AD 2020-25-04

(1) Within 7,500 engine flight hours (FHs) since new or since the last inspection or within 150 flight cycles (FCs) after January 5, 2017 (the effective date of AD 2016-24-08), whichever occurs later, inspect the engine upper bifurcation nose fairing assembly for cracks or missing material. Use paragraph (g)(3) of this AD to perform the inspection.

(2) Repeat the inspection required by paragraph (g)(1) of this AD within every 7,500 engine FHs since the last inspection.

(3) Inspect the engine upper bifurcation nose fairing assembly as follows.

Note 1 to Paragraph (g)(3): Figure 1 of Rolls-Royce plc (RR) Alert Non-Modification Service Bulletin (NMSB) RB.211-72-AJ165, Revision 2, dated August 21, 2018, provides guidance on the engine upper bifurcation nose fairing assembly inspection locations.

(i) Visually inspect upper bifurcation fairing seal face 22, seal support 23, and Zone A for any cracks or material loss on the right side.

(A) If fairing seal face 22 is found to have released material, repair or replace the fairing before further flight.

(B) If there is a single crack found on fairing seal face 22, shorter than 6 mm, repair or replace the fairing within 100 engine FCs, or at the next engine shop visit, whichever occurs first.

(C) If there is a single crack, longer than 6 mm, found on fairing seal face 22, repair or replace the fairing within 15 engine FCs or at the next engine shop visit, whichever occurs first.

(D) If there are two or more cracks found on fairing seal face 22, replace the fairing within 15 engine FCs or at the next engine shop visit, whichever occurs first.

(E) If there is any cracking or material loss found on seal support 23, replace the fairing within 15 engine FCs or at the next engine shop visit, whichever occurs first.

(ii) If the visual inspection required by paragraph (g)(3)(i) of this AD does not detect any cracks, fluorescent penetrant inspect Zone A.

(A) If a crack shorter than 6 mm is detected, repair or replace the fairing within 100 engine FCs, or at the next engine shop visit, whichever occurs first.

(B) If a crack longer than 6 mm is detected, repair or replace the fairing within 15 engine FCs or at the next engine shop visit, whichever occurs first.

Note 2 to Paragraph (g)(3)(ii): AMM TASK 70-20-02, Water Washable Fluorescent Penetrant Inspection (Maintenance Process 213), and OMat 632, high sensitivity fluorescent penetrant inspection, provides guidance on performing a fluorescent penetrant inspection.

As a mandatory terminating action to the inspections of the engine upper bifurcation nose fairing assembly required by paragraph (g) of this AD, perform one of the following:

(1) At the next engine shop visit after the effective date of this AD, modify the engine upper bifurcation nose fairing assembly in accordance with the Accomplishment Instructions, paragraph 3.C., of RR Service Bulletin (SB) RB.211-72-J803, Revision 2, dated April 1, 2019; paragraph 3.B., Revision 1, dated July 13, 2018; or paragraph 3.B., Original Issue, dated December 7, 2017; or

(2) Before the next engine shop visit after the effective date of this AD, modify the engine upper bifurcation nose fairing assembly in accordance with the Accomplishment Instructions, paragraph 3.D., of RR SB RB.211-72-J803, Revision 2, dated April 1, 2019.

For the purpose of this AD, an “engine shop visit” is defined as the induction of an engine into the shop for maintenance involving the separation of pairs of major mating engine flanges, except that the separation of engine flanges solely for the purposes of transportation without subsequent engine maintenance does not constitute an engine shop visit.