IO-520Continental IO-520

Parts most often named Cylinder (282) · Cylinder Head (133) · Lifter (16) · Exhaust Valve (15)

THE INTAKE VALVE HAS MATERIAL MISSING IN I LOCATIONS AROUND THE PERIMETER OF THE VALVE HEAD SEAT AREA, LT APPEARS TO BE VALVE FAILURE AND NOT FOD, (OTHER INFO FOUND ON VALVE WFAA PMA719077QITALY),

(CAN) OIL NOTED ON LOWER COWLING, INSPECTION SHOWED OIL LEAKING FROM PUSHROD HOUSING ON NR 1 CYLINDER. PART REMOVED AND FOUND TO BE CRACKED AROUND 50% OF ITS CIRCUMFERENCE AT THE SPRING RETENTION FERRULE.

AFTER TEARING DOWN OF THE ENGINE, THE NR 5 CYLINDER FAILED DUE TO OIL STARVATION OF THE CONNECTING ROD CAP FOR UNKNOWN REASONS. THIS CAUSED FAILURE OF THE ROD CAP BOLTS. THE CAP BOLTS STRETCHED, [S/N removed] AND THEY SHOW SIGNS OF BURN MARKS.

Parts most often named Crankcase (55) · Crankshaft (53) · Lifter (24) · Connecting Rod (17)

PILOT REPORTED LOW OIL PRESSURE AT IDLE, REMOVED OIL PRESSURE REGULATOR AND FOUND SHARP METAL CHIP IN BOTTOM OF REGULATOR WHERE IT HAD ARRIVED AFTER FALLING OUT OF REGULATOR SEAT. PREVIOUS EXPERIENCE LED US TO BELIEVE THAT THE METAL WAS FROM A LIFTER, WE INSPECTED ALL 12 LIFTERS AND DISCOVERED A SEVERELY SPALLED EXHAUST LIFTER ON CYLINDER #4. INSPECTED CAM IN ACCORDANCE WITH CONTINENTAL [S/N removed] BULLETIN SID05-1B, INSTALLED NEW LIFTER AND WILL INSPECT CAM AND LIFTER AGAIN IN 100 HOURS (AS PER THE SID).

(CAN) OWNER OF AIRCRAFT REPORTED AN OIL LEAK. UPON INSPECTING FOR THE OIL LEAK A CRACK WAS FOUND. CRACK WAS APPROXIMATELY 6 INCH LONG IN THE CASE HALF ABOVE THE THE #2 CYLINDER BORE INTERSECTING WITH TOP REAR CYLINDER BASE STUD. ENGINE WAS REMOVED AND SENT FOR REPAIR. (TC# 20190823007)

AFTER TEARING DOWN THE ENGINE IN QUESTION IT IS OUR OPINION THAT THE FAILURE WAS DO TO OIL STARVATION OF THE NR 5 CYLINDER CONNECTING ROD CAP FOR UNKNOWN REASONS. THIS CAUSED FAILURE OF THE ROD CAP BOLTS. THE CAP BOLTS STRETCHED, [S/N removed] AND THEY SHOW SIGNS OF BURN MARKS.

Parts most often named Magneto (47) · Distributor Blk (26) · Impulse Coupling (25) · Brushes (18)

FOUND FACTORY DEFECT WHILE PERFORMING FIRST 500-HOUR INSPECTION MAGNETO WITH TT 477.6 IN ACCORDANCE WITH [S/N removed] SUPPORT MANUAL X42001. COIL TAB HAD NOT BEEN INSTALLED PARALLEL WITH HOUSING TO COVER MATING SURFACE, AS SPECIFIED IN 6-2.4 5.C. THIS HAD RESULTED IN EXCESSIVE WEAR ON BOTH THE COIL TAB AND THE CARBON BRUSH.

ROUGH RT ENGINE, LT MAGNETO OPERATION DURING RUN-UP CHECK. REMOVED MAGNETO, PN BL-349350-4, [S/N removed], MODEL S6RN-1225 AND FOUND MAGNETO GEAR BUSHING AND RETAINER BROKEN. CONSULTED WITH MFG FOR ADDITIONAL INSTRUCTIONS. REMOVED OIL PAN AND RECOVERED MISSING PIECES OF BUSHING AND RETAINER. VERIFIED ALL PIECES RECOVERED BY MATCHING UP BROKEN, MISSING PIECES. FOUND MAGNETO GEAR ROTATED WITH INTERMITTENT BINDING, GRINDING. INSPECTED ACCESSORY GEARS FOR CONDITION WITH NO DEFECTS NOTED.

(CAN) DURING 200HR INSPECTION OIL LEAK NOTICED ON LH SIDE OF ENGINE. AFTER CLEANING AREA WAS DETERMINED THAT IT WAS THE LH MAG GASKET LEAKING. MAGNETO WAS REMOVED AND MOUNTING FLANGE WAS FOUND TO BE BROKEN. BROKEN AT THE POINT THE HOLD DOWN PLATE IS USED TO HOLD DOWN THE MAGNETO TO ENGINE. CORRECT GASKET HAD BEEN USED AND THE MOUNTING PLATES & NUTS WERE TIGHT. NO IDEA HOW MANY HOURS WERE ON THE MAG FROM NEW. MAGNETO SENT TO ENGINE SHOP.

Parts most often named Hub (47) · Propeller (2) · Piston (2) · Cylinder (1)

PISTON CYLINDER BECAME SEPARATED FROM THE HUB. IT APPEARS THAT THE THREADS STRIPPED OUT OF THE HUB ABOUT 1/8 INCH. AT THIS TIME WE ARE SENDING TO H&S PROPELLER IN MICHIGAN FOR AN DETAILED TEAR DOWN INSPECTION REPORT TO DETERMINE THE FAILURE.

PROP ASSY WAS SUBMITTED FOR O/H AND OIL LEAK FROM CRACK. CRACK EXTENDS FROM BLADE NR 1 PORTAL THROUGH THE CYL MOUNTING SURFACE.

CRACK DISCOVERED ON ENGINE SIDE OF PROPELLER HUB. DISCOVERED WHEN PILOT EXPERIENCED A GREASE LEAK AND REMOVED SPINNER TO INVESTIGATE.

Parts most often named Engine (38) · Crankcase (6) · Lifter (2) · Case (2)

DURING CLIMB A PARTIAL LOSS OF ENGINE POWER OCCURRED WITH FLUCTUATING MANIFOLD PRESSURE. ALL OTHER ENGINE PARAMETERS WERE NORMAL. MAGNETO DROPS WERE NORMAL. PILOT RETURNED TO AIRPORT.

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.

EXPERIENCED POWER SURGES IN FLIGHT. FOLLOWED BY RPM DECLINE AND ENGINE FAILURE. UPON INSPECTION BY MECHANIC FOUND METAL IN OIL FILTER.

Parts most often named Adapter (6) · Pump (4) · Line (4) · Sump (2)

DURING EXTENDED FLIGHT, LOSS OF OIL PRESSURE OCCURED AND LEAD TO TOTAL ENGINE FAILURE. GASKET FOR OIL FILTER ADAPTER TO ENGINE FAILED. ON REMOVAL, NOTED THE GASKET HAD SPLIT AND WAS OFF TO ONE SIDE OF THE ADAPTER.

(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)

STARFLEX 193, LOW PRESSURE HOSE, LP MIL-H-50555 WAS USED TO CONNECT OIL COOLER TO FIREWALL FITTING. OIL PRESSURE WILL RUN BETWEEN 50-100 PSI IN LINE. HOSE BROKE AT FITTING AT OIL COOLER OUTLET, ALL OIL WAS PUMPED OUT OF ENGINE CAUSING ROD TO BE RAMMED THROUGH LT CASE HALF. (NORMAL TSO AS1072 HOSE IS INSTALLED IN THIS POSITION. STARFLEX 2650). (K)

Parts most often named Alternator (27) · Bearing (3) · Housing (3) · Circuit Breaker (3)

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.

DURING GROUND RUNUP, THE PILOT REPORTED THAT THE ALTERNATOR WAS DISCHARGING AND THE ALTERNATOR OUT LIGHT WAS ON. DURING TROUBLESHOOTING IT WAS FOUND THAT THE ALTERNATOR CIRCUIT BREAKER HAD FAILED, WITH AN ESTIMATED 17504 CYCLES. A NEW CIRCUIT BREAKER INSTALLED AND ALTERNATOR OPS NORMAL.

Parts most often named Pump (34) · Fuel Pump (3) · Gasket (2) · Vapor Separator (1)

(CAN) ON AN INSPECTION PRE-RUN UP IT WAS FOUND BY MAINTENANCE THAT THE FUEL PRESSURE WAS ON THE LOW SIDE OF THE GREEN BUT NOT IN THE STANDARD RANGE. FURTHER INSPECTION REVEALED A WORN ENGINE DRIVEN FUEL PUMP, THE FUEL PUMP WAS R & R WITH AN O/H UNIT AND THE SYSTEM WAS GROUND FUNCTION CHECKED [S/N removed]. THIS ENGINE ONLY HAS 972.9 HRS TTSO.

ENGINE DIED ON INITIAL RUN-UP DUE TO FUEL STARVATION. FOUND GALLING BETWEEN FUEL PUMP DRIVE GEAR AND HOUSING. CAUSE UNDETERMINED. SENT BOTH PARTS OUT FOR O/H.

ENGINE KEPT DYING AT IDLE. MAINTENANCE TECH TROUBLESHOT SYSTEM AND FOUND THAT THE ENGINE DRIVEN FUEL PUMP PRESSURE WILL NOT STABILIZE. VARIES BETWEEN 7.5 TO 10 PSI. REMOVED AND REPLACED ENGINE DRIVEN FUEL PUMP OPS CHECK NORMAL. PROBABLE CAUSE INTERNAL FAILURE IN FUEL PUMP. (K)

Parts most often named Fuel Control (10) · Fcu (4) · Support (2) · Lever (2)

ENGINE LOOSES POWER DURING FLIGHT. MAINTENANCE INSPECTED ENGINE AND CONTROLS, CLEANED INJECTORS AND PERFORMED GROUND RUN WITH NO DEFECTS NOTED. FLIGHT CHECK FOLLOWED WITH NO INDICATION OF PROBLEMS.

(CAN) ACFT APPLIED POWER FOR TAKEOFF AND ENGINE DID NOT ACCELERATE PAST IDLE. FCU REPLACED AND GROUND TESTED [S/N removed]. NOT FURTHER PROBLEMS NOTED.

PILOT REPORTED ENGINE RUNNING ROUGH AT IDLE UPON RETURNING TO BASE. ON TROUBLESHOOTING, THE MECHANIC FOUND THE ARM ON THE THROTTLE SIDE VERY ROUGH. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

Parts most often named Alternator (20) · Bearing (5) · Case (2) · Thru Bolt (1)

(CAN) ON RUN UP PILOT DISCOVERED THE ALTERNATOR WAS NOT CHARGING. REMOVED ALTERNATOR PN DOFF10300JR, 123.9 TSOH. INSTALLED [S/N removed] ALTERNATOR PN DOFF10300JR. RUN UP CARRIED OUT ALTERNATOR FUNCTION CHECKED OK.

(CAN) ON ENGINE START UP THE CREW NOTICED THE ALTERNATOR AMP GAUGE WAS SHOWING A DISCHARGE, THE ACFT SHUTDOWN AND MAINTENANCE REPLACED THE ALTERNATOR WITH NEW. THE SYSTEM GROUND FUNCTION CHECKED [S/N removed].

PILOT REPORTED ELECTRICAL FAILURE. INSPECTED ACFT, FOUND A/C IDLER PULLEY BEARING SEIZED, CAUSING PULLEY TO COME OFF AND CUT THROUGH SENSOR ALTERNATOR-OUT CONTROL BOX WIRING BUNDLE, CAUSING A/C AND ELECTRICAL POWER TO FAIL.