General Aviation FAA
Joint Steering Committee Aviation Safety
Safety Enhancement Topic
Engine Maintenance and Performance Monitoring
In order to reduce the risk of loss of control accidents due to engine failure related factors, the FAA and
industry are reviewing the current technological capabilities available for engine trend monitoring, engine health
analysis, fuel management, and fuel indicator systems. Between 2001-2010, 35 of 70 randomly selected accidents had
engine maintenance errors identified as a contributing factor. When a pilot makes an error, the consequences
sometimes manifest immediately. A maintenance error, on the other hand, can take many years to manifest into an
accident. Proper engine maintenance, post maintenance advanced pre-flights, and engine performance monitoring
can go a long way in eliminating this type of mishap.
Accidents Happen … But This One Probably Didn’t Have To ...
On Jan. 11, 2005, an airplane First, poor engine maintenance directly
experienced a total loss of contributed to this mishap. From the report:
engine power and collided with The engine was overhauled last in 2001. The engine
wires and a power line pole manufacturer recommends replacement of oil hoses
while descending for a forced landing. The pilot- at normal engine overhaul. A note in the airplane
rated student reported that while returning, he maintenance manual indicates that rubber engine
noted a smell of something burning which triggered compartment hoses are to be replaced every five
him to look at the engine gauges; he noted " … that years or at engine overhaul, whichever occurs first.
we had no oil pressure." The flight continued for 5 Examination of the hose by the NTSB Materials
minutes 3 seconds until the engine quit. The CFI Laboratory revealed a .7 inch long crack located
took the controls and tried to maneuver for a approximately 4.25 inches from the oil cooler adapter
forced landing but the airplane collided with power end.
lines, then a power pole. A post-accident inspection
The NTSB determined a contributing factor of this
noted oil film on the exterior surface of the fuselage
accident was:
bottom skin, and in the engine compartment area
on the aft side of the baffling. A leak was noted The failure of company maintenance personnel to
from a flexible hose near the oil cooler end. Ten replace the flexible oil cooler hoses during engine
ounces of oil remained in the engine, which installation following overhaul, as recommended by
exhibited internal evidence of oil exhaustion which the engine manufacturer.
resulted in failure of the No. 2 cylinder connecting Second, this mishap serves
rod cap and bolt. as a great example for how
engine performance
monitoring might have
detected an issue far
sooner.
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AFS-850 16-06
Sound Maintenance Practices Engine Performance Monitoring
Get to know your airplane, and your mechanic! Basic instrumentation such as airspeed
Ideally, pilots and mechanics should work together indicators, attitude indicators, angle of attack
to make sure the aircraft is operated and indicators, manifold pressure gauges, RPM
maintained properly. As a pilot, you are encouraged gauges, and G-force meters all give immediate
to take an active role in maintenance by reviewing feedback as to whether design limitations have
inspection results and discussing Airworthiness or are about to be exceeded. This information is
Directives and Service Bulletins with your mechanic. available real-time on every flight.
Engine diagnostic equipment can come in many
different forms. One version is the external,
Don’t ignore regular hand-held test kit that attaches to ignition plugs
maintenance! and determines system functionality. A good
Be sure to comply with all test kit can check engine compression,
manufacturer-recommended service intervals. magnetos, ignition leads, and engine timing, to
name a few.
Fifty-hour oil changes are recommended for
most normally-aspirated piston engines. Engine data management (EDM) systems come
in a variety of forms and are offered by a host of
Turbo-charged engines should undergo oil
different companies. These devices watch over
changes more frequently.
your engine while you concentrate on flying the
An oil filter inspection with each oil change will aircraft and, combined with a controller, can
yield immediate feedback. meter your mixture and exhaust gas
Investigate further if you find metal particulate temperature (EGT) to optimize lean-of-peak
in the filter. operations. Some brands even offer the
interpretive software and/or provide
Oil analysis can reveal a lot about engine health,
professional analysis as to what your data might
but it works best when several samples create a
indicate. In most cases, you can upload your
trend.
information directly to a website, and if need
It’s not a bad idea to do a compression check as be, request a report when anomalies present
well as check magneto timing, spark plugs and themselves.
the exhaust system every other oil change.
A digital/electronic engine control (D/EEC)
Resources: regulates the functions of the injection system
To learn more about engine data management to ensure the engine provides the power that is
systems read “Check Engine!” in the May/June 2015 required of it. An engine control unit reads a
edition of FAA Safety Briefing. multitude of sensors and then manipulates the
engine by adjusting a series of actuators.
Sensors include ones for airflow, engine cooling,
throttle position, and fuel flow.
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