EngineTroubleshootingGuide
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:[email protected] AlltechnicalportionsofthisbookletareFAADERapproved(09/22/2004) Forinstallationeligibility,visitourwebsiteatwww.eci.aero 19982011EngineComponentsInternational.Allrightsreserved.
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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
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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.
Impropergradeofoil Pressurereliefvalvestuckclosedorimproperlyadjusted Oilcoldorfrozen Oilpipebentorcrushed Defectivepressuregauge Insufficientbearingclearance OilScreenorfilterclogged Bearingtightduetoengineoverheating
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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.
Bentpulley Alternatorbearingsorarmature Worndynamicdampnerbushingsorpins
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.
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Mixturetoolean Impropergradeoffuel Airleaksininductionsystem Highcarburetorairinlettemperature Magnetosimproperlytimed Damagedcylinderbaffles,fins,orrestrictionsinairflow
EngineTroubleshootingGuide
10
7. 8. 9. 10. 11. 12. 13. 14. 15.
Incorrectvalveoperationorclearance Restrictionsinexhaustsystem Temperaturegaugedefective Thermocouplewirestooclosetoexhaustmanifold Sparkretarded Preignitionthroughcarbonordefectivesparkplugs Warpedvalves Loosevalveseatsandguides Wornvalveguides
EngineWontStopWhenSwitchisTurnedOff
4points 1. 2. 3. 4.
Magnetogroundwireslooseorbroken Faultymagnetoswitch Engineexcessivelyhot Incandescentcarbonincylinders
CarburetorLeaksFuel
6points 1. 2. 3. 4. 5. 6.
Leakyorstuckfloat Excessivefuelsupplypressure Poorseatingofneedlevalve Wornfloatfulcrumpin Improperfloatlevel Looseneedlevalveseat
EngineSpitsBackinCarburetor
13points 1. 2. 3. 4. 5.
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Coldengineorcoldmixture Leanmixture Airleaksinmanifold Airleaksaroundintakevalvestems Weakvalvesprings
11
EngineTroubleshootingGuide
6. 7. 8. 9. 10. 11. 12. 13.
Stickingvalves Sparkplugwirescrossedorincorrectlyconnected Ignitionoutoftimeorretarded Camshaftoutoftime Overheating Carbon Impropergradeoffuel Wateringasoline
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
Fouledsparkplug Defectivesparkplug Brokenorgroundedsparkplugwire Impropervalveclearance Lowcompressionononeormorecylinders Damagedmagnetodistributorhead
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.
Shortcircuitedsparkplugs Shortcircuitedsparkplugwire Shortcircuiteddistributorblock Sparkpluggaptoowide Weakexhaustvalvesprings Insufficientvalvetappetclearance
SingleCylinderMissatLowSpeed
7points 1. 2. 3. 4. 5. 6. 7.
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Shortcircuitedsparkplug Shortcircuitedsparkplugwire Shortcircuiteddistributorblock Wrongsparkpluggap Weakcompression Airleakaroundintakevalvestem Weakexhaustvalvespring
13
EngineTroubleshootingGuide
CausesofPreIgnition
5points 1. 2. 3. 4. 5.
Carbon Overheating Excessivelyrichmixture Ignitionoutoftime Sparkplugwirescrossedorconnectedtowrongcylinder
CausesofExcessiveCarbonDeposit
5points 1. 2. 3. 4. 5.
Enginefloodedwithoil Wornpistonrings Inferiorqualityofengineoil Richmixture Engineoperatedforlongperiodwithoutcleaningcarbon
MagnetoFailstoDeliveranySpark
4points 1. 2. 3. 4.
Primarycircuitgroundedoropen Secondarycircuitgroundedoropen Groundwireorswitchgrounded Condensercircuitopenorshorted,orcondenserpunctured
CrankcaseFillswithOil(DrysumpSystem)
6points 1. 2. 3. 4. 5. 6.
2011 EngineComponentsInternational
Scavengerpumphaslostitsprime Scavengerpumpscreenstoppedup Scavengersuctionorpressurelinesstoppedup Airleakinsuctionsideofscavengerpump Brokenscavengerpumpdrive Scavengerpumpbadlyworn
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.
RichMixture:Longdeepblueflamewithredtip,blacksmoke. LeanMixture:Shortirregularlightblueflamewithyellowtip. ProperMixture:Quickblueflamewithoutyellowtip. Oilpumpingisshownbyblueexhaustsmoke.
ATooRichMixturemaybecausedby:
6points 1. 2. 3. 4. 5. 6.
Highfuelpressure Oilincylinders Carburetorfloatvalveseatingimproperly Floatleakingair Jetgasketsofimproperthicknessoroutofshape Floatleveltoohigh(thesetroubleswouldberesponsibleforthe carburetorfloodingandarichmixture,particularlyatlowspeeds)
ATooLeanMixturemaybecausedby:
9points 1. 2. 3. 4. 5. 6. 7. 8. 9.
Insufficientfuelintank Partiallycloggedfuelline Insufficientairpressureinpressurefueltank Airventonfueltankclogged Fuelfilterorjetsclogged Carburetorfloatleveltoolow Waterincarburetororsystem Airleaksininductionsystem Stickingvalves
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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.
CrossReferencePartsList(Booklet#M157) PMASupplements ServicePublications
ECiPartNumberstoLycoming,TCM&SAP ECiPartNumberstoPMASupplementnumber
PistonRingSetsInstructionsforAEL65102CylindersPlasmaFacedPistonRings InstructionsforAEL320&360CrankshaftsECiCylforTCM470520550ColorCodeson CylindersContinuingAirworthinessDataandInstallationEligibilityofECiCrankcases andmanyothers.
TITANCylinderAssemblies
Features&Benefits:WhatYouShouldKnow(Booklet #M105)
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M125(06/14/2011)
