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ShortcutstoCostly EngineDiagnostics
IncludesSectionson: LowPowerandUnevenRunning HighOilTemperature ExcessOilConsumption EngineStops HighCylinderHeadTemperature EngineMisses CausesofExcessiveCarbonDeposit ATooRichMixture ATooLeanMixture andmanyothers
EngineTroubleshootingGuide
ShortcutstoCostly EngineDiagnostics
Publishedby EngineComponentsInternational 9503Middlex SanAntonio,TX782175994 1800ECi2FLY (8003242359) www.eci.aero Email:salesservice@eci.aero AlltechnicalportionsofthisbookletareFAADERapproved(09/22/2004) Forinstallationeligibility,visitourwebsiteatwww.eci.aero 19982011EngineComponentsInternational.Allrightsreserved.
EngineTroubleshootingGuide
TableofContents
EngineTroubleshootingGuide.........................................4 TableofContents.............................................................4 FailureofEnginetoStart..................................................2 LowPowerandUnevenRunning.....................................3 HighOilTemperature.......................................................4 ExcessOilConsumption...................................................4 LowOilPressure...............................................................5 HighOilPressure..............................................................5 ImproperEngineAcceleration .........................................6 . FailureofEnginetoIdleProperly.....................................6 FailureofEnginetoDevelopFullPower..........................7 EngineStops.....................................................................8 EngineVibratesExcessively..............................................8 EngineContinuallyThrowsAlternatorBelt......................9 EngineOverheats.............................................................9 HighCylinderHeadTemperature.....................................9 EngineWontStopWhenSwitchisTurnedOff..............10 CarburetorLeaksFuel....................................................10 EngineSpitsBackinCarburetor..................................10 EngineMissesIntermittently.........................................11 EngineMissesRegularly.................................................11 ScatteringMisfire...........................................................12 SingleCylinderMissatHighSpeed................................12 SingleCylinderMissatLowSpeed.................................12 CausesofPreIgnition....................................................13 CausesofExcessiveCarbonDeposit..............................13 MagnetoFailstoDeliveranySpark................................13 CrankcaseFillswithOil(DrysumpSystem)...................13 EnginePumpsOil ...........................................................14 . FaultySpark....................................................................14 MixtureAnalysisbyExhaustFlame................................15 ATooRichMixturemaybecausedby: ......................15 . ATooLeanMixturemaybecausedby:......................15 Notes..............................................................................16 ECiTechnicalReferenceMaterials................................17
EngineTroubleshootingGuide
2011 EngineComponentsInternational
EngineTroubleshootingGuide
FailureofEnginetoStart
27points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Lackoffuel Ignitionswitchoff Underprimingoroverpriming Incorrectthrottlesetting Coldoil Defectivebattery(batteryignitionsystems) Dirtyordefectivesparkplugs Waterinmagneto Wetignitionharness Wronggradeoffuel Sparkadvanceretardedtoofar Vaporinfuelsystem Waterincarburetor Defectiveignitionwiring Boostermagnetodefective Incorrectvalveand/orignitiontiming Defectivemagneto Brokenimpulsecoupling Magnetobreakerpointsdefective Incorrectvalveclearance Defectiveprimingsystem Internaltroubleincarburetor Intakemanifoldairleaks Broken,shreddedordefectivecamshaft Internalenginefailure Sparkplugwirescrossed Miscellaneous(turnengineoverslowlybyhandwiththemaster& magnetoswitchoffandnoteanyunusualcondition,particularlylow compression.
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EngineTroubleshootingGuide
LowPowerandUnevenRunning
29points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Mixturetoorichortoolean Leaksininductionsystem Defectiveorfouledsparkplugsandlooseplugconnections Improperfuelgrades Wetordefectiveignitionwiring Engineoverheating Defectivemagnetobreakerpoints Dirtyorbrokencarbonbrushesinmagneto Impropervalveand/orignitiontiming Propelleroutoftrack,orhubnutloose Carburetorheatcontrolmalfunction Crackedenginemountorloosemountbolts Foreignmatterininductionsystemorfuellines Incorrectlyadjustedcarburetorcontrollinkage Fuelfeedvalveleakingornotoperatingproperly Warpedorburnedvalvesorvalveseats Brokenvalvesprings Wornorstickingpistonsorcylinders Crackedpistonsorcylinders Bentpushrods Cylindergasketsblown Magnetogroundwirelooseandgrounding Carburetoricing Fluctuatingfuelpressure Defectiverockerarmsorbearings Defectivevalveguides Bentcrankshaft Crosswindonpropellerduringgroundoperation Sparkplugwirescrossed
2011 EngineComponentsInternational
EngineTroubleshootingGuide
HighOilTemperature
12points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Insufficientoilsupply Defectiveoiltemperaturegauge Airflowthroughoilcoolerblocked Oilcoolerbypassvalvemalfunction Cylinderbafflesmissingorinsecure Poorairflowaroundoiltank Cloggedoillinesorscreens Overheatedbearings Dirtyorimpropergradeofoil Impropergradeoffuel Improperignitiontiming Mainbearingshiftingincrankcasebearingbore.
ExcessOilConsumption
9points 1. 2. 3. 4. 5. 6. 7. 8. 9.
Impropergradeofoil Improperventingofoilsystem Pistonringsworn,brokenorincorrectlyinstalled Breatherlineexitinginlowpressureareaandblockedormissing vacuumbreakholeonbreatherline Crackedpistons Defectivesuperchargerseal Pistonoildrainholesclogged Oilpressuretoohigh Toomuchclearancebetweenintakevalveandguide
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EngineTroubleshootingGuide
LowOilPressure
18points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Insufficientoilsupply Oilpumpnotprimed Impropersettingofpressurereliefvalve Foreignmatterinreliefvalve Defectivepressuregauge,orcloggedgaugeline Impropergradeofoil Highoiltemperature Leakinsuctionlines Dirtinoilscreens Foaminginoiltank Oilcongealedinintakeline Excessivelydilutedoil Brokenoilline Excessivecamfollowertocrankcaseclearance Excessivebearingclearanceorwrongundersizebearings Crankshaftplugsleakingormissing Wornoilpumpgears Brokenoilpumpgearsordriveshaft
HighOilPressure
8points 1. 2. 3. 4. 5. 6. 7. 8.
2011 EngineComponentsInternational
EngineTroubleshootingGuide
ImproperEngineAcceleration
11points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Incorrectlyadjustedcarburetor Defectiveacceleratingpump Coldoil Defectivetachometer Improperpropellerpitchorwarpedpropeller Improperthrottleormixturecontrollinkageadjustment Fuelvalveleakingornotoperatingproperly Impropersparkadjustment Improperenginetiming Internalcarburetortrouble,orpressuretypecarburetoringravity fuelsystem 11. Airleaksorrestrictionininductionsystem
FailureofEnginetoIdleProperly
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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20points Carburetorcontrollinkageimproperlyadjusted Loosesparkplugconnectors Wateroroilinmagnetos Burnedorpittedcontactbreakerpoints Impropermagnetotiming Defectiveignitionharness Impropergradeoffuel Incorrectidlingspeedadjustment Throttlevalveclosingtoofar Idlingjetrestricted Airleaksininductionsystem Vaporinfuelsystem Improperfuelpressure Internalcarburetortrouble Partialobstructioninfuellines Fuelvalveleakingornotoperatingproperly Defectiveprimervalve Impropervalveclearance Lowcylindercompression Excessiveplayincarburetorcontrollinkage
EngineTroubleshootingGuide
FailureofEnginetoDevelopFullPower
29points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Carburetorcontrollinkageimproperlyadjusted Mixturetooleanortoorich Throttlevalvenotfullyopen Impropergradeoffuel Airleakincarburetor Incorrectfuelpressure Impropervalveclearance Impropergradeofoil Oiltoohotortoocold Rockerarmsnotproperlylubricated Incorrectvalveorignitiontiming Defectivesparkplugs Weakmagnetomagnets Burnedorpittedcontactbreakerpoints Excessivecarbonandpreignition Intakemanifoldtoocold Pressuretypecarburetoringravitysystem Weakorbrokenvalvesprings Lowcylindercompression Valveseatsscoredorworn Bentpushrods Excessivebackpressurefromexhaustmanifold Enginestiffortight Incorrectpropellersetting,orwarpedpropellerblades Engineoverheating Carburetorventuritoosmall Carburetoricing Impropergradeoffuel Defectivesupercharger
2011 EngineComponentsInternational
EngineTroubleshootingGuide
EngineStops
12points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Magnetosgrounded Outoffuel Carburetorjetsrestricted Airorvaporlockinfuelline Fuellinespartiallyobstructed Foreignobjectininductionsystem Waterinfuel Brokenfuellines Shearedtiminggears Internalstructuralfailure Propellercontactssolidobject Airventorfueltankobstructed
EngineVibratesExcessively
11points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Propelleroutofbalanceoroutoftrack Bentcrankshaft Unequalvalveclearance Defectivesparkplugs Enginelooseonmount Propellerhubnutloose Carburetoricing Incorrectcarburetorsetting Enginetoocold Improperignitiontiming Worndynamicdampnerbushingsorpins
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EngineTroubleshootingGuide
EngineContinuallyThrowsAlternatorBelt
3points 1. 2. 3.
EngineOverheats
15points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Retardedsparkorsparktimedlate Defectivewatercirculation Defectiveoilcirculation Thinoil LeanMixture Camshaftoutoftime Idlingenginetoolong Runningaircooledengineongroundtoolong Insufficientoilcooling Insufficientoilsupply Runningenginewithradiatororcowlingshuttersclosed Excessivecarbon Engineimproperlycowled Overheatedbearing Tightbearingsorpistonsoutofline
HighCylinderHeadTemperature
15points 1. 2. 3. 4. 5. 6.
2011 EngineComponentsInternational
EngineTroubleshootingGuide
10
EngineWontStopWhenSwitchisTurnedOff
4points 1. 2. 3. 4.
CarburetorLeaksFuel
6points 1. 2. 3. 4. 5. 6.
EngineSpitsBackinCarburetor
13points 1. 2. 3. 4. 5.
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11
EngineTroubleshootingGuide
EngineMissesIntermittently
13points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Incorrectmixture Impropergradeoffuel Waterinfuel Airleaksininductionsystem Slowvalveaction Defectivemagnetosorignitionharness Distributorpointsorcontactbreakerpointsdirtyorpitted Carburetorairheaterdefective Highoiltemperature Defectivesparkplugs Impropertiming Carburetoricing Magnetogroundwireswingingandperiodicallygrounding
EngineMissesRegularly
6points 1. 2. 3. 4. 5. 6.
2011 EngineComponentsInternational
EngineTroubleshootingGuide
12
ScatteringMisfire
12points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Leanmixture Richmixture Wateringasoline Airleakinintakemanifold Intakevalveholdingopen Stickyvalveguides Weakvalvesprings Excessivebreakerpointclearance Weakbreakerarmspring Excessiverotorcontactgapclearance Moistureondistributorblock Faultyspark
SingleCylinderMissatHighSpeed
6points 1. 2. 3. 4. 5. 6.
SingleCylinderMissatLowSpeed
7points 1. 2. 3. 4. 5. 6. 7.
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13
EngineTroubleshootingGuide
CausesofPreIgnition
5points 1. 2. 3. 4. 5.
CausesofExcessiveCarbonDeposit
5points 1. 2. 3. 4. 5.
MagnetoFailstoDeliveranySpark
4points 1. 2. 3. 4.
CrankcaseFillswithOil(DrysumpSystem)
6points 1. 2. 3. 4. 5. 6.
2011 EngineComponentsInternational
EngineTroubleshootingGuide
14
EnginePumpsOil
10points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Pistonringspoorfitinpistongrooves Pistonringspoorfitincylinder Brokenpistonrings Scoredcylinderwalls Excessivepistonclearance Excessiveoilpressure Thinoil Impropergradeofoil Excessivebearingclearance Faultyscavengerpump
FaultySpark
19points 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Breakerpointclearanceincorrect Breakerpointsburnedordirty Collectorbrushwornoutordirty Distributorbrushwornoutordirty Distributorsegments/rotorcontactcorrodedorburnt Collectorringshortcircuitedordirty Distributorrotorshortcircuitedordirty IncorrectEgap Primarywindingshortcircuitedordirty Secondarywindingshortcircuitedorburnedout Condensershortcircuitedorpunctured Magnetsweakorcrossed Looseorcorrodedconnectionwithinthemagneto Groundwireorswitchshortcircuited Moisturewithinthemagneto Armaturetouchespolepieces Foreignmaterialcollectedonarmature Defectivesparkplugs Carbontracksresultingfromflashovercausedbymoisture.
15
EngineTroubleshootingGuide
MixtureAnalysisbyExhaustFlame
4points 1. 2. 3. 4.
ATooRichMixturemaybecausedby:
6points 1. 2. 3. 4. 5. 6.
ATooLeanMixturemaybecausedby:
9points 1. 2. 3. 4. 5. 6. 7. 8. 9.
2011 EngineComponentsInternational
EngineTroubleshootingGuide
16
Notes
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17
EngineTroubleshootingGuide
ECiTechnicalReferenceMaterials
BreakinInstructions(Booklet#M101)
OilTalkforDummiesSuggestedPrecautionsforNewand RemanufacturedEnginesRuninvs.BreakinLubricationfor RuninandBreakinBreakinProceduresLubricationfor NormalOperationCylinderReplacementOilFiltration BreakinRecord.
ClassReferenceManual(Booklet#M108)
Crossreferencingsectionsinclude:Lycoming&Continental EngineModelstoECiCylinderStudAssemblyClassNumberto LYC/TCMCylinder,Piston,Ring,Valve,Guide,Seat,etc. ReferenceRadialEngineManufacturers&ModeltoECiCylinderStudAssemblyClass NumbersCylinderStudAssemblyClassNumberDifferentiationsContinentalCylinder ClassDifferencesLycomingCoreP/NinAscendingOrdertoECiCylinderClassNumber ContinentalCoreP/NinAscendingOrdertoECiCylinderClassNumber.
ECiPartNumberstoLycoming,TCM&SAP ECiPartNumberstoPMASupplementnumber
TITANCylinderAssemblies
Features&Benefits:WhatYouShouldKnow(Booklet #M105)
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ENGINECOMPONENTSINTERNATIONAL 9503Middlex|SanAntonioTX78217 TollFree1800ECi2FLY(8003242359) Tel2108208101|Fax2108208102 www.eci.aero|Email:salesservice@eci.aero FederalAviationAdministration ECServicesFAACertifiedRepairStationNumberAG2R689K JointAviationAuthorities JAR145AcceptanceCertifiedJAA\MAINT\A10\93L530 ECiisrecognizedforQualityManagementSystemcompliancetoISO9001:2000
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