SR22and SR22T

Parts most often named Magneto (13) · Distributor Gear (9) · Gear (4) · Housing (2)

PRESSURIZED MAGNETO AIR SOURCE FILTER MELTED/DEFORMED AFTER ONLY 79H AFTER INSTALLATION. BLOCKAGE OF AIR TO MAGNETO CAUSED LEFT MAGNETO FAILURE, WHICH WAS ALSO JUST 79H AFTER REPLACEMENT. PROBLEM SEEMS TO OCCUR FREQUENTLY WITH THAT FILTER INSTALLATION IN SR22 TURBO MODELS. [S/N removed] RISK FOR INFLIGHT ENGINE FAILURE. FILTER WITH THAT INSTALLATION OBVIOUSLY NOT FIT FOR PURPOSE AND NOT SAFE FOR OPERATION. SIL24-02 WITH ROBUST FILTER DOES UNFORTUNATELY NOT APPLY FOR TN MODELS.

ON APPROACH INTO KCPR FROM U68 THE PILOT OBSERVED ENGINE BEGAN TO RUN ROUGH FOLLOWED BY EGT AND CHT TEMPERATURES DRASTICALLY INCREASE. THE PILOT LANDED AT KCPR WITHOUT INCIDENT. MAINTENANCE REPLACED BOTH MAGNETOS AND OPS CHECK GOOD. UPON TEARDOWN OF MAGNETOS, EDWARDS JET CENTER MAINTENANCE (KBIL) FOUND 25% OF THE TEETH ON THE DRIVEN PLASTIC MAGNETO DISTRIBUTER GEAR MISSING, ON THE RH MAGNETO.

PRESSURIZED MAGNETO AIR SOURCE FILTER MELTED/DEFORMED. IF CONTINUED COULD CAUSE BLOCKAGE OF AIR TO MAGNETO CAUSING PREMATURE MAGNETO FAILURE. PROBLEM SEEMS TO COINCIDE WITH RELOCATION OF FILTER CLOSER TO CYLINDERS WITH NEWER MANUFACTURED AIRCRAFT

Parts most often named Cylinder Head (12) · Cylinder (11) · Exhaust Header (3) · Piston Pin (1)

DURING ANNUAL INSPECTION, I WAS BORESCOPING TCM TSIO 550 K ENGINE AND FOUND NUMBER 2 CYLINDER INTAKE VALVE CRACKED AND THE EDGES WERE CHIPPED AWAY. THE CYLINDER ONLY HAD 220 HOURS SINCE OVERHAUL. I REMOVED THE CYLINDER ASSEMBLY AND SENT TO CONTINENTAL ENGINES FOR REPAIR.

SEPARATION OF CYLINDER HEAD, EXHAUST SIDE FROM NR 5 CYLINDER DURING CRUISE/LEVEL FLIGHT. APPROXIMATELY 30 MINUTES INTO FLIGHT.

ENGINE COMPRESSION CHECK CYLINDER #5 WAS 10/80 PSI. REMOVED CYLINDER, PISTON WAS BURNED BADLY AROUND THE OUTSIDE EDGES. TOP SPARK PLUG PORCELAIN WAS BROKEN AND DAMAGED.

Parts most often named Exhaust Header (10) · Exhaust Riser (4) · Manifold (4) · Exhaust Pipe (3)

NR 1 CYLINDER EXHAUST STACK HAS AN ELONGATED BOLT HOLE THAT IS ALLOWING FOR THE BOLT HEAD TO REST ON THE STACK AND IS WEARING INTO THE SIDE WALL. (PHOTOS TO FOLLOW.)

NR 4 EXHAUST STACK HAS AN ELONGATED BOLT HOLE WHICH IS ALLOWING THE BOLT HEAD TO REST ON AND WEAR INTO THE STACK SIDE WALL. (PHOTOS TO FOLLOW.)

INSTALLED MANIFOLD WAS USED AT THIS ANNUAL INSPECTION TO FIND NR 4 CYLINDER EXHAUST STACK AFT END AT SLIP JOINT BULGED AND CRACKED. STAINS IN THAT AREA WERE NOTED, HEATSHIELD DEFLECTED LEAT FROM ANY FURTHER DAMAGE. PART NOT SOLD SEPARATELY, NEW REDESIGN LEFT EXHAUST MANIFOLD ASSEMBLY INSTALLED.

Parts most often named Brake Disc (14) · O-Ring (2) · Warning System (1) · Lug (1)

WHILE TAXIIING AFTER LANDING THE PILOT APPLIED BRAKES AND THE AIRCRAFT VEERED LEFT OFF THE TAXI WAY AND INTO THE GRASS. MAINTENANCE REMOVED THE RIGHT WHEEL AND FOUND THE RIGHT BRAKE DISK HAD FULLY SEPARATED FROM THE MOUNTING FLANGE THAT BOLTS TO THE INNER WHEEL HALF..

APPROX. 12 MONTH OLD RIGHT MAIN GEAR BRAKE DISC, RAPCO PART #RA164-02504, SEPARATED DURING APPLICATION OF BRAKES DURING LANDING SEQUENCE. RESULTING DAMAGE REQUIRED REPLACEMENT OF INNER HUB AND PADS.

RIGHT MAIN DISC COMPLETELY SEPARATED FROM THE MOUNTING FLANGE OF THE WHEEL ASSY. SIGNIFICANT GRINDING NOISE FELT DURING TAXI AND ALL BRAKING AUTHORITY WAS LOST ON THE RIGHT MAIN, CAUSING AIRPLANE TO UNCONTROLLABLY PIVOT AROUND LEFT MAIN WHEN THE BRAKES WERE APPLIED IN AN ATTEMPT TO STOP THE PLANE. RESULTING SEPARATION REQUIRED REPLACEMENT OF BRAKE PADS.

Parts most often named Camshaft (4) · Connecting Rod (2) · Gear (2) · Lifter (2)

AN UNACCEPTABLE OIL SAMPLE LEAD TO A RECOMMENDATION BY AN OUTSIDE COMPANY TO HAVE AN INSPECTION OF THE CAMSHAFT AND LIFTERS PERFORMED. WE PERFORMED THESE INSPECTIONS AND FOUND A GOUGE ON THE #6 INTAKE LOBE ON THE CAMSHAFT. A PICK CAN BE CAUGHT IN THIS GOUGE THEREFORE IT IS REASON FOR REJECTION. THE LIFTER WAS IN GOOD CONDITION. THE #6 EXHAUST LIFTER SHOWED SIGNS OF HEAT/DISCOLORATION.

ENGINE WAS DISASSEMBLED FOR INSPECTION DUE TO PROPELLER STRIKE. UPON DISASSEMBLY IT WAS NOTED THAT THE CONNECTING ROD BUSHING HAS MIGRATED PARTLY OUT OF THE BORE ON THE SMALL END OF CONNECTING ROD #2, #3, & #5. THIS IS THE THIRD TIME THAT WE HAVE SEEN THIS PROBLEM ON THIS MODEL ENGINE.

DURING MAINTENANCE TO TROUBLESHOOT A FAILED NR 2 ALTERNATOR, WE NOTICED A THRU-BOLT NUT MISSING FROM NR 4 TOP CYLINDER AND THE THRU-BOLT MIGRATED OUT ONTO THE NR 5 CYLINDER. THE NUT WAS FOUND IN THE BAFFLING BENEATH THE CYLINDER AND IT HAD FAILED BY CRACKING.

Parts most often named Starter (6) · Adapter (5) · Solenoid (1) · Drive Assy (1)

ATTEMPTED TO START THE AIRCRAFT, ON STARTER ENGAGEMENT A LOUD NOISE WAS HEARD AND THE ENGINE SEIZED. UPON INITIAL INSPECTION IT WAS FOUND THAT THE ENGINE WOULD NOT ROTATE EITHER DIRECTION. AFTER FURTHER INSPECTION IT WAS FOUND THAT MULTIPLE TEETH WERE MISSING FROM THE STARTER ADAPTER GEAR AND A COUPLE WERE STUCK IN THE CAM GEAR THUS NOT ALLOWING THE ENGINE TO ROTATE.

A REBUILT STARTER ADAPTER, WAS INSTALLED AT 336.8 HRS. AT 818 HRS, STARTER ADAPTER BEGAN SLIPPING DURING START, REPAIRED.

PILOT STATED THAT ENG WOULD NOT START & STARTER WOULD NOT ENGAGE. ALSO STATED THAT THERE WAS ONLY A CLICKING SOUND WHEN START WAS SELECTED.

Parts most often named Air Filter (4) · Attach Bolt (3) · Bolt (2) · Wire (1)

DURING AN ANNUAL INSPECTION, WHILE CHANGING THE INDUCTION AIR FILTER IT WAS DISCOVERED THE FILTER BASKET HAS STARTED TO COME APART. THERE ARE SEVERAL PIECES OF THE BASKET MISSING. THE BASKET APPEARS TO BE MADE OF STAINLESS STEEL. THE BASKET SETS IN THE INDUCTION SYSTEM AND THE ONLY PATH THE PIECES OF MISSING MATERIAL COULD HAVE TAKEN IS INTO THE ENGINE INTAKE. CIRRUS HAS BE NOTIFIED VIA E-MAIL AND PICTURES OF THE DEFECT.

AIR FILTER SUPPORT, MADE OF A CYLINDRICALLY SHAPED WIRE SCREEN WAS FOUND TO HAVE THE SCREEN MATERIAL BREAKING AT THE JUNCTION OF THE RADIAL TO VERTICAL WIRES. CAUSING, IN SEVERAL INSTANCES, TO SHED SECTIONS OF THE WIRE, UP TO AN INCH LONG. WHEN THESE WIRES SHED, THEY ARE ALLOWED TO FALL INTO THE INTAKE AIR STREAM, AS THEY ARE INSIDE THE FILTER. THIS COULD ULTIMATELY ALLOW THEM TO BE INGESTED INTO THE ENGINE.

DURING AN ANNUAL INSPECTION, THE AIR FILTER WAS DISCOVERED TO BE SPLIT OPEN AT THE SEAM. THIS SAME CONDITION HAS BEEN FOUND ON SEVERAL OTHER AIR FILTERS OF THE SAME PN. WHILE NOT AN IMMEDIATE SAFTEY OF FLIGHT ISSUE, THIS CONDITION ALLOWS UNFILTERED AIR TO ENTER THE INDUCTION SYSTEM WHICH IF ALLOWED TO CONTINUE FOR ANY GREAT LENGTH OF TIME CAN CAUSE PREMATURE WEAR AND POSSIBLE EARLY FAILURE OF THE ENGINE.

Parts most often named Spark Plug (13) · Igniter (1)

WHILE PERFORMING A CAPS SYSTEM EXCHANGE ON [tail no. removed], THE TOOL SPECIFIED TO INSTALL AND TORQUE THE IGNITER ASSEMBLY INTO THE ROCKET ASSEMBLY WAS DIFFICULT TO INSTALL. WHILE PERFORMING THE TORQUE, THE TOOLING [S/N removed]. THIS LEFT A DOWEL IN THE SQUIB THAT CANNOT BE REMOVED. THIS TOOLING HAD BEEN USED ON OTHER INSTALLATIONS. WHEN ANOTHER TOOL, SAME PN, WAS USED THE TIGHT FIT WAS REPEATED ON THE IGNITER IN QUESTION. IGNITER LOT/DOM 235019-VS-IGN-CERT-MOD 1 TRM-350-018 IGNITER. PICTURES OF TOOLING AND PARTS ARE AVAILABLE.

REPLACED ALL FINE WIRE SPARK PLUGS RHB32S WITH NEW RHB32E MASSIVE ELECTRODE PLUGS. TWO SPARK PLUGS HAD CRACKED INSULATION WITH SOME INSULATION MISSING.

ENGINE START NORMAL. MAGNETO CHECK ON RUNUP REVEALED ROUGH RUNNING AND MAG CHECK FAILED ON SEVERAL CYLINDERS. REMOVED THE PLUGS - CRACKS FOUND ALL AROUND THE INSULATOR. RHB32S IS CURRENTLY IN THE ENGINE. HAVE BEEN FINDING SEVERAL OF THESE ON MULTIPLE AIRCRAFT - BOTH NA AND TURBO. THE ISSUE IS ISOLATED TO THE BRAND.

Parts most often named Dipstick (5) · Check Valve (2) · Hose (1) · Relief Valve (1)

ENGINE LOSS OIL PRESSURE, DUE TO OIL LINE LOOSING TORQUE AT THE OIL COOLER CROSS FITTING. THE OIL LINE SUPPLY OIL FROM THE OIL COOLER CROSS FITTING TO THE TURBO IS SECURE TO THE ENGINE MOUNT, IT SEEM VERY TIGHT FIT, SHORT AND STIFF, WITH THE ENGINE VIBRATION IT SEEM VERY EASY TO CAUSE IT TO BREAK LOOSE WITH OUT ABLE TO DETECT THE PROBLEM DURING MAINTENANCE. THE ENGINE WILL LOSS OIL PRESSURE AND CAUSE ENGINE POWER LOSS INFLIGHT.

ACFT WAS COMING OUT OF ANNUAL INSPECTION. LOW ALTITUDE FUNCTIONAL FLIGHT CHECK INDICATED NO ABNORMALITIES. HIGH ALTITUDE FUNCTIONAL FLIGHT CHECK INDICATED SMOKING EXHAUST PIPE AND LOSS OF TURBO SYSTEM. DECOWLING SHOWED OIL SPRAY. TRACED BACK TO FITTING ON SCAVENGE PUMP. FURTHER INSPECTION REVEALED FITTING WAS NOT TIGHTENED FOLLOWING REINSTALLATION FOLLOWING STARTER ADAPTER O/H.

LEFT OIL LINE GOING TO THE LT TURBO WASTGATE CONTROLLER WAS UP AGAINST THE WASTEGATE DOWN PIPE. THIS CAUSED A HOLE TO BE BURNED INTO THE OIL HOSE. THE ENGINE LOST 10 QTS OF OIL BEFORE THE PILOT COULD LAND AT THE NEAREST AIRPORT. THIS PROBLEM ORIGINATED AT THE MFG. THE HOSE NEEDS TO BE LONGER TO ALLOW FOR THE RE-ROUTING OF THE HOSE AWAY FROM THE TURBO AND EXHAUST COMPONENTS.

Parts most often named Landing Gear (2) · Nut (2) · Bracket (1) · Fairing (1)

NOSE LANDING GEAR COLLAPSED WHILE TAXING LEADING TO A PROP STRIKE. THIS IS A KNOWN ISSUE. THE CIRRUS NOSE GEAR IS SUPPORTED BY SIX RUBBER "PUCKS" HELD IN PLACE BY METAL PANS AT THE TOP AND BOTTOM WITH A METAL ROD RUNNING THROUGH THE CENTER OF THE PUCKS. THE ROD IS KNOWN TO SEPARATE FROM THE TOP PAN ALLOWING THE PUCKS TO SHIFT AND THE NOSE STRUT TO GO FORWARD ALLOWING THE PROPELLER TO IMPACT THE GROUND. THERE IS NO WAY TO INSPECT THE WELD BETWEEN THE TOP OF THE PAN AND THE ROD SINCE IT IS COVERED BY THE PUCKS.

ON LANDING AT SCOTTSDALE AIRPORT KSDL, AIRCRAFT EXPERIENCED A NOSE GEAR FAILURE. NOSE GEAR BROKE AFT OF THE ACTUATOR ATTACH POINT, FOLDED UNDER THE ENGINE TO THE LEFT SIDE, THE PROP STRUCK THE GROUND AND THE AIRCRAFT SLIDE FOR A SHORT DISTANCE. NO INJURIES OR FIRE.

(CAN) WHILE COMPLETING THE 100HR/ANNUAL INSP REQUIREMENTS IAW THE MM, IT WAS NOTICED THE COTTER PIN THAT LOCKS THE FORK ASSY ON THE NOSE GEAR STRUT WAS SHEARED. UPON FURTHER INVESTIGATION AND NOSE GEAR REMOVAL AND DISASSEMBLY, NUMEROUS CRACKS WERE SUSPECTED. PERFORMED A DYE PEN INSP OFF ALL KNOW AREAS OF CRACKING IAW THE MM AND SB 22-32-19. 2 CRACKS WERE CONFIRMED ON THE UPPER PUCK PAC ASSY WELD. NEW PARTS WERE INSTALLED AND ACFT WAS RETURNED TO [S/N removed].