Service difficulty report · Intake Valve · Robsin R44

Difficulty date
October 8, 2018
Submitted
October 25, 2018
Operation
General aviation
Aircraft
N41LY
Make and model
Robsin R44
Aircraft serial
30020
Aircraft time
194 hours
Engine
Lyc O540F1B5
Engine time
194 hours
Part
Intake Valve
Part number
17A23938
Condition
Burned
Location
Engine
Part time
194 hours
Component
Cylinder · Lyc
Component part number
LW13870
Stage of operation
CR
How discovered
B
Nature of condition
R
Precautionary procedure
A

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

What was found

SUPPLEMENTAL INFORMATION (PLEASE REPLACE THE TEXT FROM THE PREVIOUSLY SUBMITTED REPORT WITH THE FOLLOWING CORRECTED TEXT): THE AIRCRAFT OPERATOR COMPLAINED OF AN INTERMITTENT POWER LOSS. TROUBLESHOOTING LED TO THE POSSIBILITY OF A STUCK INTAKE OR EXHAUST VALVE. INSPECTION IN ACCORDANCE WITH SB 388C WAS PERFORMED. VALVES ON CYLINDERS NUMBER 2 AND 5 REQUIRED REAMING; HOWEVER, NO EVIDENCE WAS FOUND THAT THEY WERE ACTUALLY STICKING. NUMBER 1 CYLINDER HAD A BURNED INTAKE VALVE AND REQUIRED REPLACEMENT WITH A NEW CYLINDER KIT P/N 05K21745 UNDER WARRANTY FOR FEWER THAN 200 HOURS ON THE ENGINE. THE INTAKE VALVE SEAT IN THAT CYLINDER WAS FOUND CROOKED AND EVEN A NEW VALVE WOULD NOT MAKE FULL CONTACT WITH THE SEAT. AFTER A RETURN TO SERVICE / CYLINDER BREAK-IN FLIGHT A COMPRESSION TEST SHOWED: 1)76, 2)67 INTAKE LEAKING, 3)76, 4)76, 5)76, AND 6)75. BORESCOPE INSPECTION REVEALED NUMBER 2 INTAKE VALVE WAS NOT SEATING PROPERLY. WE REPLACED NUMBER 2 CYLINDER WITH A NEW CYLINDER KIT P/N 05K21745. THIS WAS ALSO ACCOMPLISHED UNDER WARRANTY. INSTALLED CYLINDER ASSEMBLY IN ACCORDANCE WITH SI1024D. PERFORMED A GROUND RUN AND FLIGHT IAW SI1427. COMPLIED WITH POST-FLIGHT COMPRESSION TEST. RESULTS WERE: 1) 77, 2) 77, 3) 76, 4) 76, 5) 77, AND 6) 77. AIRCRAFT WAS RETURNED TO SERVICE. PROBABLE CAUSE FOR THESE TWO CYLINDERS TO FAIL ON SUCH A LOW TIME ENGINE IS UNKNOWN TO THE SUBMITTER. BOTH CYLINDERS WERE RETURNED TO THE MANUFACTURER FOR REVIEW.