DA-42 in-flight engine failure

steve_falconer · Post by **steve_falconer** » Sat Sep 02, 2023 10:04 pm

Looks like a misquote on Lycoming engine failures. Not one engine failure out of every 1,100 hours, but about one engine failure out of 1,100 engines! or 0.91/1,000 engines from the referenced link showing Lycoming, Continental, and Rotax.

SamoL · Post by **SamoL** » Tue Sep 05, 2023 5:43 pm

Update 5th Sep 2023:
Today, after 12 days, the same mechanic came to change the fuel pump. When removing the old one he found pieces of gears (not sure which - I am still waiting for the report and images). This most probably means that the aircraft will need a new engine.

Soareyes · Post by **Soareyes** » Tue Sep 05, 2023 7:24 pm

SamoL wrote: ↑Tue Sep 05, 2023 5:43 pm Update 5th Sep 2023:
Today, after 12 days, the same mechanic came to change the fuel pump. When removing the old one he found pieces of gears (not sure which - I am still waiting for the report and images). This most probably means that the aircraft will need a new engine.

Probably this gear which is found inside the high pressure fuel pump, the subject of a previous MSB.

Did the mechanic or Diamond say you may need a new engine?

michael.g.miller · Post by **michael.g.miller** » Tue Sep 05, 2023 8:47 pm

Crazy that they could be installing faulty gears 2 years after the MSB. I hope it's not the same issue.

Boatguy · Post by **Boatguy** » Tue Sep 05, 2023 8:53 pm

michael.g.miller wrote: ↑Tue Sep 05, 2023 8:47 pm Crazy that they could be installing faulty gears 2 years after the MSB. I hope it's not the same issue.

But on the other hand, I hope it's not a new issue...

SamoL · Post by **SamoL** » Wed Sep 06, 2023 12:46 pm

Update 6th Sep 2023:
Fuel pump was removed yesterday. Pieces of gears that drive it were missing and could not be located - so they have most probably fallen into the engine. This means the engine will most probably need to be replaced, as this presents a significant risk.
Fuel pump was sent to Austroengine together with a fuel sample.

chili4way · Post by **chili4way** » Wed Sep 06, 2023 1:41 pm

If I remember correctly, the earlier situation was related to a manufacturing specification/tolerance issue with the drive gear at the end of the intake camshaft (shown in an earlier post), not with or within the HPP itself.

It's also possible that there could be an issue with the spur gear attached to the Bosch HPP. If either gear is out of tolerance, it's not good for either one.

Thanks for the updates.

SamoL · Post by **SamoL** » Wed Sep 06, 2023 2:09 pm

chili4way wrote: ↑Wed Sep 06, 2023 1:41 pm If I remember correctly, the earlier situation was related to an manufacturing specification/tolerance issue with the driving gear at the end of the intake camshaft, not with the HPP itself.

It is the gear at the end of the intake camshaft that broke...

ememic99 · Post by **ememic99** » Wed Sep 06, 2023 2:17 pm

SamoL wrote: ↑Wed Sep 06, 2023 2:09 pm
chili4way wrote: ↑Wed Sep 06, 2023 1:41 pm If I remember correctly, the earlier situation was related to an manufacturing specification/tolerance issue with the driving gear at the end of the intake camshaft, not with the HPP itself.
It is the gear at the end of the intake camshaft that broke...

So it seems it's known issue. I would check part numbers and insist on changing both engines within warranty if the parts are from the same batch.

chili4way · Post by **chili4way** » Wed Sep 06, 2023 2:46 pm

If you want to become familiar with the previous issue, see Austro Engine MSB-E4-034, MSB-E4-035, and MSB-E4-036. You can find Austro Engine documentation here: https://partners.diamondaircraft.com/s/files

It's important to let Austro complete their engineering diagnosis to determine what caused the issue. Either gear could be the source of the problem. That will determine the solution options available that will get you back in the air safely, as soon as possible with a reliable engine.

DA-42 in-flight engine failure

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