C85/​C90Continental A65, A75, C85 and C90

Parts most often named Valve (4) · Exhaust Valve (4) · Guide (3) · Cylinder (2)

(CAN) BROKEN VALVE GUIDE DETECTED AS THE ANNUAL 1 100 HR INSPECTION. CYLINDER ASSY REMOVED, LOW COMPRESSION ON DIFFERENTIAL TEST 20/80 SENT TO AMO FOR REPAIR NOTE: CYLINDER ASSY WAS PURCHASED NEW OCT. 2004 - 245.0 HR.

WHEN THE NR 4 CYLINDER WAS REMOVED, THE EXHAUST VALVE HEAD WAS FOUND TO BE BROKEN OFF, ABOUT .5 INCH FROM THE FACE OF THE VALVE, CAUSING FAILURE OF THE PISTON AND FAILURE OF THE INTAKE VALVE. THE CIRCUMSTANCES OF THE FAILURE CAUSED A LOSS OF ENGINE POWER AND A FORCED LANDING IN A FIELD. THE PILOT WAS UNHARMED. (K)

CYLINDER AND ROD FAILURE RESULTED IN CASE FAILURE CAUSING CYLINDER TO COME OF ENGINE. CAUSE UNKNOWN. NR 4 PISTON (AE-C530348) FAILURE. (WP09200502317). (K)

Parts most often named Crankshaft (8) · Connecting Rod (1) · Housing (1) · Plug (1)

DUE TO A "STUCK" EXHAUST VALVE IN 1 CYLINDER, THE ROCKER ARM BROKE, AND THE PUSHROD ASSOCIATED WITH THAT ROCKER ARM DAMAGED AND CRACKED THE FLANGE-PUSHROD HOUSING. THE CRACKED FLANGE-PUSHROD HOUSING CREATED AN OIL LEAK. THE "STUCK" EXHAUST VALVE WAS CAUSED BY THE HIGH LEAD LEVEL OF THE AV-GAS 100LL.

THE ENGINE WAS UNDER POWER WHEN THE CRANKSHAFT BROKE. THE ENGINE RAN UNTIL AIRCRAFT WAS ON GROUND. THERE WAS AN EXTREME VIBRATION. (K)

OWNER COMPLAINED ABOUT THE ENGINE KNOCKING. BROUGHT ENGINE TO US FOR INSPECTION. UPON DISASSEMBLY WE FOUND THE CRANKSHAFT IN TWO PIECES. THE CRANKSHAFT WAS BROKEN BETWEEN THE FRONT MAIN JOURNAL AND THE NR 4 ROD BEARING JOURNAL. ENGINE WAS OPERATING ON AUTO FUEL. ENGINE HAD BEEN DISASSEMBLED FOR REPAIR WORK APPROXIMATELY 20 HOURS BEFORE.

Parts most often named Coil (5) · Magneto (2) · Gear (2) · Clamp (1)

REPLACED OPEN COIL(PN K3975) ON LEFT SLICK MAGNETO PN 4301 ON 09-20-2020. MAGNETO UNIT WAS OVERHAULED BY KELLY AEROSPACE, PN 4301R [S/N removed], AND INSTALLED ON AIRCRAFT ON 03-12-2017 AT 3152.94 HOURS TACH. COIL SHOWED NO CONTINUITY (OPEN) AT 193.61 HOURS IN [S/N removed]. THIS OCCURRED DURING ENGINE RUN UP BEFORE TAKE OFF AND RETURNED TO BLOCKS.

PILOT NOTICED LACK OF POWER AND ROUGHNESS AFTER TAKEOFF. RETURNED TO FIELD, DISCOVERED INOPERATIVE RT MAGNETO. DISASSEMBLY OF RT MAGNETO REVEALED ROTOR SHAFT HAD SHEARED FLUSH WITH BOTTOM OF CAM CUTOUT. THE REMAINING ROTOR AND DISTRIBUTOR BOTH ROTATED FREELY. NO EVIDENCE OF PROBLEMS WITH EITHER GEAR. PROBABLE CAUSE IS A DEFECT IN MFG (POSSIBLY BAD METAL OR STRESS CRACK FROM MACHINING CAM SLOT. (K)

BOTH MAGS REMOVED FOR SB, 500 HOUR INSPECTION. MFG DEFECT NOTED. ROTATING MAGNET AND BEARING ASSY NOT PRESSED (FAR ENOUGH) INTO FRONT MAG HOUSING . MAGS PURCHASED NEW 1/9/98. UNEVEN WAR NOTED THROUGHOUT WITH FINE BRONZE POWDER COATING INTERNAL PARTS. OD (GREEN) IN COLOR. MORE CAREFUL ASSEMBLY OF MAG COMPONENTS AT FACTORY. (NOTE) MAG SN 14 UNITS APART. (K)

Parts most often named Carburetor (4) · Needle (2) · Linkage (1) · Needle Valve (1)

DURING FLIGHT THE THROTTLE LINKAGE BECAME DISCONNECTED FROM THE CARBURETOR. THIS CAUSED THE AIRCRAFT ENGINE TO GO TO IDLE. THE PILOT CRASH LANDED IN A FIELD.

AT SOME TIME UNKNOWN, IT APPEARS A NEW STEELE NEEDLE AND SEAT WAS INSTALLED AND THE SEAT BODY WAS NOT SAFTIED. FROM VIBRATION, IT CAME LOOSE AND CLOSED OFF FUEL FLOW INTO CARB, THEREFORE CAUSING ENGINE POWER LOSS.

CARBURETOR WAS SENT IN FOR AN OVERHAUL BECAUSE IT WOULD NOT ACCEPT THROTTLE. THERE WAS VERY LITTLE TIME ON THE CARBURETOR SINCE IT'S LAST OVERHAUL. UPON DISASSEMBLY, IT WAS FOUND THAT THE CARBURETOR HAD THE WRONG VENTURI INSTALLED AND THERE WAS OLD CORROSION IN THE FLOAT CHAMBER THAT WAS NOT REMOVED DURING THE PREVIOUS OVERHAUL. IT HAD THE WRONG SEAT INSTALLED FOR THE TYPE NEEDLE THAT WAS BEING USED. IT WAS OBVIOUS THAT SOMEONE WHO THOUGHT THEY KNEW CARBURETORS HAD ATTEMPTED TO OVERHAUL THE UNIT UNSUCCESSFULLY.

Parts most often named Engine (4) · Crankshaft (1) · Ring Assembly (1)

LOSS OF COMPRESSION AND OIL ON #2 CYLINDER DUE TO WORN PISTON RINGS WITH 35 HOURS SINCE OVERHAULED CYLINDER WITH NEW RINGS GAPPED TO .014. *NOT FOUND IN AIRCRAFT INQUIRY

PILOT REPORTED ENGINE QUIT IN-FLIGHT, PILOT EXECUTED AN EMERGENCY OFF-AIRPORT LANDING. MINOR DAMAGE TO AIRCRAFT. ENGINE INSPECTED, BUT NOT DISASSEMBLED, ENGINE OIL WAS CLEAN, NO METAL FOUND IN OIL, 6 GALLONS OF FUEL (APPROX) FOUND IN TANKS, ENGINE COMPRESSION APEARS NORMAL, ENGINE TURNS SMOOTH AND NORMAL NOT TIGHT FROM POSSIBLE LOCK-UP. MAGNETO TIMER OK. NO DISCREPANCIES FOUND.

ENGINE POWER FAILURE DURING TAKEOFF. MAINTENANCE INVESTIGATION AND POST-ENGINE RUN WAS CONDUCTED. ENGINE RAN SATISFACTORY. MAINTENANCE ADVISED, SUSPECT FUEL STARVATION DUE TO FREEZING OF WATER CONTAMINATION IN LOW SECTION OF FUEL LINE.

Parts most often named Oil Filter (2) · Bearing (1) · Elbow (1)

ENGINE REMOVED FOR INSPECTION DUE TO LOW OIL PRESSURE. ON DISASSEMBLY DISCOVERED .020 UNDERSIZE CRANKSHAFT RUNNING IN .010 BEARINGS.

OIL PRESSURE LINE LEAKING AT 45 DEGREES, ELBOW EXITING THE CRANKCASE. REPLACED AUTOMOBILE FITTING WITH MS20823-4D FITTING WITH A NR 60 RESTRICTOR. ALSO, REPLACED OIL PRESSURE LINE FROM CRANKCASE TO FIREWALL.

Parts most often named Propeller (3)

PROPELLER IN [S/N removed] SINCE 2015/100 HOURS. METAL TIPPING REPLACED DEC 2021. DURING INITIAL CLIMB AFTER REINSTALLATION, CUSTOMER REPORTED SEVERE VIBRATION; HE CUT POWER AND MADE SUCCESSFUL POWER-OFF LANDING ON ROAD CLOSE TO AIRPORT (IN QUEBEC). NO INJURIES OR MAJOR DAMAGE. MINOR PORTION OF METAL TIPPING AND MAJOR PORTION OF WOODEN BLADE MISSING ON ONE SIDE. SPINNER SKULL CAP ALSO MISSING (WAS PRESENT DURING TAKE-OFF).

SUBMITTED FOR OVERHAUL DUE TO VIBRATION OVER 1500 RPMS. PROPELLER WAS FOUND WITH POSSIBLE ELECTRICAL ARC BURNS ON SEVERAL PLACES IN THE AIRFOIL OF BOTH BLADES AND A 1.5 INCH LONG CRACK ON THE OUTSIDE OF THE HUB.

Parts most often named Blade (3)

(CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. EXTRA WORK REQUIRED TO REMOVE CORROSION CARRIED OUT: AN OVERHAUL. AS PER MCCAULEY MANUAL 730720

Parts most often named Air Box (1) · Muff (1)

INSTALLED NEW UNIVAIR FAA/PMA CARBURETOR AIR-BOX, P/N U4-601-1 (144348). AFTER 1.3 HOURS FLIGHT TIME THE AIR OUTLET TUBE FLANGE ON THE BOTTOM OF THE BOX WHICH HAD BEEN ATTACHED BY SPOT WELDING, COMPLETELY SEPARATED AT THE SPOT WELDS AND DEPARTED FROM THE AIRCRAFT. IT WAS DISCOVERED DURING THE POST FLIGHT INSPECTION.

Parts most often named Isolation Mount (1) · Belt (1)

ULTRALIGHT FRACTURED ENGINE BELT REDUCTION BRACKET CAUSING IN-FLIGHT SHUTDOWN AND EMERGENCY LANDING. PROBABLE CAUSE: ENGINE BELT REDUCTION BRACKET STRESS/FATIGUE CRACK CAUSING HEAVY ENGINE VIBRATION AND SHUTDOWN. (K)