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:salesservice@eci.aero 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

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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

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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

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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.

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Fouledsparkplug Defectivesparkplug Brokenorgroundedsparkplugwire Impropervalveclearance Lowcompressionononeormorecylinders Damagedmagnetodistributorhead

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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

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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.

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Scavengerpumphaslostitsprime Scavengerpumpscreenstoppedup Scavengersuctionorpressurelinesstoppedup Airleakinsuctionsideofscavengerpump Brokenscavengerpumpdrive Scavengerpumpbadlyworn

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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.

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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

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Notes

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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)
Allpublicationsareavailableonourwebsite,CDsandinprinted format.PleasecontactoneofourTerritoryManagersor contactyourlocalengineshopforyourcopytoday!

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