A319
Maintenance Airframe; Maintenance Powerplant
Communication Breakdown
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Published Material / Policy
General Maintenance Action
Chart Or Publication; Human Factors; Manuals; Procedure
January 2012; a Boroscope Inspection was performed on an A319 aircraft #1 Engine. Job card was used to accomplish this task. All steps of the job card were accomplished and the aircraft was returned to service. I was the Inspector and Mr. X was the Mechanic. A flight crew discrepancy in ZZZ1 found oil leaking from under #1 engine cowling; five quarts in a 50-minute flight. I was made aware of this the following morning by phone from ZZZ2 Maintenance. Apparent mis-installation of drive pad cover. Job card details installation of the Drive Pad cover as follows: Step 10. INSTALL N2 ROTATION PAD COVER. A. Work Accomplishment Instructions: (1) If used; remove tool from pad. Position pad cover and two new O-rings and secure with bolts lightly coated with graphite grease. Torque 97-106 LB/inches; [then] lockwire. This step is a Mechanic's only stamp [sign-off]. Furthermore; Step 14 reads: ENSURE ALL BORESCOPE PORT PLUGS; IGNITER PLUGS AND THE N2 ROTATION PAD COVER ARE INSTALLED. This is a Mechanic's [item] and 'checked by' stamp. When called to accomplish Step-14; I did not notice that the drive pad cover was not properly installed. I looked at it from both the front (looking aft) and side (looking inboard). The cover did not look cocked and I did not see any evidence of extruded o-ring; or any other condition that would have led me to believe that the drive pad cover was mis-installed. ZZZ2 Maintenance was dispatched to ZZZ1; where it was noted that the drive pad cover was not properly installed. The drive pad cover was reinstalled and leak checked per Maintenance Manual (M/M) 72-63-00. I have reviewed the job card and the Maintenance Manual (M/M) 72-63-00-400 and would like to point out that the M/M requires a leak check after installation of the drive pad; whereas the job card does not. The Practices and Procedures Manual (PPM) Section describes in detail the job cards purpose. In part; I would like to point out [that] these job cards are developed directly from approved Maintenance and Inspection data and are to be used for compliance of the task they cover [for] efficiency and prevention of errors. I feel in this case; that the requirement from the M/M to do a minimum idle check (71-00-00-400) and [to] do a check for leaks during the visual inspection of the oil system (79-00-00-210); would have detected the oil leak and would have prevented an unsafe condition. Furthermore; I requested a submittal of an Engineering Request to initiate a correction that reflects the M/M leak check requirement.
January 2012; I was involved with a Borescope Inspection on the left engine of an A319 aircraft. Approximately twelve days later; it was brought to my attention that the N2 rotation pad cover that I installed was installed incorrectly. On the date of the Borescope inspection; I installed the N2 rotation pad cover as per Job Card.
A Mechanic and Inspector report a five quart oil leak from the left engine; N2 rotation drive pad cover of an A319 aircraft; after they had completed a Boroscope inspection.