# SDR 2026FA0000543

- Type: Service difficulty report (as reported; unverified)
- Difficulty date: June 26, 2026
- Submitted: June 26, 2026
- Operation: General aviation
- Engine: Ge GE90115B
- System (JASC): [7230 · Turbine Engine Compressor Section](https://openairdocs.org/jasc/7230)
- Part: Guide Vane
- Part number: 3511084010
- Condition: Misinstalled
- Location: Hpc
- Stage of operation: UK
- How discovered: O
- Nature of condition: O
- Precautionary procedure: O
- FAA source: FAA Service Difficulty Reporting System (https://sdrs.faa.gov/)
- Page: https://openairdocs.org/sdr/2026FA0000543

## Discrepancy

DURING DISAS-SEMBLY, AN INCORRECTLY INSTALLED HIGH-PRESSURE COMPRESSOR (HPC) INLET GUIDE VANE (IGV) WAS IDENTIFIED ON ENGINE.  SPECIFICALLY IT WAS DISCOVERED AT THE FAN HUB FRAME EXPOSURE THAT IGV POSITION 19 WAS INSTALLED WITH ITS LEADING AND TRAILING EDGES ORIENTED 180° OPPOSITE TO THOSE OF THE OTHER IGVS IN THE FAN BOOSTER COMPRESSOR (FBC) MODULE.  FOR VARIABLE HPC STATOR VANES THIS CONDITION WOULD BE CLASSIFIED AS OFF-SCHEDULE VANE (VSV) OPERATION, AS OUT-LINED IN EM 72-00-00 INSPECTION 002, SUBTASK 72-00-00-220-089 WHILE THIS CONDITION FOR IGVS IS NOT DESCRIBED. ACCORDING TO THE REFERENCED SUBTASK, THE BLADES OF ONE STAGE FORWARD AND TWO STAGES AFT MUST BE SCRAPPED. PER RECENT OEM INQUIRIES IGV MISORIENTATION DOES NOT REQUIRE THE FORWARD (LPC STAGE) TO BE SCRAPPED.  THE AFFECTED ENGINE HAD PREVIOUSLY UNDERGONE MAINTENANCE.  INITIATED AN INTERNAL INVESTIGATION TO DETERMINE THE ROOT CAUSE AND IMPLEMENT APPROPRIATE CORRECTION.  A REVIEW OF MAINTENANCE RECORDS INDICATED THAT SIMILAR WORK WAS PERFORMED ON A TOTAL OF 29 ENGINES (2 ENGINES UNDER N-REGISTRATION ESN: 901500 AND 906440 ). ALL OF THESE ENGINES UNDERWENT MAINTENANCE ON THE FBC MODULE OR PROPULSOR, WHICH INCLUDED THE REPLACEMENT OF THE VSV PIN BUSHINGS. THIS WORK SCOPE NECESSITATES THE REMOVAL OF EACH INDIVIDUAL IGV LEVER ARM, ALLOWING THE IGVS TO MOVE FREELY ALONG THEIR AXES. CONSEQUENTLY, THE CHANGE IN ORIENTATION MAY GO UNDETECTED PRIOR TO THE REINSTALLATION OF THE LEVER ARM, POTENTIAL-LY LEADING TO MISALIGNMENT. BASED ON THE MAINTENANCE RECORDS, IT CANNOT BE RULED OUT THAT INDIVIDUAL IGVS RE-MAINED IN INCORRECTLY INSTALLED POSITION IN THE POTENTIALLY AFFECTED ENGINE POPULATION.  REACHED OUT TO THE ORIGINAL EQUIPMENT MANUFACTURER (OEM) FOR TECHNICAL SUPPORT. THE OEM HAS STATED THAT AN INSPECTION SHALL TAKE PLACE ON THE NEXT OPPORTUNITY AND THE ENGINE CANNOT CONTINUE TO OPERATE AFTER DETECTION OF AN INCORRECTLY INSTALLED IGV.  IN THE EVENT THAT AN INCORRECTLY INSTALLED IGV IS IDENTIFIED, THE AFFECTED HARDWARE MIGHT BE MANAGED IN ACCORD-ANCE WITH EM 72-00-00 INSPECTION 002, SUBTASK 72-00-00-220-089. ACCORDING TO THIS SUBTASK, THE LPC STAGE 5, HPC BLISK STAGE 1, AND HPC BLADES STAGE 2 SHALL BE REPLACED BEFORE ANY FURTHER OPERATION CAN TAKE PLACE.  AS OUTLINED IN GE CASE #02094147 FOR ESN 906603, #02028374 FOR ESN 906607 (BOTH CASES INITIATED BY MTU-H), AND #02382854-B FOR ESN 907411 (INITIATED BY HAECO), ONLY THE HPC BLISK STAGE 1 AND HPC BLADES STAGE 2, AS WELL AS THE IMPACTED IGVS WITH LEVER ARMS AND ASSOCIATED HARDWARE, ALONG WITH BOTH ADJACENT IGVS (RIGHT AND LEFT) OF THE REVERSED IGV WITH LEVER ARMS AND ASSOCIATED HARDWARE, MUST BE DISCARDED REGARDLESS OF THEIR VISUAL CONDITION.   CONTINUE TO COLLABORATE WITH THE OEM IN THIS MATTER.
THIS INCIDENT WAS DOCUMENTED UNDER THE "MALFUNCTION OR DEFECT REPORT" CATEGORY, AS ACCESS TO THE "AIR CARRIERS, AIR OPERATORS, AND REPAIR STATIONS REPORTING" SYSTEM WAS UNAVAILABLE AT THE TIME OF THE REPORT, WITH FAILURE CODE LG22.

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