TIO-540Lycoming TIO-540

Parts most often named Cylinder (88) · Stud (20) · Cylinder Head (18) · Valve Seat (11)

ENGINE LOST POWER ON TAKEOFF ROLL AND TAKE OFF WAS SAFELY ABORTED. FOUND NO COMPRESSION ON CYLINDER #6 AND DETERMINED THE ENTIRE INTAKE VALVE WAS MISSING. FOUND VALVE IN THREE PIECES IN INTAKE PLENUM. VALVE STEM TIP HAD SEPARATED FROM THE VALVE STEM AT THE KEEPER GROOVE AND WAS STILL IN THE ROTATOR CAP. LIFTER, PUSH ROD ENDS, ROCKER, VALVE SPRING RETAINER AND KEEPERS WERE STILL IN PLACE AND UNREMARKABLE. PARTS SENT TO LYCOMING FOR EVALUATION.

PILOT REPORTED ENGINE NOT MAKING POWER. FOUND EXHAUST ROCKER SHAFT HOLDER BROKEN AND NO LONGER ATTACHED TO CYLINDER ASSEMBLY. CAUSING EXHAUST VALVE TO NOT OPEN WHEN REQUIRED.

RIGHT ENGINE #1 CYLINDER INDICATED ZERO DURING A COMPRESSION CHECK. UPON CLOSER EXAMINATION A CRACK WAS DISCOVERED AROUND THE UPPER SPARK PLUG HOLE THAT EXTENDED INTO THE INTAKE PORT BETWEEN COOLING FINS 14 AND 15. THIS IS THE 2ND FAILURE ON THIS AIRCRAFT AND THE 3RD TOTAL AMONG BOTH COMPANY AIRCRAFT.

Parts most often named Crankcase (42) · Camshaft (35) · Crankshaft (30) · Bearing (19)

AT CRUISE ALTITUDE, AN OIL PRESSURE FLUCTUATION WAS OBSERVED ON NO.1 ENGINE INSTRUMENTS. ALSO NOTICED A SMALL OIL STREAK ON NO. 1 ENGINE COWL. DECISION WAS IMMEDIATELY MADE TO RETURN TO BASE, FOR FURTHER INVESTIGATION BY ENGINEERS.

(CAN) DURING REGULAR OIL CHANGE ABNORMAL AMOUNTS OF FERROUS METAL NOTED IN OIL FILTER INSPECTION. CYLINDERS NR 4 & 6 REMOVED FOR INSPECTION & DISCOVERED GALLING DAMAGE TO CYLINDER NR 6 EXHAUST LOBE & CAM FOLLOWER. ENGINE REMOVED FOR REPAIR.

(CAN) DURING REPETITIVE TROUBLESHOOTING FOR REPORTED LT ENGINE OIL LEAK, MAINTENANCE FOUND ENGINE CRANK CASE CRACKED APPROXIMATELY 6" LONG, EXTENDING FROM NR 6 CYLINDER BASE, UPWARD INTO CASE. ENGINE WILL BE REPLACED.

Parts most often named Magneto (84) · Capacitor (14) · Distributor Blk (11) · Coil (9)

THE RT ENGINE WOULD NOT START OR EVEN FIRE. A STARTER VIBRATOR SYSTEM IS USED AND WAS FOUND TO BE FUNCTIONAL THROUGH TROUBLESHOOTING. THE LT MAGNETO WAS REMOVED, DISASSEMBLED. INSPECTION FOUND THAT THE PLASTIC COM LOBE HAD SIGNIFICANT WEAR CAUSED BY PRIMARY BREAKER TAB CONTACTING THE RETARD BREAKER AND NOT BEING ABLE TO FULLY OPEN. THIS CONTACT AND WEAR ON THE LOBE PREVENTED THE RETARD BREAKER FROM FULLY OPENING. THIS MAGNETO WAS PART OF A NEW ZERO TIMED ENGINE WITH ONLY 12.8 HRS TIS.

OPERATOR REPORTED DIFFICULTY STARTING THE AIRCRAFT. UPON CHECKING THE MAGNETO TO ENGINE TIMING, IT WAS FOUND THAT THE RETARD BREAKER POINTS WERE OPENING VERY LATE. REMOVED MAGNETO, DISASSEMBLED AND INSPECTED. THE CAM FOR POINTS WAS FOUND TO BE SEVERELY WORN. MAGNETO WAS REPLACED AND OPERATIONS WERE SATISFACTORY. IT SHOULD BE NOTED THAT THE CHAMPION / SLICK FOR THE 6300 [S/N removed] MAG CALLS OUT FOR A 500 HOUR INSPECTION. THIS MAGNETO HAD NOT BEEN REMOVED FROM ENGINE SINCE NEW AND WAS 100 HOURS PAST RECOMMENDED TIME.

EXPERIENCED ENGINE ROUGHNESS ON LEFT ENGINE, 5-10 MINUTES AFTER DEPARTURE, AT CRUISE ALTITUDE OF APPROXIMATELY 2,500 FEET MSL. ISOLATED THE PROBLEM TO THE RIGHT SIDE OF LEFT ENGINE DUAL MAGNETO AND CONTINUED THE FLIGHT ON THE LEFT SIDE OF DUAL MAGNETO(RIGHT SIDE COCKPIT SWITCH OF DUAL MAGNETO TURNED OFF ON LEFT ENGINE UNTIL REACHING THE AIRPORT.

Parts most often named Turbocharger (54) · Bearing (15) · Seal (9) · Wastegate Valve (9)

PILOT WAS IN CRUISE FLIGHT AND EXPERIENCED A PARTIAL POWER LOSS AND THEN OIL PRESSURE LOSS OF THE RIGHT ENGINE. PILOT SHUT DOWN ENGINE AND LANDED WITHOUT FURTHER INCIDENT. UPON INSPECTION OF ENGINE IT WAS FOUND THAT THE SHAFT WAS BROKEN AND BOTHER TURBINE AND COMPRESSOR BLADES WERE DAMAGED. TURBO WAS A RECENT INSTALL AFTER OVERHAUL BY ATC AND HAD 87.9 HOURS TSO. MECHANICS VERIFIED THAT THE TURBO WAS PRE-OILED PRIOR TO RETURN TO [S/N removed] AND NO ISSUES WERE REPORTED POST-INSTALL.

WHILE PERFORMING AN OIL CHANGE AND AD 17-11-10, WE DISCOVERED A CRACK IN THE WELD ASSEMBLY P/N 12509927 FOUND JUST AFTER THE WASTE GATE. INSTALLED NEW EXHAUST WELD ASSY P/N 1250992-7 (8130-3) GASKET P/N 24096-225N (8130-3) AND COUPLING P/N S3262-6 IAW CESSNA SINGLE ENGINE (1996 & ON) 206HMM: REVISION - 21, REVISION DATE - APR 1, 2020 CHAPTER 78-10-01. PICTURES WILL BE SENT TO SUPPLEMENT REPORT.

TURBOCHARGER FAILURE DUE TO MAIN BEARING FAILURE. TURBOCHARGER LOCKED UP (FROZE) AND BLOCKED AIR TO THE INDUCTION SYSTEM. PIC DID NOT EXECUTE PROCEDURES IN THE POH (MANUAL SELECTION OF ALTERNATE AIR SOURCE) RESULTING IN OFF AIRPORT LANDING AND INCIDENT REPORT. LAS VEGAS FSDO

Parts most often named Pump (66) · Fuel Pump (7) · Gasket (5) · Shaft (4)

PRE-FLIGHT RUN-UP DISCOVERED LACK OF TAKE OFF POWER AND ENGINE VIBRATION. THE AIRCRAFT FLIGHT WAS ABORTED AND THE AIRCRAFT RETURNED TO THE HANGER. THE ENGINE WAS TROUBLESHOT AND THE ENGINE DRIVEN FUEL PUMP WAS DISCOVERED TO HAVE MULTIPLE DEFECTS IN ITS LOWER DIAPHRAGM. THIS DEFECT ALLOWED FUEL TO ENTER THE INTAKE SYSTEM WITH THE MIXTURE IN CUT-OFF AND THE THROTTLE RETARDED WITH THE AIRFRAME ELECTRIC PUMP RUNNING. THE PUMP HAD 228 HOURS SINCE INSTALLATION AND NO ABNORMAL OPERATING PRACTICES WERE NOTED.

ENGINE WOULD NOT SHUT DOWN WITH MIXTURE CONTROL AT IDLE CUTOFF. FOUND ENGINE DRIVEN FUEL PUMP LEAKING FROM RELIEF VALVE INTO DECK PRESSURE REFERENCE LINE INTO INTAKE. ENGINE DRIVEN FUEL PUMP REPLACED WITH NEW.

OVERHAULED ENGINE DRIVEN FUEL PUMP FAILED AFTER 23.2 HOUR TIS. FUEL PUMP FAILED TO MAINTAIN FUEL PRESSURE AT IDLE RPM. MAJOR PROBLEM INDUSTRY WIDE.

Parts most often named Gasket (12) · Seal (11) · Baffle (9) · Oil Filter (6)

DURING CRUISE LEFT ENGINE DEVELOPED AN OIL LEAK. PILOT ELECTED TO SHUTDOWN ENGINE. MAINTENANCE INDICATED THAT THE NOSE SEAL DEVELOPED AND OIL LEAK. DUE TO THE TIME REMAINING ON THE ENGINE, ENGINE WILL BE REPLACED AS OPPOSED TO REPAIR.

ON CLIMBOUT TO 9000 FT OIL TEMP WENT TO 240 DEGREES F AT 7500 FT. REDUCED POWER TO 20MAP AND TEMP KEPT CLIMBING TO 270. MADE A PRECAUTIONARY LANDING. GROUND TEMP 21 DEGREE F AIR TEMP AT 7500 FT 0 DEGREE F

OIL LEAKING FROM OIL FILTER ADAPTER. THIS HAS BEEN A PROBLEM WITH THIS MODEL OF ENGINES IN THE PAST THAT HAS CAUSED ENGINE FIRES. THIS OIL LEAK WAS FOUND POST FLIGHT AND THERE WAS NO EVIDENCE OF A FIRE IN THE ENGINE COMPARTMENT. WE INSTALLED A NEW OIL FILTER ADAPTER GASKET IAW MFG SI1543B AND SB543.

Parts most often named Engine (53) · Bearing (4) · Tube (2) · Shaft (1)

RIGHT ENGINE BECAME ROUGH IN CRUISE. AIRCRAFT LANDED UNEVENTFULLY. FOUND #2 CYLINDER HYDRAULIC LIFTER P/N: 15B28037 COLLAPSED. INTAKE VALVE STEM BROKEN. PISTON DAMAGED.

DURING ANNUAL INSPECTION, FOUND OIL LEAK AT SWITCH AROUND PLASTIC BODY. THIS SWITCH APPLIES TO AD 13-11-11. TOTAL TIME ON SWITCH 883.0 SWITCH WAS NEW WITH AIRCRAFT=2006.

PILOT PERFORMED PRECAUTIONARY INFLIGHT ENGINE SHUTDOWN OF THE LEFT ENGINE DUE TO THE FOLLOWING: CHT INDICATING 500, OIL PRESSURE HIGH RED LINE, OIL TEMP CREEPING UP TOWARDS 200. ENGINE CONFIGURATION AS FOLLOWS: COWL FLAPS OPEN, MANIFOLD PRESSURE OF 20'. MAINTENANCE IS ASSESSING THIS CONDITION, NO FURTHER INFORMATION AT THIS TIME.

Parts most often named Exhaust Pipe (24) · Exhaust Duct (7) · Clamp (6) · Exhaust Stack (5)

PILOT REPORTED MANIFOLD PRESSURE SPIKE AND ENGINE SURGE. FOUND A LOOSE EXHAUST V-BAND COUPLING AND MISSING THE V-BAND COUPLING GASKET. FOUND THE MISSING GASKET LODGED IN THE TURBOCHARGER AND DESTROYED THE TURBINE BLADES. PLEASE CONTACT ME FOR PICTURES AND VIDEO.

A 12 MONTH / 250 HOUR INSPECTION OF THE EXHAUST SYSTEM SLIP JOINTS AND MARMON CLAMPS, IS WAS NOTED THAT THE CROSSOVER EXHAUST TUBES COULD NOT BE SEPARATED. THE PIPES WERE ALSO DEFORMED. THIS IS A CRITICAL AREA OF THIS ENGINE INSTALLATION AND THIS INSPECTION IS REFERENCED IN LYCOMING 521 AND 531C.FAILURE TO PERFORM THIS INSPECTION AT LEAST ANNUALLY COULD LEAD TO EXHAUST PIPER FAILURE AND POSSIBLE FIRE IN THE ENGINE COMPARTMENT. WE REPLACED THE CROSSOVER PIPES P/N 40B19850 AND 40B19974 PER LYCOMING INSTRUCTIONS.

ELECTRICAL WIRES ON FORWARD SIDE OF FIREWALL WERE COMPROMISED DUE TO EXHAUST LEAK AT TURBO/DOWN PIPE INTERFACE, AND SHORTED OUT ON EACH OTHER. CAUSING A TEMPORARY, SMALL SMOKE PLUME. NOT EVIDENCE OF SUSTAINED FIRE WAS FOUND.

Parts most often named Line (16) · Hose (5) · Fuel Line (3) · Filter (3)

PILOT REPORTED FUEL SMELL DURING FLIGHT. MAINTENANCE INSPECTED AND WHILE TROUBLESHOOTING FOUND RIGHT ENGINE INBOARD FUEL RAIL LEAKING AT WELD IN VICINITY OF #2 CYLINDER INJECTOR AT MALE B NUT. THE FUEL RAIL ASSEMBLY WAS REPLACED WITH NO FURTHER DEFECT NOTED. ENGINE MODEL NUMBER NOT LISTED IN SECTION 3. ENGINE MODEL TEO-540-C1A

A STRONG VIBRATION IN THE ENGINE AT 60 NM FROM THE AIRPORT WAS PRESENTED, TO 40 NM THIS IS ACCOMPANIED BY NOISE UNABLE TO CORRECT BY REDUCING THE RPM THE ENGINE "COUGHED" LIKE A LACK OF FUEL, CONTINUED FAILURE TO REPORT THE EMERGENCY TO 10NM FROM THE AIRPORT. THE ENGINE WAS INSPECTED AND FOUND THE ASSY FUEL MANIFOLD TO NOZZLE CYLINDER NR 3 WITH A BREAK.

DURING CRUISE FLIGHT, RT ENGINE NR 6 CYLINDER EGT AND CHT DROPPED TO ZERO DEGREES AT THE SAME TIME AN ENGINE VIBRATION STARTED. RT ENGINE WAS THEN SHUTDOWN AS A PRECAUTIONARY MEASURE. LANDED AT AIRPORT WITHOUT INCIDENT. INSPECTED RT ENGINE AND FOUND NR 6 CYLINDER FUEL INJECTOR LINE BROKEN AT THE SOLDER JOINT AT THE FUEL INJECTOR. NR 6 CYLINDER AREA AND ENTIRE BOTTOM SIDE OF ENGINE WERE SATURATED WITH FUEL.

Parts most often named Starter (22) · Mount (6) · Housing (3) · Drive Gear (1)

PILOT REPORTED ENGINE WOULD NOT START / STARTER WOULD NOT ENGAGE. A VISUAL INSPECTION OF THE STARTER REVEALED THE HOUSING HAD COMPLETELY CRACKED AROUND THE FORWARD PORTION OF THE HOUSING SEPARATING THE FORWARD SECTION OF THE HOUSING FROM THE MAIN STARTER BODY. STARTER WAS INSTALLED ON 01/21/2018 AND HAD ACCUMULATED 223.3 HOURS TIME IN [S/N removed] SINCE NEW / INSTALLATION.

(CAN) CASE LUG FOR ACCESSORY BELT IDLER ASSY FOUND BROKEN. CONTRACT AMO DISCOVERED DEFECT WHEN INSTALLING O/H PROPELLER. STARTER CASE NOT [S/N removed] WITH LUG BROKEN. REMOVED FROM [S/N removed]. TO BE SENT TO MFG FOR ANALYSIS, REPAIR WHEN SDR WAITING PERIOD COMPLETE.

(CAN) DURING A SCHEDULED INSPECTION, THE RT STARTER AFT CASE WAS FOUND LOOSE. THE CASE ATTACH BOLT LOCK TABS WERE STILL ENGAGED, BUT THE BOLTS WERE LOOSE. STARTER WAS REMOVED AND REPLACED WITH A [S/N removed] SPARE.