IO-360Lycoming IO-360

Parts most often named Magneto (66) · Impulse Coupling (47) · Screw (25) · Rivet (11)

UNDER NORMAL FLIGHT OPERATIONS, AT FIRST ROUTINE 500-HOUR INSPECTION FOUND COIL TAB WORN OUT OF LIMITS BECAUSE THE TAB WAS INCORRECTLY BEND AT FACTORY.

AFTER COMPLETION OF THE ANNUAL INSPECTION, WE PERFORMED A POST INSPECTION RUN. DURING IDLE WE CHECKED EACH MAGNETO AND FOUND THAT THE ENGINE RAN SIGNIFICANTLY ROUGHER ON THE LEFT MAGNETO THAN THE RIGHT MAGNETO. AT HIGHER RPM OPERATION WAS NORMAL. REMOVED LEFT MAGNETO AND OPENED FOR INSPECTION. IT WAS FOUND THAT THE MAGNETO OIL SEAL FAILED. THIS MAGNETO IS NEW WITH ONLY 105 HOURS SINCE INSTALLATION.

IN FLIGHT, RH ENGINE SUFFERED PARTIAL OIL PRESSURE LOSS. PRECAUTIONARY LANDING MADE AT KOXB. TROUBLESHOT LOSS OF OIL PRESSURE, DETERMINED TO BE AN INTERNAL ENGINE ISSUE. REMOVED ENGINE FROM [S/N removed] AND SENT TO COLUMBIA AIRCRAFT [S/N removed] INC. FOR INSPECTION/REPAIR. CAUSE DETERMINED TO BE A CATASTROPHIC FAILURE OF THE MAGNETO IMPULSE COUPLING IN WHICH FOD DAMAGED THE OIL PUMP ASSEMBLY. NOTE: DURING A 500HR MAGNETO [S/N removed]/IMPULSE COUPLING INSPECTION; NO DEFECTS WERE NOTED AT 1083.7 HOURS MAGNETO TT. 4330

Parts most often named Cylinder (49) · Pushrod (27) · Exhaust Valve (25) · Cylinder Head (17)

PILOT REPORTED LOUD NOISE FROM ENGINE, SIGNIFICANT POWER LOSS, AND LOUD VIBRATIONS. PILOT LANDED AT A NEARBY AIRPORT WHERE MANTIENCE DISCOVERED A LARGE CRACK IN CYLINDER #2(HEAD SEPERATING FROM THE BARREL).

ENGINE CYLINDER #2 CRACKED ACROSS COOLING FINS. CREW NOTICED LOSS OF POWER/SHUDDER. BURNING SMELL COMING THROUGH CABIN AIR VENTS.

ROCKER BOX COVER ON NUMBER 5 CYLINDER HEAD LEAKING OIL THROUGH HAIRLINE CRACK AT THE STAMPING MARK. THE LINE THAT UNDERLINES THE STAMPED "LYCOMING" LETTERS HAS A CRACK ALLOWING SLOW SEEPAGE OF ENGINE OIL AT ALL TIMES.

Parts most often named Crankcase (21) · Crankshaft (20) · Camshaft (15) · Stud (10)

UPON DISASSEMBLY FOR ITS FIRST OVERHAUL, DAMAGE WAS FOUND ON THE LEFT HAND CRANCASE TO ALL 4 THRU STUD LOCATIONS. THE DAMAGE APPEARS TO BE A GOUGE WITH DISPLACED METAL JUST UNDER THE CYLINDER PAD INSIDE THE THRU STUD BORE. IN ADDITION, 1 OF THE THRU STUDS HAVE A MINOR AMOUNT OF DISPLACED STEEL UNDER THE THREADED PORTION ON THE SHOULDER OF THE THRU STUD.

UPON DISASSEMBLY FOR IT'S FIRST OVERHAUL, DAMAGE WAS FOUND ON 1 OF THE THRU STUDS. THE DAMAGE APPEARS TO BE DISPLACED STEEL UNDER THE THREADED PORTION ON THE SHOULDER OF THE THRU STUD. THE DAMAGE IS MINOR BUT DUE TO THE SIMILAR LOCATION AND SEVERITY OF THE DAMAGE REPORTED IN SDR CONTROL# NX422026020600002, I FELT IT WAS BEST PRACTICE TO REPORT IT. THE LEFT HAND CRANKCASE OF THIS ENGINE ALSO HAS DAMAGE TO THE INSIDE OF ALL 4 THRU STUD BORE LOCATIONS

FORWARD MOST THROUGH CASE BOLT BEHIND CRANKSHAFT SEAL AND #1 MAIN BEARING, TOP STUD AND NUT MISSING. BOTTOM BOLT AND NUT LOOSE. LYCOMING WANTED ENGINE BACK IN CASE MAIN BEARING SPUN.

Parts most often named Fuel Control (34) · Servo (17) · Carburetor (11) · Fuel Servo (7)

NOTED THAT THE FUEL INJECTOR SERVO WOULD NOT HOLD AN IDLE MIXTURE SETTING. MIXTURE SETTING WOULD NEED TO BE ADJUSTED FREQUENTLY. MIXTURE SETTING WAS NOTED TO CHANGE FROM BEGINNING TO END OF A FLIGHT. MIXTURE CONTROL SETTING KNOB ON THE FUEL INJECTOR SERVO WOULD ALWAYS REMAIN WHERE IT WAS SET, HOWEVER, ACTUAL FUEL DELIVERY WOULD BE INCONSISTENT DUE TO A SUSPECTED INTERNAL COMPONENT FAILURE OF THE FUEL INJECTOR SERVO.

(CAN) CUSTOMER REPORTED THEY HAD AN IO360-M1A SHUTDOWN ON TAXI. THE COMPONENT SHOP SUSPECTED THE BELLOW (P/N: 2576568-1) FROM THE FUEL INJECTOR SYSTEM BEING THE ISSUE. (TC# 20190424007)

DUE TO PAST ISSUES WITH FUEL [S/N removed] MAINTENANCE STARTED DOING A FUEL SERVO VENTURI INSPECTION AT EVERY 100 HOUR INSPECTION. DURING THIS 100 HOUR INSPECTION WE FOUND THAT THE AREA BEHIND THE FUEL SERVO WAS CONTAMINATED WITH FUEL. IN THE PAST THIS CONTAMINATION HAS CAUSED ENGINE FAILURE. MANUFACTURE HAS INSISTED THAT THE ISSUE IS OVER-PRIMING. HOWEVER, THE MANUFACTURER STARTING PROCEDURE HAS BEEN FOLLOWED WITHOUT THE USE OF PRIME AT ALL SINCE THE LAST 100 HOUR.

Parts most often named Starter (51) · Drive Gear (8) · Housing (4) · Gear (4)

(CAN) DURING WALKAROUND, IT WAS OBSERVED THAT THE STARTER ENGAGEMENT GEAR WAS RUBBING ON THE CRANKSHAFT RING GEAR. IT APPEARS AS IF THE ENGAGEMENT GEAR IS UNABLE TO FULLY RETURN TO ITS RESTING POSITION. (TC# 20190912007)

STARTER MOTOR BODY HAD SEPARATED IN TWO SECTIONS. ONE OF TWO BOLTS HOLDING TWO SECTIONS HAD DEPARTED/MISSING. ONE BOLT IS HOLDING THE MOTOR IN ONE PIECE. THIS IS SECOND TIME I AM SEEING THIS TYPE OF FAILURE WITH THIS MODEL STARTER MOTOR IN ABOUT A MONTH.

PILOT REPORTED PILOT DRIVE FAILED WITH LESS THAN 140 HOURS SINCE O/H. DRIVE UNIT WAS FROZEN AND WOULD NOT RETRACT, NO LUBE WAS VISIBLE ON THE SHAFT AND NO PART, SN, OR MARKINGS WERE FOUND ON DRIVE ASSY. A CALL TO STATED THAT A PN, [S/N removed] APPEAR ON THE END OPPOSITE OF THE SPLINE, ALONG WITH AN FAA/PMA MARKING.

Parts most often named Engine (44) · Powerplant (4) · Power Plant (3) · Plug (2)

ON TAKE-OFF THE ENGINE LOST POWER MOMENTARILY AND PILOT WAS ABLE TO ABORT TAKE-OFF AND LAND WITHOUT INJURIES. POWER RESTORED ITS SELF AND TROUBLESHOOTING COULD NOT DUPLICATE THE LOSS OF POWER.

WHILE IN STRAIGHT AND LEVEL FLIGHT PILOT REPORTED THE ENGINE RPM REDUCED SIGNIFYINGLY RESULTING IN POWER LOSS. AFTER A BRIEF TIME THE ENGINE RPM BEGAN TO OPERATE NORMALLY AND POWER WAS RESTORED. PILOT LANDED WITHOUT INCIDENT. TROUBLESHOOTING COULD NOT DUPLICATE THE PROBLEM.

SCRATCHED AT THE ROD ASSY – PUSH AND ROCKER ASSEMBLY. THE SCORED CONDITIONS HAVE BEEN FOUND AFTER REPORTS OF: HIGH OIL TEMPERATURE, LOSS OF POWER, HIGH OIL CONSUMPTION

Parts most often named Bulkhead (36) · Spinner (13) · Plate (2) · Dome (1)

WHILE PERFORMING A PREFLIGHT INSPECTION THE PILOT FOUND THE AFT SPINNER BULKHEAD CRACKED AT THE EDGE WHERE THE PROP EXITS THE SPINNER. REMOVED PROP AND INSTALLED NEW SPINNER BULKHEAD P/N 0550321-12.

SPINNER BULKHEAD FOUND CRACKED AFTER 2 MONTHS OF OPERATION, WITH NEW ONE PREVIOUSLY INSTALLED. HAVE TO REPLACE THESE AT ABOUT EVERY 200 HRS DO TO CRACKS.

(CAN) FORWARD SPINNER BULKHEAD WAS FOUND CRACKED NEAR THE OUTSIDE OF AT LEAST 4 OF THE 6 PROPELLER BOLT HOLES. NO DAMAGE OR OTHER TRAUMA WAS NOTED ON THE SPINNER, PROPELLER OR AFT SPINNER BULKHEAD AND THE BULKHEAD WAS NOT FOUND TO HAVE BEEN STRESSED WHILE INSTALLED. SUBMITTER SUSPECTS IMPROPER HEAT TREATMENT AFTER FORMING DURING MFG.

Parts most often named Pump (36) · Washer (5) · Fuel Pump (2) · Seal (1)

FUEL WAS DISCOVERED IN ENGINE OIL. INSPECTION REVEALED THAT THE FUEL PUMP LW-15473 SEAL HAD FAILED AND LEAKED INTO THE OIL. THE ENGINE WAS CHANGED.

(CAN) OVER U78 RED MESSAGE SAID LOW FUEL PRESSURE AND ENGINE SPUTTERED 2X ON R TANK. TURNED ON AUX PUMP AND SWITCHED TO L, NO MORE ISSUES. (TC# 20190925009)

DURING A DUAL LESSON AT 2500MSL THE AIRCRAFT EXPERIENCED A POWER INTERRUPTION. FOLLOWING THE CHECKLIST, THE ELECTRICAL FUEL PUMP WAS TURNED ON WHICH RESTORED NORMAL POWER IMMEDIATELY. THE FLIGHT RETURNED TO KLOT WITHOUT FURTHER INCIDENT. UPON INSPECTION OF THE AIRCRAFT IT WAS DETERMINED THAT THE ENGINE DRIVEN FUEL PUMP WAS THE SOURCE OF INTERRUPTION.

Parts most often named Packing (10) · Fuel Line (8) · Servo (7) · Manifold (3)

PILOT REPORTED POWER LOSS AND ENGINE ROUGHNESS. UPON INSPECTION, FOUND #1 INJECTOR LINE BROKEN AT FERRULE AT INJECTOR NOZZLE. ENGINE HAS 1653.4 HOURS SINCE FACTORY OVERHAUL AND 33.0 HOURS SINCE LAST INSPECTION IN ACCORDANCE WITH AD 2015-19-07.

AIRCRAFT DIED IN RUNUP AREA TWICE. ONCE ON RAMP, ONCE IN RUNUP. FAILED IDLE CHECK. FUEL SERVO WAS REMOVED AND FOUND TO BE CONTAMINATED. REPLACED WITH NEW.

AIRCRAFT HAD MOMENTARY POWER LOSS/VIBRATION AFTER ADDING FULL POWER ON A TOUCH AND GO. ABORTED TAKEOFF. TOOK AIRCRAFT TO A RUNUP AREA AND CYCLED THE ENGINE FROM POWER IDLE TO FULL POWER MULTIPLE TIMES AND COULD NOT RECREATE THE ISSUE. FUEL SERVO REPLACED.

Parts most often named Alternator (24) · Brushes (4) · Bearing (2) · Stud (2)

ALTERNATOR ATTACHMENT BRACKET MOUNTING HOLES ELONGATED CAUSING THE ALTERNATOR FAN/FLYWHEEL TO GRIND AGAINST THE ALTERNATOR ATTACHMENT BRACKET LEADING TO ALTERNATOR FAILURE. THIS ENGINE WAS RECENTLY OVERHAULED AND HAD ONLY 80 HOURS SINCE OVERHAUL. THE FRONT BUSHING AND MOUNTING HOLE IN THE BRACKET WERE [S/N removed] ELONGATED ALONG WITH ONE OF THE BOLT HOLES IN THE BASE PLATE OF THE MOUNTING BRACKET. THIS ALLOWED ENOUGH PLAY FOR THE ALTERNATOR FLY WHEEL TO CONTACT THE MOUNTING BRACKET.

(CAN) OVERHAULED ALTERNATOR WITH LESS THAN 250 HRS TSOH. PILOT REPORTED DISCHARGE AT LOW RPM AND WAS CONFIRMED WITH GROUND RUN. RECOMMENDED OVERHAUL IS 2500 HRS.

ON APPROACH, THE LOW VOLTAGE LIGHT ILLUMINATED. RESET OF THE ELECTRICAL SYS WAS UNSUCCESSFUL. ELECTRICAL LOAD WAS MINIMIZED WITH AN UNEVENTFUL LANDING. THE ELECTRICAL SYSTEM WAS TROUBLESHOT AND THE ALTERNATOR WAS FOUND AT FAULT, NOT CHARGING. ALTERNATOR WAS REPLACED.