Owners, Drivers, and Maintainers of Continental engines...

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Roger, Roger

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Just in case you haven't heard, recent conversations and google searches have brought it to my attention that ECI cylinders are garbage. Just so you know...
 
Re: Owners, Drivers, and Maintainers of Continental engines.

I just flew a plane from Dallas to FLL and found out after the fact that it had a cracked cylinder. WTF.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

A friend of mine changed a cylinder on the ramp at an outstation because it cracked, then blew a hole in the cylinder after less than 600 hours total time. Note, this was NOT one of the cylinders covered under the ECI cylinder AD. I have heard stories from other operators of similar events-one guy said they topped an entire IO-520 because all 6 jugs were cracked after less than 400 hours. BE CAREFUL and I highly suggest a compression check with soapy water to check for cracks at least at every 100 hour, and possibly every 50 hours. Those cylinders are downright dangerous. ANY Continental cylinder manufactured by ECI, whether the AD applies to it or not, should be regarded as an accident waiting to happen.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

I'm tired of single pistons. I think I'm going to get a job flying a twin or a turbine. Too many cracked jugs and other problems for my taste. At least with a twin you can limp it somewhere and shoot an approach.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

Update: after getting the plane back to the maintenance base and thoroughly checking it out, my friend found 4 more cracked cylinders on the same engine. Yikes.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

Sounds ECI could be due for a lawsuite here soon.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

trafficinsight said:
Depending on where the crack is and the size of it you wouldn't even notice.
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'zakly. Until exhaust gas widens the crack enough to blow a hole in the cylinder head. 1500° gas at 1000+ PSI is a pretty good blowtorch for anything else in the engine compartment. Not sure what the time frame is from first crack to hole in the head though. As far as finding the cracks, word has it that spraying soap solution on the cylinder head while doing a standard compression check works pretty well.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

trafficinsight said:
Depending on where the crack is and the size of it you wouldn't even notice.


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That's exactly why it's so concerning. If you noticed it you wouldn't fly it. Ironically, this particular jug had the highest of the 6 on the motor at the last annual (only a couple months ago).
 
Re: Owners, Drivers, and Maintainers of Continental engines.

roundout said:
That's exactly why it's so concerning. If you noticed it you wouldn't fly it. Ironically, this particular jug had the highest of the 6 on the motor at the last annual (only a couple months ago).
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That's not limited to continental or ECI cylinders exclusively. I've seen it on any and all. Lycoming cylinders tend to crack near the lower spark plug hole or the exhaust port... The ECI Lycoming cylinders affected by the AD crack around the cylinder head where they screw it onto the barrel, that's why you spray soapy water onto the joint, a cracked cylinder blows bubbles ;).
 
Re: Owners, Drivers, and Maintainers of Continental engines.

trafficinsight said:
The ECI Lycoming cylinders affected by the AD crack around the cylinder head where they screw it onto the barrel, that's why you spray soapy water onto the joint, a cracked cylinder blows bubbles ;).
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Not this round. The ones my friend has been seeing on ECI Continental jugs originate near the top spark plug hole and seem to migrate over to the intake valve seat. At least, that is what he said all the cracked, but not blown out jugs had done. After the bubble trick a small oil line was visible between the 2nd and 3rd cooling fin inboard of the fuel injector nozzle winding its way down the side of the cylinder. None of these (other than the one that totally failed) showed any indication of cracks on the exhaust side of the cylinder, which is quite odd considering it is the hottest and most highly stressed part of the cylinder. I doubt he would let me share any pictures, some companies are awful sensitive about stuff like that getting out to anyone other than the proper authorities. I might see if I can get some just for my own education though.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

Roger said:
Not this round. The ones my friend has been seeing on ECI Continental jugs originate near the top spark plug hole and seem to migrate over to the intake valve seat. At least, that is what he said all the cracked, but not blown out jugs had done. After the bubble trick a small oil line was visible between the 2nd and 3rd cooling fin inboard of the fuel injector nozzle winding its way down the side of the cylinder. None of these (other than the one that totally failed) showed any indication of cracks on the exhaust side of the cylinder, which is quite odd considering it is the hottest and most highly stressed part of the cylinder. I doubt he would let me share any pictures, some companies are awful sensitive about stuff like that getting out to anyone other than the proper authorities. I might see if I can get some just for my own education though.
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If you took the photos or your friend took the photos I don't see how they could stop you from sharing them. Who knows, you may save a life!
 
Re: Owners, Drivers, and Maintainers of Continental engines.

It could be that the friend is trying to work with operators who use ECI cylinders instead of peeing in their cheerios first. I'm sure when the time comes to stand his ground over safety Rogers friend will hold the line. Diplomacy first, table the nuclear option so to speak.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

I'll see what I can do about the pictures. If nothing else, if anyone is curious I'm sure I can e-mail them.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

ECI cylinders may be crap, but isn't this a common problem with Continental? Every one I have ever flown you have to watch cyl. head temps like a hawk.
 
Re: Owners, Drivers, and Maintainers of Continental engines.

pulled two TCM cylinders off today for leakage past the exhaust valves with barely 500 hours on them.
 
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