21 May – 19 June 2019

503
Failure of attachment lugs on crankshaft seal/cover. DR 611953748
PISTON
LYCOMING IO540 K1A5 – ATA 7322 FUEL CONTROL/RECIPROCATING ENGINES – FCU – Off schedule. DR 611953700
Engine stopped before take-off when engine was in idle. Fuel control unit replaced, idle mixture and RPM adjusted, full power run and idle check carried out – all parameters within limits and the aircraft released to service.
A strip report will be requested when sent for test/repair.
CONTINENTAL GTSIO520 M – ATA 8520 RECIPROCATING ENGINE POWER SECTION – PISTON ENGINE – CONTAM-METAL. DR 611953730
RH engine reported as rough running for about 5 minutes during climb to 4000 ft.

Engineers inspected engine and found visible pre-ignition damage to piston #2 and metal in oil system.
Causes of the damage are yet to be identified. Engine has been removed. Investigation is continuing.

Engine is operating in extension period and due for overhaul in 50 hours’ time.
Last cylinder compression check, carried out 24.5 flight hours before event showed compression for # 2 Cylinder at 65 psi (Ref 48 psi)

CONTINENTAL TSIO520 VB – ATA 8520 RECIPROCATING ENGINE POWER SECTION – PISTON – HOLED. DR 611953731
Right-hand engine position lost power caused by a hole, burnt through # 5 piston.
The cause of the hole burn through is yet to be identified.Engine is in extension period and due for overhaul in 68.9 Hours.Last cylinder compression check carried out at 41.7 flight hours, before failure, recorded a reading of 70 psi (Ref 48 PSI) for this cylinder.
LYCOMING TIO540 J2BD – ATA 8550 RECIPROCATING ENGINE INTERNAL OIL SYSTEM – PISTON ENGINE – CONTAM-METAL. DR 611953735
Excessive metal found in filter at annual check. Lycoming Service Bulletin 480 refers to limits.
Last filter change about 6 hrs ago. Engine removed and forwarded to overhaul shop for strip-down underway.
CONTINENTAL TSIO520 VB – ATA 8120 EXHAUST TURBOCHARGER – Wastegate – UNSERVICEABLE. DR 611953745
Left engine manifold pressure does not increase above 29” in cruise (9000’ @ full throttle).

Wastegate was replaced with a serviceable assembly. Borescope inspection carried out on all cylinders with no defect found. Moreover, turbo inlet to throttle body coupling found in poor condition, replaced with a new item. Cylinder #6 failed compression test leaking past exhaust valve. Exhaust valve removed, cleaned, valve seat re-cut and re-installed. Engine found satisfactory.

LYCOMING IO540 AB1A5 – ATA 8550 RECIPROCATING ENGINE INTERNAL OIL SYSTEM – PRESSURE SWITCH – LEAKING. DR 611953746
Oil pressure switch found leaking after 930.2 hours TIS, when inspecting as per recommendation in FAA Special Airworthiness Information Bulletin CE-19-01.

Aircraft grounded and will have a new switch installed before enter service again. The issue is already known so we have incorporated an inspection in accordance with this SAIB until FAA issues some resolution.

Austro E4-A – ATA 8520 RECIPROCATING ENGINE POWER SECTION – LUG – CRACKED. DR 611953748
Failure of attachment lugs on crankshaft seal/cover. Replaced with new item.
LYCOMING IO540 AE1A5 – ATA 7414 MAGNETO/DISTRIBUTOR – BEARING – FAILED. DR 611953750
On carrying out 100 hourly inspection, metal noticed on oil screen.

Root cause: Left-hand magneto bearing PN 67542 had disintegrated with several ball bearings coming out with the magneto drive.

Engine removed to be sent for repair.

LYCOMING O320 B2C – ATA 8520 RECIPROCATING ENGINE POWER SECTION – EXHAUST VALVE – LEAKING. DR 611953759
Leak down test results below 40/80 psi.
Root cause: Worn exhaust guides causing valve and valve seat damage.
Both # 3- and # 4-cylinder assemblies replaced.
LYCOMING IO540 AE1A5 – ATA 8520 RECIPROCATING ENGINE POWER SECTION   – INLET VALVE – DAMAGED. DR 611953767
Sudden vibration felt after about 15 minutes in cruise, no other abnormal indications. Forced landing carried out in cricket oval, no injuries reported.

 

 

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