EngineTroubleshootingGuide

ShortcutstoCostly
EngineDiagnostics

IncludesSectionson:
LowPowerandUnevenRunning
HighOilTemperature
ExcessOilConsumption
EngineStops
HighCylinderHeadTemperature
EngineMisses
CausesofExcessiveCarbonDeposit
ATooRichMixture
ATooLeanMixture
andmanyothers

EngineTroubleshootingGuide

ShortcutstoCostly
EngineDiagnostics

Publishedby
EngineComponentsInternational
9503Middlex
SanAntonio,TX782175994

1800ECi2FLY
(8003242359)

www.eci.aero
Email:salesservice@eci.aero

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Forinstallationeligibility,visitourwebsiteatwww.eci.aero

19982011EngineComponentsInternational.Allrightsreserved.

Copyright2011EngineComponentsInternational.Allrightsreserved.Nopartofthisbookletmaybe
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photocopying,recording,orbyanyinformationstorageorretrievalsystemwithoutwrittenpermission
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PrintedintheUnitedStatesofAmerica.

EngineTroubleshootingGuide

TableofContents

EngineTroubleshootingGuide.........................................4
TableofContents.............................................................4
FailureofEnginetoStart..................................................2
LowPowerandUnevenRunning.....................................3
HighOilTemperature.......................................................4
ExcessOilConsumption...................................................4
LowOilPressure...............................................................5
HighOilPressure..............................................................5
ImproperEngineAcceleration..........................................6
FailureofEnginetoIdleProperly.....................................6
FailureofEnginetoDevelopFullPower..........................7
EngineStops.....................................................................8
EngineVibratesExcessively..............................................8
EngineContinuallyThrowsAlternatorBelt......................9
EngineOverheats.............................................................9
HighCylinderHeadTemperature.....................................9
EngineWontStopWhenSwitchisTurnedOff..............10
CarburetorLeaksFuel....................................................10
EngineSpitsBackinCarburetor..................................10
EngineMissesIntermittently.........................................11
EngineMissesRegularly.................................................11
ScatteringMisfire...........................................................12
SingleCylinderMissatHighSpeed................................12
SingleCylinderMissatLowSpeed.................................12
CausesofPreIgnition....................................................13
CausesofExcessiveCarbonDeposit..............................13
MagnetoFailstoDeliveranySpark................................13
CrankcaseFillswithOil(DrysumpSystem)...................13
EnginePumpsOil............................................................14
FaultySpark....................................................................14
MixtureAnalysisbyExhaustFlame................................15
ATooRichMixturemaybecausedby:.......................15
ATooLeanMixturemaybecausedby:......................15
Notes..............................................................................16
ECiTechnicalReferenceMaterials................................17

EngineTroubleshootingGuide

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EngineComponentsInternational

EngineTroubleshootingGuide

FailureofEnginetoStart
27points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

Lackoffuel
Ignitionswitchoff
Underprimingoroverpriming
Incorrectthrottlesetting
Coldoil
Defectivebattery(batteryignitionsystems)
Dirtyordefectivesparkplugs
Waterinmagneto
Wetignitionharness
Wronggradeoffuel
Sparkadvanceretardedtoofar
Vaporinfuelsystem
Waterincarburetor
Defectiveignitionwiring
Boostermagnetodefective
Incorrectvalveand/orignitiontiming
Defectivemagneto
Brokenimpulsecoupling
Magnetobreakerpointsdefective
Incorrectvalveclearance
Defectiveprimingsystem
Internaltroubleincarburetor
Intakemanifoldairleaks
Broken,shreddedordefectivecamshaft
Internalenginefailure
Sparkplugwirescrossed
Miscellaneous(turnengineoverslowlybyhandwiththemaster&
magnetoswitchoffandnoteanyunusualcondition,particularlylow
compression.

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EngineTroubleshootingGuide

LowPowerandUnevenRunning
29points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

Mixturetoorichortoolean
Leaksininductionsystem
Defectiveorfouledsparkplugsandlooseplugconnections
Improperfuelgrades
Wetordefectiveignitionwiring
Engineoverheating
Defectivemagnetobreakerpoints
Dirtyorbrokencarbonbrushesinmagneto
Impropervalveand/orignitiontiming
Propelleroutoftrack,orhubnutloose
Carburetorheatcontrolmalfunction
Crackedenginemountorloosemountbolts
Foreignmatterininductionsystemorfuellines
Incorrectlyadjustedcarburetorcontrollinkage
Fuelfeedvalveleakingornotoperatingproperly
Warpedorburnedvalvesorvalveseats
Brokenvalvesprings
Wornorstickingpistonsorcylinders
Crackedpistonsorcylinders
Bentpushrods
Cylindergasketsblown
Magnetogroundwirelooseandgrounding
Carburetoricing
Fluctuatingfuelpressure
Defectiverockerarmsorbearings
Defectivevalveguides
Bentcrankshaft
Crosswindonpropellerduringgroundoperation
Sparkplugwirescrossed

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EngineTroubleshootingGuide

HighOilTemperature
12points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Insufficientoilsupply
Defectiveoiltemperaturegauge
Airflowthroughoilcoolerblocked
Oilcoolerbypassvalvemalfunction
Cylinderbafflesmissingorinsecure
Poorairflowaroundoiltank
Cloggedoillinesorscreens
Overheatedbearings
Dirtyorimpropergradeofoil
Impropergradeoffuel
Improperignitiontiming
Mainbearingshiftingincrankcasebearingbore.

ExcessOilConsumption
9points
1.
2.
3.
4.
5.
6.
7.
8.
9.

Impropergradeofoil
Improperventingofoilsystem
Pistonringsworn,brokenorincorrectlyinstalled
Breatherlineexitinginlowpressureareaandblockedormissing
vacuumbreakholeonbreatherline
Crackedpistons
Defectivesuperchargerseal
Pistonoildrainholesclogged
Oilpressuretoohigh
Toomuchclearancebetweenintakevalveandguide

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EngineTroubleshootingGuide

LowOilPressure
18points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Insufficientoilsupply
Oilpumpnotprimed
Impropersettingofpressurereliefvalve
Foreignmatterinreliefvalve
Defectivepressuregauge,orcloggedgaugeline
Impropergradeofoil
Highoiltemperature
Leakinsuctionlines
Dirtinoilscreens
Foaminginoiltank
Oilcongealedinintakeline
Excessivelydilutedoil
Brokenoilline
Excessivecamfollowertocrankcaseclearance
Excessivebearingclearanceorwrongundersizebearings
Crankshaftplugsleakingormissing
Wornoilpumpgears
Brokenoilpumpgearsordriveshaft

HighOilPressure
8points
1.
2.
3.
4.
5.
6.
7.
8.

Impropergradeofoil
Pressurereliefvalvestuckclosedorimproperlyadjusted
Oilcoldorfrozen
Oilpipebentorcrushed
Defectivepressuregauge
Insufficientbearingclearance
OilScreenorfilterclogged
Bearingtightduetoengineoverheating

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EngineComponentsInternational

EngineTroubleshootingGuide

ImproperEngineAcceleration
11points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Incorrectlyadjustedcarburetor
Defectiveacceleratingpump
Coldoil
Defectivetachometer
Improperpropellerpitchorwarpedpropeller
Improperthrottleormixturecontrollinkageadjustment
Fuelvalveleakingornotoperatingproperly
Impropersparkadjustment
Improperenginetiming
Internalcarburetortrouble,orpressuretypecarburetoringravity
fuelsystem
11. Airleaksorrestrictionininductionsystem

FailureofEnginetoIdleProperly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

20points
Carburetorcontrollinkageimproperlyadjusted
Loosesparkplugconnectors
Wateroroilinmagnetos
Burnedorpittedcontactbreakerpoints
Impropermagnetotiming
Defectiveignitionharness
Impropergradeoffuel
Incorrectidlingspeedadjustment
Throttlevalveclosingtoofar
Idlingjetrestricted
Airleaksininductionsystem
Vaporinfuelsystem
Improperfuelpressure
Internalcarburetortrouble
Partialobstructioninfuellines
Fuelvalveleakingornotoperatingproperly
Defectiveprimervalve
Impropervalveclearance
Lowcylindercompression
Excessiveplayincarburetorcontrollinkage

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EngineTroubleshootingGuide

FailureofEnginetoDevelopFullPower
29points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

Carburetorcontrollinkageimproperlyadjusted
Mixturetooleanortoorich
Throttlevalvenotfullyopen
Impropergradeoffuel
Airleakincarburetor
Incorrectfuelpressure
Impropervalveclearance
Impropergradeofoil
Oiltoohotortoocold
Rockerarmsnotproperlylubricated
Incorrectvalveorignitiontiming
Defectivesparkplugs
Weakmagnetomagnets
Burnedorpittedcontactbreakerpoints
Excessivecarbonandpreignition
Intakemanifoldtoocold
Pressuretypecarburetoringravitysystem
Weakorbrokenvalvesprings
Lowcylindercompression
Valveseatsscoredorworn
Bentpushrods
Excessivebackpressurefromexhaustmanifold
Enginestiffortight
Incorrectpropellersetting,orwarpedpropellerblades
Engineoverheating
Carburetorventuritoosmall
Carburetoricing
Impropergradeoffuel
Defectivesupercharger

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EngineTroubleshootingGuide

EngineStops
12points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Magnetosgrounded
Outoffuel
Carburetorjetsrestricted
Airorvaporlockinfuelline
Fuellinespartiallyobstructed
Foreignobjectininductionsystem
Waterinfuel
Brokenfuellines
Shearedtiminggears
Internalstructuralfailure
Propellercontactssolidobject
Airventorfueltankobstructed

EngineVibratesExcessively
11points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Propelleroutofbalanceoroutoftrack
Bentcrankshaft
Unequalvalveclearance
Defectivesparkplugs
Enginelooseonmount
Propellerhubnutloose
Carburetoricing
Incorrectcarburetorsetting
Enginetoocold
Improperignitiontiming
Worndynamicdampnerbushingsorpins

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EngineTroubleshootingGuide

EngineContinuallyThrowsAlternatorBelt
3points
1.
2.
3.

Bentpulley
Alternatorbearingsorarmature
Worndynamicdampnerbushingsorpins

EngineOverheats
15points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Retardedsparkorsparktimedlate
Defectivewatercirculation
Defectiveoilcirculation
Thinoil
LeanMixture
Camshaftoutoftime
Idlingenginetoolong
Runningaircooledengineongroundtoolong
Insufficientoilcooling
Insufficientoilsupply
Runningenginewithradiatororcowlingshuttersclosed
Excessivecarbon
Engineimproperlycowled
Overheatedbearing
Tightbearingsorpistonsoutofline

HighCylinderHeadTemperature
15points
1.
2.
3.
4.
5.
6.

Mixturetoolean
Impropergradeoffuel
Airleaksininductionsystem
Highcarburetorairinlettemperature
Magnetosimproperlytimed
Damagedcylinderbaffles,fins,orrestrictionsinairflow

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EngineComponentsInternational

EngineTroubleshootingGuide

7.
8.
9.
10.
11.
12.
13.
14.
15.

Incorrectvalveoperationorclearance
Restrictionsinexhaustsystem
Temperaturegaugedefective
Thermocouplewirestooclosetoexhaustmanifold
Sparkretarded
Preignitionthroughcarbonordefectivesparkplugs
Warpedvalves
Loosevalveseatsandguides
Wornvalveguides

EngineWontStopWhenSwitchisTurnedOff
4points
1.
2.
3.
4.

Magnetogroundwireslooseorbroken
Faultymagnetoswitch
Engineexcessivelyhot
Incandescentcarbonincylinders

CarburetorLeaksFuel
6points
1.
2.
3.
4.
5.
6.

Leakyorstuckfloat
Excessivefuelsupplypressure
Poorseatingofneedlevalve
Wornfloatfulcrumpin
Improperfloatlevel
Looseneedlevalveseat

EngineSpitsBackinCarburetor
13points
1.
2.
3.
4.
5.

Coldengineorcoldmixture
Leanmixture
Airleaksinmanifold
Airleaksaroundintakevalvestems
Weakvalvesprings

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10

11

EngineTroubleshootingGuide

6.
7.
8.
9.
10.
11.
12.
13.

Stickingvalves
Sparkplugwirescrossedorincorrectlyconnected
Ignitionoutoftimeorretarded
Camshaftoutoftime
Overheating
Carbon
Impropergradeoffuel
Wateringasoline

EngineMissesIntermittently
13points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Incorrectmixture
Impropergradeoffuel
Waterinfuel
Airleaksininductionsystem
Slowvalveaction
Defectivemagnetosorignitionharness
Distributorpointsorcontactbreakerpointsdirtyorpitted
Carburetorairheaterdefective
Highoiltemperature
Defectivesparkplugs
Impropertiming
Carburetoricing
Magnetogroundwireswingingandperiodicallygrounding

EngineMissesRegularly
6points
1.
2.
3.
4.
5.
6.

Fouledsparkplug
Defectivesparkplug
Brokenorgroundedsparkplugwire
Impropervalveclearance
Lowcompressionononeormorecylinders
Damagedmagnetodistributorhead

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EngineComponentsInternational

EngineTroubleshootingGuide

ScatteringMisfire
12points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Leanmixture
Richmixture
Wateringasoline
Airleakinintakemanifold
Intakevalveholdingopen
Stickyvalveguides
Weakvalvesprings
Excessivebreakerpointclearance
Weakbreakerarmspring
Excessiverotorcontactgapclearance
Moistureondistributorblock
Faultyspark

SingleCylinderMissatHighSpeed
6points
1.
2.
3.
4.
5.
6.

Shortcircuitedsparkplugs
Shortcircuitedsparkplugwire
Shortcircuiteddistributorblock
Sparkpluggaptoowide
Weakexhaustvalvesprings
Insufficientvalvetappetclearance

SingleCylinderMissatLowSpeed
7points
1.
2.
3.
4.
5.
6.
7.

Shortcircuitedsparkplug
Shortcircuitedsparkplugwire
Shortcircuiteddistributorblock
Wrongsparkpluggap
Weakcompression
Airleakaroundintakevalvestem
Weakexhaustvalvespring

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EngineTroubleshootingGuide

CausesofPreIgnition
5points
1.
2.
3.
4.
5.

Carbon
Overheating
Excessivelyrichmixture
Ignitionoutoftime
Sparkplugwirescrossedorconnectedtowrongcylinder

CausesofExcessiveCarbonDeposit
5points
1.
2.
3.
4.
5.

Enginefloodedwithoil
Wornpistonrings
Inferiorqualityofengineoil
Richmixture
Engineoperatedforlongperiodwithoutcleaningcarbon

MagnetoFailstoDeliveranySpark
4points
1.
2.
3.
4.

Primarycircuitgroundedoropen
Secondarycircuitgroundedoropen
Groundwireorswitchgrounded
Condensercircuitopenorshorted,orcondenserpunctured

CrankcaseFillswithOil(DrysumpSystem)
6points
1.
2.
3.
4.
5.
6.

Scavengerpumphaslostitsprime
Scavengerpumpscreenstoppedup
Scavengersuctionorpressurelinesstoppedup
Airleakinsuctionsideofscavengerpump
Brokenscavengerpumpdrive
Scavengerpumpbadlyworn

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EngineComponentsInternational

EngineTroubleshootingGuide

EnginePumpsOil
10points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Pistonringspoorfitinpistongrooves
Pistonringspoorfitincylinder
Brokenpistonrings
Scoredcylinderwalls
Excessivepistonclearance
Excessiveoilpressure
Thinoil
Impropergradeofoil
Excessivebearingclearance
Faultyscavengerpump

FaultySpark
19points
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Breakerpointclearanceincorrect
Breakerpointsburnedordirty
Collectorbrushwornoutordirty
Distributorbrushwornoutordirty
Distributorsegments/rotorcontactcorrodedorburnt
Collectorringshortcircuitedordirty
Distributorrotorshortcircuitedordirty
IncorrectEgap
Primarywindingshortcircuitedordirty
Secondarywindingshortcircuitedorburnedout
Condensershortcircuitedorpunctured
Magnetsweakorcrossed
Looseorcorrodedconnectionwithinthemagneto
Groundwireorswitchshortcircuited
Moisturewithinthemagneto
Armaturetouchespolepieces
Foreignmaterialcollectedonarmature
Defectivesparkplugs
Carbontracksresultingfromflashovercausedbymoisture.

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14

15

EngineTroubleshootingGuide

MixtureAnalysisbyExhaustFlame
4points
1.
2.
3.
4.

RichMixture:Longdeepblueflamewithredtip,blacksmoke.
LeanMixture:Shortirregularlightblueflamewithyellowtip.
ProperMixture:Quickblueflamewithoutyellowtip.
Oilpumpingisshownbyblueexhaustsmoke.

ATooRichMixturemaybecausedby:
6points
1.
2.
3.
4.
5.
6.

Highfuelpressure
Oilincylinders
Carburetorfloatvalveseatingimproperly
Floatleakingair
Jetgasketsofimproperthicknessoroutofshape
Floatleveltoohigh(thesetroubleswouldberesponsibleforthe
carburetorfloodingandarichmixture,particularlyatlowspeeds)

ATooLeanMixturemaybecausedby:
9points
1.
2.
3.
4.
5.
6.
7.
8.
9.

Insufficientfuelintank
Partiallycloggedfuelline
Insufficientairpressureinpressurefueltank
Airventonfueltankclogged
Fuelfilterorjetsclogged
Carburetorfloatleveltoolow
Waterincarburetororsystem
Airleaksininductionsystem
Stickingvalves

2011

EngineComponentsInternational

EngineTroubleshootingGuide

16

Notes

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17

EngineTroubleshootingGuide

ECiTechnicalReferenceMaterials

BreakinInstructions(Booklet#M101)
OilTalkforDummiesSuggestedPrecautionsforNewand
RemanufacturedEnginesRuninvs.BreakinLubricationfor
RuninandBreakinBreakinProceduresLubricationfor
NormalOperationCylinderReplacementOilFiltration
BreakinRecord.

ClassReferenceManual(Booklet#M108)
Crossreferencingsectionsinclude:Lycoming&Continental
EngineModelstoECiCylinderStudAssemblyClassNumberto
LYC/TCMCylinder,Piston,Ring,Valve,Guide,Seat,etc.
ReferenceRadialEngineManufacturers&ModeltoECiCylinderStudAssemblyClass
NumbersCylinderStudAssemblyClassNumberDifferentiationsContinentalCylinder
ClassDifferencesLycomingCoreP/NinAscendingOrdertoECiCylinderClassNumber
ContinentalCoreP/NinAscendingOrdertoECiCylinderClassNumber.

CrossReferencePartsList(Booklet#M157)

ECiPartNumberstoLycoming,TCM&SAP
ECiPartNumberstoPMASupplementnumber

PMASupplements
ServicePublications
PistonRingSetsInstructionsforAEL65102CylindersPlasmaFacedPistonRings
InstructionsforAEL320&360CrankshaftsECiCylforTCM470520550ColorCodeson
CylindersContinuingAirworthinessDataandInstallationEligibilityofECiCrankcases
andmanyothers.

TITANCylinderAssemblies

Features&Benefits:WhatYouShouldKnow(Booklet
#M105)
Allpublicationsareavailableonourwebsite,CDsandinprinted
format.PleasecontactoneofourTerritoryManagersor
contactyourlocalengineshopforyourcopytoday!

Findalloftheseandmuchmoreonlineat

orcallforacomplimentarybooklettoday.
800ECi2FLY(8003242359)
Email:salesservice@eci.aero
Findus:ECiTitan

2011

EngineComponentsInternational

M125(06/14/2011)

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