TSIO-360Continental TSIO-360

Parts most often named Cylinder (19) · Seal (9) · Retainer (6) · Tube (5)

ROCKER ARM SHAFT RETAINER CONTINENTAL P/N # 631996. FOUND CRACKED RETAINERS DURING ANNUAL INSPECTION WHILE PERFORMING VISUAL INSPECTION. ORDER REPLACEMENTS. OLD PARTS ARE CAST AND NEW STYLE REPLACEMENT WITH SAME PART NUMBER LOOKS TO BE BILLET.

CYLINDER NR 6 HAD BROKEN BOTH EXHAUST ROCKER SHAFT STUDS. HAPPENED ON SAME CYLINDER APPROXIMATELY 200 HOURS AGO ON A FACTORY CYLINDER WITH 1000 HOURS. PUSH ROD IS NOT BENT, LIFTER DOES NOT SHOW ANY SCORING. OUR ASSUMPTION IS THE LIFTER HYDRAULICALLY LOCKED AND PUT EXCESSIVE PRESSURE ON THE ROCKER CAUSING THE STUDS TO BREAK.

DURING ANNUAL INSPECTION, AN OIL LEAK WAS FOUND AT THE BOTTOM OF THE NR 2 CYLINDER AFTER WASHING THE ENGINE AND RUNNING IT AGAIN IT WAS NOTICED THAT THE OIL WAS LEAKING FROM THE CYLINDER IN THE AREA WHERE THE BARREL ATTACHES TO THE HEAD. THE CYLINDER HAD BEEN O/H 280 HOURS PRIOR TO THE FAILURE AND THE COMPRESSION ON THAT CYLINDER WAS 68/80. WE REMOVED THE CYLINDER AND FOUND A CRACK ABOUT 5" FROM THE END OF THE BARREL.

Parts most often named Servo (57) · Controller (12) · Fuel Control (2) · Fuel Servo (1)

(AUS) ENGINE FCU SERVO STEM SEAL LEAKING FUEL. FURTHER INVESTIGATION FOUND THAT THERE WERE MANY SMALL PARTS OF BLUE RUBBER THROUGH OUT THE UNIT. THESE RUBBER PARTS HAD COME FROM A POSSIBLE DAMAGED O RING SEAL DURING ASSEMBLY. ON TOTAL STRIP OF THE UNIT NONE OF THE O RINGS SHOWED SIGNS OF DAMAGE INDICATING THAT THE DAMAGED ORING MAY HAVE BEEN CHANGED BUT THE RUBBER NOT REMOVED.

COULD NOT ADJUST OVERLY RIGHT MIXTURE. SENT FOR FACTORY [S/N removed]. INSTALLED ON AIRCRAFT STILL COULD NOT ADJUST. SENT BACK TO FACTORY FOR REPAIRS. NOTE THESE UNITS ARE INSTALLED ON NEW AIRCRAFT, THIS IS 3RD SET OF [S/N removed] ON THIS AIRCRAFT.

FUEL SERVO GOUGED AT BASE BY SHOCK MOUNT ATTACHED TO ENGINE. SUBMITTED STATED SHOCK MOUNT DOES NOT COVER COMPLETE BASE OF SERVO. (X)

Parts most often named Crankshaft (15) · Crankcase (8) · Stud (4) · Cotter Pin (3)

(CAN) DURING A ROUTINE INSPECTION, A CRACK WAS DISCOVERED ON THE ENGINE CRANKSHAFT FLANGE, WHERE THE PROPELLER MOUNTS. THE CRACK WAS VERY SEVERE AS VERY TINY PIECES OF THE FLANGE HAD BROKEN OFF. THE CRACK APPEARS TO EXTEND THROUGH THE FLANGE OTBD OF THE DOWEL PIN HOLE TO THE RADIUS AND POSSIBLY AROUND THE RADIUS OF THE CRANKSHAFT. THERE HAVE BEEN NO REPORTED OR DOCUMENTED PROPELLER STRIKES SINCE THE ENGINE WAS INSTALLED APRIL OF 2012, FOLLOWING AN O/H.

DURING ANNUAL INSP, OIL WAS FOUND AT FRONT OF ENGINE. FURTHER INVESTIGATION REVEALED A CRACK OF THE CRANKSHAFT AT THE PROP MOUNTING FLANGE. CAUSE HAS NOT BEEN DETERMINED. (K)

DURING THE PROCESS OF INSPECTING (6 EA) CONNECTING RODS IAW SB 07-1 AND SB 00-3, IT WAS FOUND THAT ALL WRIST PIN BUSHINGS WERE INSTALLED NOT IAW THEIR POSITIONS AS REQUIRED IN THE APPLICABLE SB AS REFERENCED. SPLIT LINE OF BUSHING ON WRONG SIDE OF CENTERLINE. PARTS AS RECEIVED FROM MFG. (K)

Parts most often named Magneto (11) · Impulse Coupling (4) · Distributor Blk (3) · Distributor (3)

PERFORMED A MAGNETO CHECK BEFORE TAXI OUT, DETECTED NO RPM DROPPED WHEN LT MAGNETO TURNED OFF FOR LT ENGINE, TURNED OFF RT MAGNETO FOR LT ENGINE, ENGINE WAS GOING TO STALL. WHEN MX REMOVED THE MAGNETO, FOUND LT MAGNETO PLASTIC GEAR SHAFT LOSE AND MADE PLASTIC GEAR VIBRATE IN FORWARD AND AFT DIRECTION. DEFECT RECTIFIED AFTER MAGNETO REPLACED.

DURING A POST ACFT ACCIDENT ENGINE TEARDOWN IT WAS NOTED THAT THE RT MAGNETO FIRED ERRATICALLY BELOW 1400 RPM. FURTHER INVESTIGATION REVEALED THAT THE DISTRIBUTOR GEAR WAS LOOSE AND THE ROTOR GEAR WAS LOOSE. PILOT REPORTED LOSS OF POWER ON TAKEOFF.

POINTS WERE FOUND NOT MAKING CONTACT, UPON FURTHER EXAMINATION, FOUND THE STATIONARY CONTACT LOOSE IN MAG. IT SEEMED TO HAVE COME OFF THE END, THE CONTACT DISK SEPARATED FROM THE BASE. (K)

Parts most often named Pump (31) · Fuel Pump (3) · Shaft (1) · Bearing (1)

INSTALLED A FACTORY REMANUFACTURED ENGINE FROM CONTINENTAL THAT CAME WITH A NEW FUEL PUMP. UPON DOING THE ENGINE GROUND RUNS AND INITIAL ENGINE SET UP THE FUEL PUMP WOULD NOT SHUT OFF THE FUEL AFTER THE MIXTURE HAD BEEN PULLED BACK. INSPECTED SYSTEM FOUND TO HAVE A DEFECTIVE FUEL PUMP, REPLACED FUEL PUMP WITH A FACTORY NEW PUMP FROM CONTINENTAL. NO FURTHER ACTION NEEDED.

PILOT SQUAWKED THAT THE FUEL FLOW FOR THE RIGHT ENGINE WAS LOW AND ERRATIC IN-FLIGHT. MAINTENANCE INSPECTED AND TRIED TO ADJUST THE FUEL SYSTEM, REPLACED FUEL PUMP. NO FURTHER ACTION NEEDED.

ENGINE DRIVEN FUEL PUMP LEAKING. THE PUMP WAS DISMANTLED AND THE FOLLOWING DEFECTS WERE FOUND, ROTOR SHAFT FOUND WITH EXCESSIVE WEAR AND EXTREME SCORING, DEEP SCORING IN SHAFT BEARING (BUSHING), LOWER FACE OF ROTOR SHAFT HAS CONTACTED AND DAMAGED LOWER THRUST PLATE. THE WEAR ON PARTS HAS ALLOWED THE ROTOR TO BE LOADED TO ONE SIDE CAUSING WEAR ON LINER WALL 5. ROTOR SHAFT (AT VANE SEGMENTS) SHOWS SIGNS OF BEING SUBJECT TO EXTREME HEAT.

Parts most often named Housing (8) · Turbocharger (4) · Clamp (2) · Hose (1)

DURING INSP OF AD82-27-03, THERE IS A .5 INCH CRACK IN THE INTERNAL AREA OF THE HOUSING THAT DOES NOT PENETRATE THE OUTER WALL. IT WAS DETERMINED THAT THIS AD NO LONGER APPLIES, BECAUSE THE PN OF THIS HOUSING WAS FOUND TO BE 600510-04 (SEE PARA J) OF THIS AD.

TURBOCHARGER COMPRESSOR DAMAGED BY FOD INGESTED THROUGH THE ALTERNATE AIR DOOR. THIS DOOR IS ON TOP OF THE AIR FILTER BOX ALLOWING ANY OBJECT THROWN UP BY THE NOSE WHEEL TO ENTER THE INDUCTION SYSTEM WHEN THE DOOR IS ACTIVATED DURING PREFLIGHT CHECKS.

REMOVED TURBO FOR OTHER WORK, INSPECTED HOUSING PN 600510-04 AND FOUND IT TO BE CRACKED AS SHOWN IN AD 82-27-03 FIGURE 2, AD 82-27-03 DOES NOT APPLY TO THIS HOUSING NUMBER, RECOMMEND INSPECTING ALL TURBOS REGARDLESS OF AD.

Parts most often named Check Valve (2) · Drive Shaft (2) · Shaft (1) · Oil Filter (1)

UPON REMOVAL OF STARTER ADAPTOR FOR REPAIR DUE TO SLIPPAGE, IT WAS FOUND THA THE SCAVENGER PUMP HAD OUT OF TOLERANCE IMPESSER GEARS, PITTING AND CORROSION. ALSO, OTHER BUSHINGS WERE FOUND OUT OF LIMITS. THE ENGINE HAS BEEN INSERVICE FOR 49 HOURS AND 1 MONTH, SINCE MAJOR O/H. SUSPECT UN-[S/N removed] PARTS INSTALLED.

(CAN) ONE OF THE END CAPS THAT HOLD THE PAPER FILTER WAS NOT CRIMPED LIKE THE OTHER END WHEN THE FILTER WAS CUT FOR EXAMINATION DURING ROUTINE MAINTENANCE AND INSPECTION.

INFLIGHT FAILURE OF ENGINE, DUE TO OIL PUMP DRIVE GEAR SHAFT SHEARING. PILOT WAS IN CRUISE . ALTITUDE APPROXIMATELY 4000 FT MSL, UNSCHEDULED LANDING AT AIRPORT.

Parts most often named Mixture Plate (4) · Servo (2) · Valve (1) · Fitting (1)

ON BASE LEG TO GOODYEAR AIRPORT, THE LEFT ENGINE LAGGED POWER TO LANDING. A SAFE LANDING WAS MADE AND THE AIRCRAFT WAS TAKEN TO MAINTENANCE FOR INSP OF THE LEFT ENGINE. ON GROUND RUN-UP, FOUND THE LEFT ENGINE WAS RUNNING RICH AT LOW POWER SETTINGS. THE LEFT FUEL SERVO WAS REMOVED AND SENT TO TCM FOR WARRANTY. A NEW FUEL SERVO WAS INSTALLED FROM STOCK AND TRIM RUN COMPLETED, THE AIRCRAFT RETURNED TO [S/N removed]. (X)

ENGINE RAN RICH, UNABLE TO ADJUST IDLE MIXTURE. REMOVED SERVO FROM ENGINE AND INSPECTED IDLE MIXTURE PLATE FOR GALLING. PLATE WAS FOUND GALLED. SERVO SENT TO PRECISION FOR REPAIR. THIS SERVO HAS 24 HOURS TT SINCE NEW. 8 HOURS SINCE PRECISION REPAIRED SERVO AT FACTORY.

FITTING BROKE IN THREADS WHERE THEY SCREW INTO THROTTLE CONTROL. ENGINE QUIT IN FLIGHT. CONTINUED FLIGHT ON OTHER ENGINE TO BNA. PILOT SAW FUEL COMING FROM COWLING AFTER ENGINE QUIT. REMOVED AND REPLACED BROKEN FITTINGS. LEAK AND OPS CHECK OK. FITTING APPEARED DAMAGED BY PREVIOUS REMOVAL ATTEMPT. THIS AREA IS MISTAKEN FOR HAVING A SCREEN TO INSPECT, BUT NO SCREEN IS INSTALLED.

Parts most often named Engine (6) · Cotter Pin (1)

DURING ROUTINE OIL AND FILTER CHANGE, NON-FERROUS METAL CHUNKS WERE FOUND IN OIL FILTER. AIRCRAFT WAS REMOVED FROM [S/N removed] PENDING ENGINE TEAR DOWN AND REPAIR. FURTHER DETAILS WILL FOLLOW WHEN AVAILABLE.

UPON ROTATION, ENGINE ROUGHNESS WAS NOTED BY PILOT. TOWER REPORTED SMOKE FROM RIGHT ENGINE. LANDING PATTERN WAS ENTERED IMMEDIATELY, AND UNEVENTFUL LANDING MADE. MAINTENANCE COULD NOT DUPLICATE PROBLEM ON GROUND. RUN-UPS AND ENGINE INSPECTIONS SHOWED NO VISUAL EXTERNAL DEFECTS. MAINTENANCE INVESTIGATIONS ARE CONTINUING INTO THE PROBLEM. OCCURRED NOV 19, 1996.

DURING 100 HR INSPECTION, THE LEFT ENGINE OIL FILTER WAS FOUND TO BE CONTAMINATED WITH METAL. REMOVAL OF PROPELLER REVEALED METAL CONTAMINATION IN CRANKSHAFT. ENGINE WAS REMOVED FOR OVERHAUL. FURTHER DETAILS WILL BE PROVIDED UPON RECEIPT OF TEAR DOWN REPORT.

Parts most often named Valve (2) · Fitting (2) · Fuel Line (1) · Line (1)

AIRCRAFT WAS IN CRUISE FLIGHT WHEN IT EXPERIENCED AN IMMEDIATE ENGINE FAILURE ON THE RIGHT ENGINE, PILOT COULD NOT RESTART ENGINE. AFTER LANDING MAINTENANCE REPORTED A FITTING ON THE FUEL PUMP FOR THE VAPOR RETURN LINE HAD SHEARED.

THE FUEL INJECTOR LINE FROM THE FLOW DIVIDER TO THE NR3 CYLINDER ON THE RT ENGINE WAS ROUTED UNDER A COWL LATCH FOR THE COWLING NOSE BOWL WHICH CAUSED SEVER CHAFING IN A LOCALIZED AREA. THIS WAS ORIGINAL FACTORY ROUTING. NO FAILURE OCCURRED, PART WAS REPLACED AND DIGITAL PHOTO'S WERE PROVIDED TO MFG TECH [S/N removed].

FUEL INJECTION LINE TO NR 3 CYLINDER CHAFED BY CLAMP SECURING RUBBER INDUCTION COUPLING FROM INDUCTION SPIDER TO NR 5 CYLINDER INTAKE TUBE.