EASA AD No.

: 2017-0090

Airworthiness Directive
AD No.: 2017-0090
Issued: 17 May 2017
Note: This Airworthiness Directive (AD) is issued by EASA, acting in accordance with Regulation
(EC) 216/2008 on behalf of the European Union, its Member States and of the European third
countries that participate in the activities of EASA under Article 66 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, 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 agreed with the Authority of the State of Registry [Regulation (EC) 216/2008, Article 14(4) exemption].

Design Approval Holder’s Name: Type/Model designation(s):

DIAMOND AIRCRAFT INDUSTRIES GmbH DA 42 and DA 42 M aeroplanes

Effective Date: 31 May 2017

TCDS Number(s): EASA.A.005 and EASA.A.513
Foreign AD: Not applicable
Supersedure: This AD supersedes EASA AD 2016-0156R1 dated 23 November 2016.

ATA 78 – Engine Exhaust – Exhaust Pipes – Modification / Inspection

Manufacturer(s):
Diamond Aircraft Industries GmbH (Austria), Diamond Aircraft Industries Inc. (Canada)

Applicability:
DA 42 and DA 42 M (both Normal and Restricted category) aeroplanes, manufacturer serial
numbers 42.004 to 42.427 inclusive, 42.AC001 to 42.AC151 inclusive, 42.M001 to 42.M027
inclusive, if equipped with TAE 125-02-99 engines (modification MÄM 42-198 or Optional Service
Bulletin (OSB) 42-046) or TAE 125-02-114 engines (modification OÄM 42-252 or OSB 42-107).

Reason:
Two cases were reported of uncommanded engine in-flight shutdown (IFSD) on DA 42 aeroplanes.
Subsequent investigations identified that these occurrences were due to failure of the propeller
regulating valve, caused by hot exhaust gases coming from fractured engine exhaust pipes. The
initiating cracks on the exhaust pipes were not detected during previous inspections, since those
exhaust pipes are equipped with non-removable heat shields that do not allow inspection for
certain sections of the exhaust pipe.

This condition, if not corrected, could lead to further cases of IFSD or overheat damage, possibly
resulting in a forced landing, with consequent damage to the aeroplane and injury to occupants.

To address this potential unsafe condition, Diamond Aircraft Industries (DAI) developed an exhaust
pipe without a directly attached integral heat shield that allows visual inspection over the entire

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exhaust pipe length. DAI issued Mandatory Service Bulletin (MSB) 42-120 and relevant Working
Instruction (WI) WI-MSB 42-120, providing instructions to install the modified exhaust pipes. As an
interim measure, an additional bracket was designed to hold the exhaust pipe in place in case of a
pipe fracture. EASA issued AD 2016-0156 (later revised), requiring replacement of the exhaust pipes
with pipes having the new design, or installation of the additional brackets.

Since EASA AD 2016-0156R1 was issued, cracks were found during inspection on modified exhaust
pipes. Further investigation determined that, with the modified exhaust pipe design, vibration leads
to cracking.

To address this potential unsafe condition, DAI published MSB 42-129 providing instructions for
inspection of modified exhaust pipes.

For the reasons described above, this AD retains the requirements of EASA AD 2016-0156R1, which
is superseded, and requires repetitive inspections of modified exhaust pipes and, depending on
findings, repair or replacement. This AD is considered interim action and further AD action may
follow upon availability of an improved exaust pipe design.

Required Action(s) and Compliance Time(s):

Required as indicated, unless accomplished previously:

Re-statement of the requirements of EASA AD 2016-0156R1:

Note 1: DAI Part Number (P/N) D60-9078-06-01, Technify P/N 52-7810-H0001 02, Technify
P/N 52-7810-H0001 03, and Technify P/N 52-7810-H0001 04 exhaust pipes are herafter
collectively reffered to as “affected exhaust pipe” in this AD.

Note 2: The modification specified in paragraph (1) of this AD is required for aeroplanes having the
original exhaust pipe installed.

Modification(s):
(1) Within the compliance time as identified in Table 1 of this AD, accomplish the actions as
required by paragraph (1.1) or (1.2) of this AD.

(1.1) Install additional brackets on each affected exhaust pipe in accordance with the
instructions of Section III.2 of DAI WI-MSB 42-120.

(1.2) Replace each affected exhaust pipe with a modified exhaust pipe and modify the
aeroplane by installing heat shielding in accordance with the instructions of Section III.1
of DAI WI-MSB 42-120.

Table 1 – Brackets Installation / Exhaust Pipe Replacement (see Note 3 of this AD)
FH Accumulated Compliance Time
1 300 FH or less Before the exhaust pipe exceeds 1 500 FH
Within 200 FH or 12 months, whichever occurs first
More than 1 300 FH
after 16 August 2016

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Note 3: Unless specified otherwise, the FH in Table 1 of this AD are those accumulated on
16 August 2016 [the effective date of the original issue of EASA AD 2016-0156] since first
installation of an affected exhaust pipe. If those FH are not known, the total time accumulated
by the aeroplane since its first flight applies instead.

New requirements of this AD:

Note 4: DAI P/N D60-9078-06-01_01 and Technify P/N 52-7810-H0014 01 exhaust pipes are
hereafter collectively referred to as “modified exhaust pipe” in this AD.

Note 5: The inspection specified in paragraph (2) of this AD is required for aeroplanes which have
been modified in accordance with Section III.1 of DAI MSB 42-120 (installation of modified exhaust
pipe and heat shielding). No action is required for aeroplanes which have been modified in
accordance with Section III.2 of DAI MSB 42-120 (installation of additional brackets).

Inspection(s):
(2) Within the compliance time as identified in Table 2 of this AD and, thereafter, at intervals not
to exceed 50 FH, inspect each modified exhaust pipe in accordance with the instructions of
DAI MSB 42-129.

Table 2 – Initial Inspection of Modified Exhaust Pipes (see Note 6 of this AD)
FH Accumulated Compliance Time
40 FH or more Within 10 FH after the effective date of this AD
Less than 40 FH Before the exhaust pipe exceeds 50 FH

Note 6: For the purpose of this AD, the FH in Table 2 of this AD are those accumulated since
installation of modified exhaust pipes on an aeroplane as specified in paragraph (1.2) of this AD.

Corrective Action(s):
(3) If, during any inspection as required by paragraph (2) of this AD, any cracks are found on a
modified exhaust pipe, before next flight, repair the exhaust pipe or replace it with a new
exhaust pipe in accordance with the instructions of DAI MSB 42-129.

Terminating Action:
(4) None.

Ref. Publications:
DAI MSB 42-120 original issue, dated 24 June 2016, or revision 01, dated 10 November 2016.

DAI WI-MSB 42-120 original issue, dated 24 June 2016.

DAI MSB 42-129 original issue, dated 17 May 2017.

The use of later approved revisions of these documents is acceptable for compliance with the
requirements of this AD.

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Remarks:
1. If requested and appropriately substantiated, EASA can approve Alternative Methods of
Compliance for this AD.

2. Based on the required actions and the compliance time, EASA have decided to issue a Final AD
with Request for Comments, postponing the public consultation process until after publication.

3. Enquiries regarding this AD should be referred to the EASA Safety Information Section,
Certification Directorate. E-mail: ADs@easa.europa.eu.

4. For any question concerning the technical content of the requirements in this AD, please
contact: Diamond Aircraft Industries GmbH, Austria.
Telephone +43 2622 26700, Fax +43 2622 26780,
E-mail: airworthiness@diamond-air.at.

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