Narrative:

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 pound/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.

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Original NASA ASRS Text

Title: 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.

Narrative: 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.

Data retrieved from NASA's ASRS site as of July 2013 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.