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1. 08:01 AM - Engine troubleshooting (Sonja Englert)
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| Subject: | Engine troubleshooting |
Hi Everyone,
If you ever had a problem with your engine and have spent a lot of
time trying to figure out what is wrong (as I have a number of times),
you will understand this. I have written a new book called Piston
Engine Troubleshooting for Pilots. It has 80 pages and many
illustrations, my retail price is $15.00. I am now taking it with me
when I go fly. The book has a comprehensive list of symptoms along
with possible causes and descriptions of the systems. This should make
it much easier to find and fix whatever is the issue.
Most four-stroke engines are very similar, so most of the descriptions
apply to all engines. Where differences exist, this book lists
engine-specific issues for Lycoming, Continental, Rotax, Jabiru and
Volkswagen engines. Look up my web site www.caro-engineering.com for
the details.
Sonja
Here is the index:
Section 1 Symptoms.................................................................................................................1
1. Engine Quits
.........................................................................................................................1
1.1 Without Warning, High Power
.....................................................................................1
1.2 Without Warning, Low Power or Idle
..........................................................................1
1.3 With Preceding Warning
...............................................................................................2
1.3.1 Engine Cuts Out and Restarts
................................................................................2
1.3.2. Rising CHT before Power Loss, Engine
Smooth................................................2
1.3.3. Low Oil Pressure Before Power Loss
..................................................................2
1.3.4 Engine Roughness before Power
Loss..................................................................3
1.3.5 Engine Roughness when advancing
Throttle........................................................3
2. Engine Runs Rough..............................................................................................................3
2.1 At High Power Settings (Throttle Far Forward)
..........................................................3
2.1.1 Intermittent, Brief
...................................................................................................4
2.1.2 Continuous
Roughness...........................................................................................4
2.1.3 Intermittent Severe
Roughness..............................................................................5
2.1.4 Roughness Right after Startup
...............................................................................6
2.1.5 Sudden Severe
Vibration........................................................................................7
2.1.6 Roughness at High Altitude
...................................................................................7
2.2 Rough at Low Power or Idle
.........................................................................................7
3. Vibrations .............................................................................................................................8
3.1 At Certain RPM..............................................................................................................8
3.2 At High Power Settings
.................................................................................................8
3.3 At All Power Settings
....................................................................................................9
3.4 Intermittent
Vibrations.................................................................................................10
3.5 Vibration Worst at Low Power
...................................................................................10
4. Partial Power
Loss..............................................................................................................10
4.1 Low EGT......................................................................................................................10
4.2 Drop in Manifold Pressure
..........................................................................................10
4.3 Engine Does Not Produce Full Power
........................................................................11
4.4 Turbocharged Engine, Loss of Manifold Pressure
....................................................12
4.5 Low Fuel Pressure, Level Flight
.................................................................................13
4.6 Fuel Pressure Dropping in Climb
...............................................................................13
4.7 Gradual loss of
Power/RPM........................................................................................13
4.8 Low Static RPM on the
Ground..................................................................................14
4.9 Engine Surges...............................................................................................................14
5. Poor Engine Acceleration
..................................................................................................15
6. High Oil Consumption.......................................................................................................16
7. High or Uneven Engine Temperatures
.............................................................................18
7.1 High CHT.....................................................................................................................18
7.2 High Oil Temperature..................................................................................................20
8. Abnormal Instrument
Readings.........................................................................................20
8.1 Fluctuating Oil Pressure
..............................................................................................20
8.2 Low Oil Pressure..........................................................................................................21
8.3 High Oil Pressure
.........................................................................................................22
8.4 Fluctuating or Unusual
EGT.......................................................................................22
8.5 High Fuel Flow Reading
.............................................................................................23
8.6 Low Fuel Flow at Full
Power......................................................................................23
9. Engine is Hard to
Start.......................................................................................................24
9.1 Engine Not or Barely
Cranking...................................................................................24
9.2 Starter not Engaging Every
Time................................................................................24
9.3 Engine Cranking But Does Not
Fire...........................................................................24
9.4 Engine Does Not Fire When
Hot................................................................................26
9.5 Engine Quits after Firing
.............................................................................................27
9.6 Rough Idle ....................................................................................................................28
10. Other.................................................................................................................................29
10.1 No RPM Drop During an Ignition Check
................................................................29
10.2 Metal Found in Oil
Filter...........................................................................................29
10.3 Overboost on Turbocharged Engine
.........................................................................29
10.4 Engine Misfires at Idle in Flight
...............................................................................30
10.5 Engine Will Not Shut Off With Mixture Cut Off
....................................................30
10.6 Engine Will Not Shut Down with Ignition
Off........................................................30
10.7 Leaded Fuel Problems
...............................................................................................30
10.8 Oil on the
Windshield................................................................................................31
10.9 Alternator Belt Comes Off
........................................................................................31
10.10 Fuel Leaking from Carburetor
................................................................................31
10.11 High Manifold Pressure on Turbocharged Engine
................................................31
10.12 White Smoke in Exhaust on Turbocharged
Engine...............................................32
10.13 Alternator
Failure.....................................................................................................32
10.14 Engine Overspeed....................................................................................................32
10.15 Engine Fire
...............................................................................................................32
Section 2 Systems...................................................................................................................33
Ignition Systems.................................................................................................................33
Lycoming Ignition
System............................................................................................33
Continental Ignition
System..........................................................................................34
Jabiru Ignition
System...................................................................................................34
Rotax 912/914 Ignition
..................................................................................................35
Spark Plugs .....................................................................................................................37
Starter System.....................................................................................................................38
Fuel Systems.......................................................................................................................40
Typical Constant Depression Carburetor
.....................................................................40
Small Engine Mechanical Fuel
Pumps.........................................................................42
Rotax Fuel Systems........................................................................................................43
Fuel Injection Schematic
Lycoming.............................................................................44
RSA Fuel Servo (Fuel/Air Control Unit)
.....................................................................46
Fuel System Continental................................................................................................48
Airframe Fuel Systems
..................................................................................................50
Liquid Cooled Engines
......................................................................................................51
Rotax Liquid Coolant
System.......................................................................................51
Oil Systems........................................................................................................................52
Rotax 912 Oil System....................................................................................................52
Lycoming Oil System....................................................................................................52
Continental Oil Systems
................................................................................................53
Volkswagen Engine Oil
System....................................................................................55
Engine Oil Pump............................................................................................................55
Inverted Oil System.......................................................................................................56
Oil Analysis and Oil
Filters...........................................................................................57
FADEC Engines .................................................................................................................58
Mechanical Systems...........................................................................................................59
Four-Stroke Engine Operation
......................................................................................59
Overview Continental Engine
.......................................................................................60
Overview Lycoming Engine
.........................................................................................61
Induction Systems..........................................................................................................62
Engine Cooling...............................................................................................................63
Valve Actuation and Issues
...........................................................................................64
Engine Bearings
.............................................................................................................67
Torsional Vibration
Dampers........................................................................................67
Turbocharger Systems
.......................................................................................................68
Continental Turbocharger System
Overview...............................................................68
Turbocharger Lubrication..............................................................................................70
Engine Vibration
................................................................................................................71
References..............................................................................................................................73
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