Piston Problems

During oil and filter change, chips and large metal pieces were found. During an annual inspection, the engine oil quick drain valve was blocked with debris. About a dozen pieces of what appeared to be piston ring pieces were removed. While performing a condition inspection, a crack was found on #6 intake. After takeoff, the crew noted engine vibration and lack of power. Inspection revealed excessive oil in the engine area and on the aircraft belly. After a precautionary landing due to power loss, a compression check showed zero on cylinder A4.

Key Takeaways:

• Across various aircraft engine models, common issues included broken piston skirts, seized or stuck piston rings, and carbon build-up leading to ring malfunction.
• Failures were discovered through diverse methods, from in-flight symptoms like power loss and vibration to routine maintenance checks revealing metal debris or blocked oil systems.
• Consequences ranged from severe internal engine damage to, in one case, surprisingly normal engine operation despite broken components, occurring at widely varying total operating hours.

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