lycoming Engines Mandatory Service Bulletin (MSB) No. 580, dated 15 February 2008; and(b) With the turbocharger SNs listed in KAPS MSB No. 029, dated1 February 2008.Note 1: Lycoming Engines (L)TIO-540-J2B and (L)TIO-540-J2BD engines are installed on, but not limited to, Piper PA31-350 Navajo Chieftain, Piper T1020 airplanes, and Colemill Panther conversion airplanes using a 350 horsepower engine.2. KAPS turbochargers, P/N 465930-0003 (Teledyne Continental Motors (TCM) P/N 641672-3), installed on TCM GTSIO-520-L and GTSIO-520-N engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated1 April 2008.3. KAPS turbochargers, P/N 466412-0003 (TCM P/N 652964), installed on TCM TSIOL-550-A and TSIOL-550-C engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008.4. KAPS turbochargers, P/N 466412-0004, installed on RAM modifications only, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated1 April 2008.5. KAPS turbochargers, P/N 466412-0003 (TCM P/N 652964), installed on Cessna 414 airplanes with a TCM TSIOL-550-A or TSIOL- 550-C engine (Supplemental Type Certificate (STC) SA7633SW), with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008.6. KAPS turbochargers, P/N 465930-0003 (TCM P/N 641672-3), installed on Cessna 421 Golden Eagle airplanes with a TCM GTSIO-520-L or GTSIO-520-N engine with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008. |\n| -------------- | ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| | 7. KAPS turbochargers, P/N 465680-0004 (Cessna P/N C295001- 0202), installed on TCM TSIO-520-AF or TSIO-520-P engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008.8. KAPS turbochargers, P/N 465930-0002 (TCM P/N 641672-2), installed on TCM GTSIO-520-M engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008.9. KAPS turbochargers, P/N 465680-0004 (Cessna P/N C295001- 0202), installed on Cessna P210 Pressurized Centurion airplanes with a TCM TSIO-520-AF or TSIO-520-P engine, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008.10. KAPS turbochargers, P/N 465930-0002 (TCM P/N 641672-2), installed on Cessna 404 Titan airplanes with a TCM GTSIO-520-M engine, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated 1 April 2008.11. KAPS overhauled turbochargers, P/N 465930-9003, installed on TCMGTSIO-520-L or GTSIO-520-N engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated 28 February 2008.12. KAPS overhauled turbochargers, P/N 409170-9001, installed on Lycoming Engines TIO-540-J2B; TIO-540-J2BD; TIO-540-N2BD, and LTIO-540-N2BD engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated28 February 2008.13. KAPS overhauled turbochargers, P/N 465680-9005, installed on Lycoming Engines TIO-540-V2AD and TIO-540-W2A engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated 28 February 2008.14. KAPS overhauled turbochargers, P/N 465930-9002, installed on TCMGTSIO-520-M engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated 28 February 2008.15. Also, the following KAPS turbochargers might have been overhauled or repaired by other than KAPS, that used a P/N 441977- 0023S or P/N 441977-0025S turbine housing sold as a spare part, through the Aviall Company. These turbine housings have the date code of 1006 and might have been installed between October 2006 and 25 January 2008. The turbocharger data plates might include manufacturer's information other than KAPS information, such as, Garrett:(a) P/N 409170-0001; installed on Lycoming Engines TIO-540-J2B;TIO-540-J2BD; TIO-540-N2BD; and LTIO versions of the noted engine models.(b) P/N 465680-0004; installed on TCM TSIO-520-AF and TSIO-520P engines. |\n\n| | (c) P/N 465680-0005; installed on Lycoming Engines TIO-540-V2AD andTIO-540-W2A engines.(d) P/N 465930-0002; installed on TCM GTSIO-520-M engines.(e) P/N 465930-0003; installed on TCM GTSIO-520-L and GTSIO-520-N engines.(f) P/N 465448-0004; installed on TCM TSIO-520-CE engines.(g) P/N 466412-0003; installed on TCM TSIOL-550-A and TSIOL-550-C engines.(h) P/N 466412-0004; installed on engines modified by RAM. |\n| ------------ | --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| Requirement: | Onetime Visual Inspection of Turbocharger1. Carefully remove the \"V'' band clamp from around the turbocharger turbine housing at the turbocharger exhaust outlet, taking care not to move the exhaust tube and tailpipe assembly.2. Visually inspect the area that was captured by the \"V'' band clamp. Use a feeler gauge at the split line between the turbine housing flange and the exhaust tube flange all around the circumference.3. The maximum gap must not exceed 0.005 inch.4. Replace any turbocharger that exceeds the 0.005 inch maximum gap, with a serviceable turbocharger.5. If the maximum gap is not exceeded, metal stamp a 1/8'' upper case \"I'' on the side of the turbocharger discharge flange. Information on the stamping location can be found in the MSBs referenced in this Directive.Definition: For the purpose of this Directive, a serviceable turbocharger is one that is not listed in the suspect SN lists of the Lycoming Engines MSB or KAPS MSBs referenced in this Directive, or one that passes the visual inspection in this Directive.Note 2: FAA AD 2008-08-17 dated 10 April 2008 refers. |\n| Compliance: | For Requirements 1, 2, 3 and 5: Within 10 hours time-in-service or at the next regular inspection interval, after the effective date of this Directive, whichever occurs first, unless previously accomplished.For Requirement 4: Before further flight. |\n| | This Airworthiness Directive becomes effective on 13 May 2008. |\n\n| Background: | This Directive results from two reports of exhaust leakage occurring between the turbocharger turbine housing flange and the exhaust tube flange due to machining defects of the turbocharger turbine housing flange. The issuing of this Directive is intended to prevent hazardous amounts of carbon monoxide from entering the cabin, an increase in under-cowl temperatures hampering engine and accessory function, and loss of tailpipe retention, which could lead to an in-flight fire and loss of control of the aeroplane. |\n| ----------- | ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ |\n\n![](image.001.png) \nJames Coyne \nDelegate of the Civil Aviation Safety Authority\n\n8 May 2008","sortOrder":0},{"sectionNumber":"AD/TURBO/2","sectionType":"part","heading":"AD/TURBO/2","content":"## AD/TURBO/2","sortOrder":1},{"sectionNumber":"Kelly Aerospace Turbochargers","sectionType":"part","heading":"Kelly Aerospace Turbochargers","content":"## Kelly Aerospace Turbochargers","sortOrder":2},{"sectionNumber":"7/2008 TX","sectionType":"part","heading":"7/2008 TX","content":"## 7/2008 TX","sortOrder":3}],"analysis":{"flash_summary_failed":{"failed":true,"reason":"Unauthenticated. Configure AI_GATEWAY_API_KEY or use a provider module. Learn more: https://ai-sdk.dev/unauthenticated-ai-gateway","source":"analysis-cron"},"flash_summary":{"complexity_score":5,"scope_assessment":{"changed":false,"description":"The Directive addresses exhaust leakage from machining defects by requiring a one‑time inspection and replacement where necessary for the listed turbochargers. The text does not indicate any change from that original safety scope; it limits application to specific P/Ns and SNs referenced in the named MSBs and prescribes inspection, replacement, and marking requirements."},"complexity_factors":["Extensive applicability table: many part numbers, engine types and serial‑number lists cross‑referenced to multiple manufacturer Service Bulletins (MSBs)","Precise technical requirement (0.005 inch maximum gap) requiring calibrated feeler gauge and skilled inspection","Immediate operational constraint: replacement required before further flight if out of tolerance","Short compliance window: within 10 hours time‑in‑service or next regular inspection","Multiple possible supply/maintenance pathways (overhauled, repaired by third parties, OEM vs aftermarket housings) affecting traceability","Stamping requirement to record compliance (practical implications for maintenance records and physical marking)"],"plain_english_summary":"This Directive requires a one‑time visual inspection of specified Kelly Aerospace (KAPS) turbochargers (identified by part numbers and serial numbers in referenced service bulletins). Technicians must remove the V‑band clamp, measure the turbine‑housing-to-exhaust‑tube flange gap with a feeler gauge, replace any turbocharger with a gap over 0.005 inch before further flight, or metal‑stamp passing units.\n\nIt applies to owners/operators and maintenance personnel of affected aircraft; compliance creates inspection and possible replacement costs and aims to prevent exhaust leakage, carbon monoxide ingress, overheating and tailpipe loss."},"kimi_summary":{"content_quality":"ok","complexity_score":6,"scope_assessment":{"changed":false,"description":"This appears to be the original issuance of AD/TURBO/2. The scope is appropriately targeted at the specific safety defect identified (machining defects in turbine housings) and does not appear to have expanded beyond the original safety purpose. The 15 applicability categories represent thorough coverage of affected populations rather than scope creep."},"complexity_factors":["15 separate applicability categories with overlapping part numbers and serial number ranges","Extensive cross-referencing to external documents (Lycoming MSB No. 580, KAPS MSB Nos. 029, 030, 031) without reproducing their contents","Complex conditional logic: different rules for new vs overhauled vs third-party repaired turbochargers","Nested definitions: 'serviceable turbocharger' is defined by exclusion from suspect serial number lists OR passing the visual inspection","Dual compliance timelines with conditional triggers ('whichever occurs first')","Multiple manufacturer part number equivalencies (KAPS P/N vs Lycoming P/N vs TCM P/N vs Cessna P/N)","Geographic/chain-of-custody complexity: covers not just original equipment but also parts sold through Aviall Company that may have been installed by non-KAPS repair stations"],"plain_english_summary":"This CASA Airworthiness Directive requires owners/operators of aircraft fitted with certain Kelly Aerospace turbochargers to perform a one‑time visual inspection (within 10 flight hours or at next maintenance) for machining‑caused gaps at the exhaust flange. Leaking exhaust can cause carbon monoxide poisoning, engine overheating or in‑flight fire. If the gap exceeds 0.005\" the turbocharger must be replaced before further flight; inspected units must be marked as compliant."}},"importantCases":[],"_links":{"self":"/api/acts/ad-turbo-2-kelly-aerospace-turbochargers","history":"/api/acts/ad-turbo-2-kelly-aerospace-turbochargers/history","analysis":"/api/acts/ad-turbo-2-kelly-aerospace-turbochargers/analysis","conflicts":"/api/acts/ad-turbo-2-kelly-aerospace-turbochargers/conflicts","importantCases":"/api/acts/ad-turbo-2-kelly-aerospace-turbochargers/important-cases","documents":"/api/acts/ad-turbo-2-kelly-aerospace-turbochargers/documents"}}