205/​207Skywagon · Stationair 7 & 8

Parts most often named Cylinder (42) · Cylinder Head (33) · Pushrod (4) · Valve (3)

DURING 100HR INSPECTION BORESCOPING ENG, FOUND THE NR 1 CYLINDER CRACKED FROM LOWER SPARK PLUG BOSS APPROX 1/2 INCH TOWARDS EXHAUST VLV SEAT.

DURING 100 HR INSPECTION BORESCOPING ENG, FOUND NR 2 CYLINDER CRACKED FROM LOWER SPARK PLUG BOSS APPROX 1/2 INCH TOWARDS EXHAUST VLV SEAT.

DURING 100 HR INSPECTION BORESCOPING ENG, FOUND NR 1 CYLINDER CRACKED FROM LOWER SPARK PLUG BOSS APPROX 1/2 INCH TOWARDS EXHAUST VLV SEAT.

Parts most often named Magneto (11) · Impulse Coupling (3) · Distributor Gear (1) · Rotor (1)

DURING CRUISE PILOT NOTICED RPM LOSS & VIBRATION FROM THE ENG. ACFT RETURNED & LANDED SAFELY WITHOUT INCIDENCE. INSPECTED ENG & REPLACED BOTH MAGNETOS & ALL SPARK PLUGS.

DURING FLIGHT, PILOT NOTICED ENG TO BE RUNNING ROUGH, PILOT ELECTED TO RETURN TO POINT OF DEPARTURE FOR EVALUATION. INSPECTED MAGNETO TIMING & ADJUSTED. TIGHTENED NR FIVE CYLINDER INTAKE TUBE CLAMP & INSPECTED FUEL CONTROL FILTER SCREEN, NO DEFECTS NOTED. POST MX FLIGHT CHECK WAS SUCCESSFUL WITH NO DEFECTS NOTED. ACFT RETURNED TO [S/N removed].

PILOT REPORTED ENG DIED WHEN IGNITION SWITCH MOVED TO LT POSITION. TROUBLESHOOTING REVEALED LT MAGNETO INOPERATIVE. REPLACED LT MAGNETO WITH [S/N removed], ALL CHECKED SATISFACTORY. PRELIMINARY INSPECTION SHOWED LT MAGNETO POINTS NOT OPENING, POSSIBLY DUE TO EXCESSIVE CAM FOLLOWER WEAR. THE MAGNETO ONLY HAD 107.6 HOURS SINCE 500 HOUR INSPECTION.

Parts most often named Antenna (17) · Transceiver (2)

DURING GROUND FUNCTIONAL CHECKS FOLLOWING INITIAL INSTALLATION, MX20 DISPLAYS THE ERROR MESSAGE (GDL90 REQUIRES MAINTENANCE). UPON INSTALLATION OF ANOTHER UNIT, ERROR MESSAGE CLEARED, SYSTEM OPERATION SATISFACTORY. (AL05200502604) (K)

DURING POST INSTALLATION CHECKS, FOUND THE GDL90 UAT REPORTING CONTINUOUS GPS FAILURE. REPLACEMENT OF THE UNIT CORRECTED THE ERROR. (K)

Parts most often named Crankshaft (5) · Bushing (3) · Lifter (3) · Conrod Bolt (1)

DURING CRUISE POWER SETTINGS ALTERNATOR BELT WOULD BE THROWN OFF. AT RECOMMENDATION OF ENGINE SHOP, REMOVED CYLINDERS ONE AND TWO. REMOVED COUNTERWEIGHT AND FOUND PINS AND BUSHINGS TO BE WORN BEYOND LIMITS LIKELY CAUSING VIBRATION.

REMOVED ALL HYDRAULIC LIFTERS TO INSPECT FOR SPALLING, DISCOVERED BADLY SPALLED EXHAUST LIFTER ON CYLINDER #4. INSPECTED CAM IN ACCORDANCE WITH CONTINENTAL [S/N removed] DIRECTIVE SID05-1B, INSTALLED NEW LIFTER AND WILL INSPECT CAM AGAIN IN 100 HOURS. IT IS DOUBTFUL THAT THIS 1900 HOUR ENGINE WILL MAKE TBO BEFORE NEEDING A NEW CAM. WE ARE NOW INSPECTING LIFTERS EVERY 200 HOURS.

THE ENGINE HAD EXPERIENCE FREQUENT ALTERNATOR BELT THROWING PROBLEMS. NO FIX WAS FOUND. THE DECISION WAS MADE TO HAVE THE ENGINE INSPECTED FOR DEFECTS. FOUND EXCESSIVELY WORN CRANKSHAFT COUNTERWEIGHT BUSHINGS. THIS IS BELIEVED TO BE THE REASON THE ALTERNATOR BELT WOULD NOT OPERATE PROPERLY.

Parts most often named Alternator (11)

LOW VOLTAGE LIGHT ILLUMINATED. 30 SECONDS LATER A STRONG ELECTRICAL BURNING SMELL CAME FROM BEHIND THE PANEL FOLLOWED BY A VERY SMALL AMOUNT OF SMOKE. RAN ELECTRICAL FIRE IN FLIGHT CHECKLIST AND LANDED 10 MINUTES LATER IN CHEFORNAK AND CALLED MX CONTROL TO REPORT ISSUE

ALTERNATOR FAILURE IN FLIGHT, PILOT MADE A PRECAUTIONARY LANDING AT PRIVATE AIRSTRIP DUE TO A BURNING SMELL IN THE CABIN. UPON INSPECTION MAINTENANCE, PERSONNEL FOUND THE ALTERNATOR HAD SEIZED, AND THE BURNING SMELL WAS FROM THE BELT SLIPPING ON THE SEIZED PULLY. THE ALTERNATOR AND BELT WERE REPLACED AND OPS CHECKED GOOD.

PILOT REPORTS A BURNING PLASTIC ODOR FOLLOWED BY LOW VOLTAGE LIGHT. MAINTENANCE INSPECTED THE AIRCRAFT AND DETERMINED THAT THE ALTERNATOR HAD FAILED AND HAD A DEFINITE BURNED ODOR EMANATING FROM THE ALTERNATOR ITSELF. THE ALTERNATOR WAS REPLACED AND NO FURTHER PROBLEMS WERE NOTED..

Parts most often named Unknown (9) · Odor (1)

DURING FLIGHT PILOT NOTICED AN UNUSUAL SMELL AND RETURNED TO BASE DUE TO THIS SMELL. AIRCRAFT IS CURRENTLY BEING INSPECTED AND NO DETERMINATION AS TO THE SOURCE OF SMELL HAS BEEN MADE.

AFTER LANDING PILOT SMELLED FUEL IN COCKPIT. PERFORMED AN INSPECTION OF THE ACFT FUEL SYS FOR LEAKS. NO LEAKS OR SIGNS OF LEAKAGE WERE NOTED DURING THE INSPECTION.

A SMELL OF ELEC BURN WAS NOTICED BY FLIGHT CREW. ACFT WAS RAN WITH FULL LOAD APPLIED TO THE ELEC SYS AS WELL AS CABIN HEAT SYS OFF & ON. NO DEFECTS OR SMELLS WERE NOTICED, COULD NOT DUPLICATE.

Parts most often named Bulkhead (10)

CRACK IN FORWARD BULKHEAD OF HORIZONTAL STABILIZER, RIGHT HAND SIDE NEAR UPPER LIGHTNING HOLE. "REPLACED BULKHEAD WITH NEW BULKHEAD 1212136-14. SEE 337 DATED 1/23/25 FOR FURTHER DETAIL."

WHILE INSPECTING ACFT IAW SEB 93-5 R1, THE ACFT WAS NOTED AS HAVING CRACKS ON BOTH LT & RT BULKHEAD AT FS 27 AT THE LOWER LIFT STRUT ATTACH FITTING. IN ORDER TO REMEDY THIS CONDITION, SUPPLIED [S/N removed] KIT SK207-19 WAS INSTALLED AS A PERMANENT REPAIR.

(AUS) FUSELAGE DOORPOST BULKHEAD CRACKED. FOUND DURING INSPECTION IAW AD/C205/21. (AD/SB DESC: AD/C205/21 ) (CASA NR 510001732)

Parts most often named Alternator (10)

Parts most often named Oil Pump (1) · Adapter (1) · Sump (1) · Drain Valve (1)

THE PILOTS REPORTED THAT HE SET TAKEOFF POWER, ENGINE PARAMETERS READ NORMAL AND UPON REACHING 40 KNOTS HE SAW A ROLL BACK. HE EXECUTED AN ABORTED TAKEOFF AND HEARD SOME ENGINE SPUTTERING FOLLOWED BY THE ENGING SHUTTING OFF. MAINTENANCE FOUND NO ABNORMAL PROBLEMS ON THE FIRST FEW RUN UPS, BUT UPON FUTURE INSPECTION THEY DID FIND AN OIL LEAK APPEARING TO COME FROM THE TURBO CHARGER. HOWEVER, IT IS NOT CONFIRMED THAT THE TURBO CHARGER IS THE ISSUE. AT THIS TIME WE DO NOT KNOW THE CAUSE OF THIS ENGINE FAILURE.

(CAN) DRUING ROUTINE 200 HOURS INSPECTION A SMALL OIL DRIP WAS OBSERVED ON OIL SUMP. INVESTIGATION SHOWED THE OIL DIPSTICK WAS WEARING THROUGH FROM THE INSIDE. OIL SUMP REPLACED. PROG AIR (ENGINE SHOP) ADVISED US TO CHECK DIPSTICK SPIGOT - AS IT WAS PRESSED INTO CASE TOO FAR ALLWOING DIPSTICK TO GO TO FAR. (TC# 20090914005)

(CAN) OIL DRAIN PLUG FROM ENGINE O-RING WEARS OUT. METAL RUBBED AGAINST METAL UNTIL COLLAR WEARS OFF. THEN CENTER PIECE FELL OUT LEAVING A 1/2 INCH HOLE FOR THE OIL TO DRAIN. (IN FLIGHT). THIS DRAIN VARIES FROM ENGINE TO ENGINE TYPE.

Parts most often named Engine (7) · Pin (1) · Crankshaft (1)

ENGINE WOULD NOT STOP THROWING ALTERNATOR BELTS. FOUND REAR COUNTERWEIGHT PIN AND CHEEK BUSHINGS AS WELL AS COUNTERWEIGHT BUSHINGS EXTREMELY WORN OUR OF [S/N removed] LIMITS.

DURING A SCHEDULED FLIGHT, PILOT NOTICED ENG WAS NOT MAKING FULL POWER, PILOT RETURNED TO BASE & LANDED WITHOUT INCIDENT. REPLACED ENG ASSEMBLY DUE TO ITS TIME IN [S/N removed] & PREVIOUS OPERATIONAL HISTORY.

(CAN) ENGINE FAILED IN FLIGHT, WEATHER WAS GOOD, RESTART FAILED, ACFT MADE FORCED LANDING MINOR INJURIES. ACFT TO BE RECOVERED AND INVESTIGATED BY SAFETY BOARD.