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The Aircraft Engine Cylinder Report

Cracks in your aircraft's cylinders will lead to problems in-flight. Somewhat fortunately, your engine will alert you with roughness, and you will have time to land. But your cylinders are crucial - keep them clean and sturdy, or expect malfunction. Here are some recent FAA Service Difficulty Reports that highlight the issue.

Gemini Sparkle

Key Takeaways:

  • Aircraft engines experienced critical cylinder failures, including cracks in various locations (spark plug holes, injector ports, exhaust ports) and complete barrel/cylinder separation.
  • These failures manifested as engine roughness, oil/fuel leaks, or low compression, impacting engine performance and safety.
  • Incidents involved cylinders from multiple manufacturers (ECI, Superior, TCM, PWC) across various aircraft models, with detection occurring during both routine inspections and in-flight operations at diverse part total times.
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Piper PA-46-301P Malibu
ECI: Cylinder/Barrel Separation

Aircraft was climbing through 8000 feet when pilot experienced a “pop” followed by engine roughness. After a safe landing, a significant amount of oil was visible on the cowling. Inspection revealed the #6 cylinder had separated.

Part total time: 632.0 hours

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