Service difficulty report · Attach Fitting · Cirrus SR22

Difficulty date
June 21, 2010
Submitted
June 21, 2010
Operation
General aviation
Aircraft
N7855Z
Make and model
Cirrus SR22
Aircraft serial
1629
Aircraft time
1,200 hours
Engine
Cont IO550N
Engine time
1,200 hours
Part
Attach Fitting
Condition
Fractured
Location
Heated Air Tube
Stage of operation
CL
How discovered
O
Nature of condition
R, Y
Precautionary procedure
A

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

ENGINE HAD CEASED TO OPERATE AT 10,000 FT, BOOST PUMP TURNED ON, ENG RE-STARTED, PILOT UNABLE TO ADVANCE THROTTLE BEYOND "1ST DETENT" WITHOUT ENG VIBRATION. ACFT RETURNED TO BASE. MX GROUND RUN, MAG DROPS & FUEL SYS PARAMETERS WITHIN LIMITS UNTIL FULL POWER ATTEMPTED. ABOVE 2000 RPM, ENG HAD SERIOUS VIBRATION. VARIOUS CYLINDERS SHOWED DROP IN CHT & EGT. GROUND CHECK DISCONTINUED. COMPRESSION CHECK REVEALED NR 4 CYLINDER AT 28 PSI, OTHER 5 WERE ABOVE LIMITS. REMOVED NR 4 CYLINDER, LEAK AT INTAKE VALVE TO SEAT. FOUND EXCESSIVE WRIST PIN TO CONNECTING ROD CLEARANCE DUE TO ROD BUSHING & PIN WEAR. CLEARANCE APPROX .005 TO .007, .0015 TO .0017 IS CALLED FOR. REMOVED REMAINING CYLINDERS TO INSPECT FOR WRIST PIN WEAR & POSSIBLE ANSWER TO WHY ENGINE SHUTDOWN. FOUND 2 PIECES OF METAL APPROX .2500 BY .3750. 1 PIECE AT INDUCTION SIDE OF NR 1 CYL. OTHER IN NR 6. DAMAGE OCCURRED TO PISTONS NR 2 & NR 5, ALSO, CYLINDER HEAD NR 2 & NR 5 HAD BEEN MARKED BY THE METAL HAVING BEEN IN COMBUSTION CHAMBERS. 2 PIECES OF METAL MIGRATED, 1 PIECE OF METAL HAD HELD NR 4 INTAKE OPEN RESULTING IN PRESSURIZATION OF INTAKE MANIFOLD & CORRESPONDING REDUCTION OF FUEL FLOW. AS ENGINE CONTINUED TO WINDMILL PIECE DISLODGED & FUEL FLOW RE-ESTABLISHED ALONG WITH SUBSEQUENT ENG RESTART. INSP OF INDUCTION SYS REVEALED NO BROKEN COMPONENTS OTHER THAN HEATED AIR SUPPORT TUBE, MISSING 1 ATTACH LEG. LEG HAD BROKEN AT CLAMP THEN BROKE AGAIN NEAR WELD. IT SEEMS DIFFICULT TO THINK THAT THIS BROKEN PIECE MIGRATED UP A 2 PLUS INCH SCAT HOSE, PASSED THROUGH THE ALTERNATE AIR DOOR AND INTO THE INDUCTION SYS, (ALTERNATE AIR DOOR WAS MIS-RIGGED AND REMAINED ALWAYS OPEN ROUGHLY .3750 OF AN INCH), BUT THE METAL FOUND IS SIMILAR IN WIDTH AND THICKNESS TO THE BROKEN MATERIAL OF THE ADAPTER PN 18293-001. CIRRUS “TECH REP” WAS CONTACTED AND AT HIS SUGGESTION THE MATERIAL WILL BE SUBMITTED FOR FACTORY FOR LABORATORY ANALYSIS IN ORDER TO ARRIVE AT A DEFINITIVE SOURCE DETERMINATION. IF THE SUSPECTED MIGRATION OCCURRED, A PROTECTIVE SCREEN SHOULD BE ADDED TO EITHER ONE END OR THE OTHER OF THE HEATED AIR TUBE, P/N 50206-250 TO PREVENT A SIMILAR INCIDENT.

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